MAAG GEAR - Techinal and Commercial Considerations Related To The Cement Mill Production

MAAG Gear AG
The mills gearbox
MAAG Gear: A
pioneer of modern
gear technology
August 09
MAAG Gear on the move
1913 Foundation of MAAG Zahnrderfabrik in Zurich, Switzerland

1927 Start of internationalisation (MAAG Italy, MAAG France, etc.)
1989 Foundation of MAAG Gear AG, Switzerland
1997 Acquired by FLSmidth
2000 Acquisition of factory in Elblag/ Poland
2003 Move to Winterthur, Switzerland
2007 Sales of marine and turbo business
2009 Move into City of Winterthur
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 2
Facts
MAAG Gear is a leading global player and belongs to FLSmidth

since 1997
Engineering, sales, marketing and project management in
Winterthur
Production in Poland and Winterthur
Quality ISO 9001 certified
More than 90 years of grown expertise
Figures 2008
Turnover: 115 mio CHF

Production capacity 80 100 gear units
Employees: 280
Engineers: 105
Technicians: 78
Service: 30
Administrative: 45
External Assistance: 14
Trainees: 8
Know-how in engineering and technology
Engineering experts Supporting tools

Gearing technology - parallel gears CAD / Solid Works
Gearing technology - bevel gears PDM-Systems / Team Center
Metallurgy Ansys for FE-Analysis
FEA Various tools for material analysis
Antifriction bearings MAAG Gear-developed program systems
Journal bearings representing the unique experience of
generations of gear exports
Toothed couplings
Collaboration with our customer
Acoustics/vibration analysis
Cooperation with universities and research
CAD/PDM
centers
Integrated Logistic Support (ILS) /
Reliability Availability Maintenance (RAM)
MAAG Gear, a member of FLS since 1997
FLSmidth & Co.
Cement Minerals
FLSmidth FLSmidth Minerals
FLSmidth Project Division FLSmidth Minerals Division
FLSmidth Customer Services FLSmidth Dorr-Oliver EIMCO
FLSmidth Airtech FLSmidth Krebs
Pfister FLSmidth Buffalo
Ventomatic FLSmidth Koch / MVT
MAAG Gear FLSmidth Mller
Excel Foundry & Machine

Dansk Eternit Holding FLSmidth RACHO
FLSmidth ABON
Driving equipment for the cement industry
Cement processes driven by MAAG Gear
WPU/WPV WPU PPU CPU/CPV/LGD

Raw mill Coal mill Roller Press Cemet mill
Driving equipment for the cement industry
Roller mills Roller mills Ball mills Ball mills

lateral drive central drive
vertical drive vertical drive LGD CPU/CPV
WPV WPU
Roller mills drive, 2-stage (Type WPU)
Benefits to customer
High operational reliability
Efficiency exceeds 96.5%
Customers-specific design of gear units
Very high efficiency Planetary stage and thrust
bearing for grinding table with very long service
life
Low-cost maintenance
Technical overview
Fully developed compact two-stage design
(bevel gear / planetary gear stage)
Case hardened or hardened and quenched tooth
Bevel gear stage with its own casing
Thrust bearing mill table hydro static and hydro
dynamic lubricated
Power: 250 to 6,000 kW
Roller mills drive, 3-stage (Type WPV)
Benefits to customer
Torque split for compact design
Flex pin solution for optimized load distribution
Efficiency exceeds approx. 95 %
Slide bearing application in bevel and planetary
gear stage
Simple mechanism for assembly and adjustment
of bevel gear stage without remove the gear unit
Technical overview
1st stage 3 planets, 2nd stage 5 planets
Toothing case hardened or quenched and
tempered
Thrust bearing mill table hydro static and hydro
dynamic lubricated
Power: 2,500 to 9,000 kW
Installation / Maintenance
Installation and commissioning Experienced and skilled service engineers

Timely managed
Maintenance Preventive
Monitoring / short reports
Assessments
Service plan agreement
Overhaul
Planning and project management
Execution and support
Troubleshooting 24/7 Hotline Tel +41 79 619 91 00
Support
Customer training During installation and commissioning

In house / in MAAG Gear workshop
Tailor-made
On-site
Expert reports Vibration and operating readings

Material analysis and monitoring
Advisory opinion
Service packages Better performance for longer periods

Guaranteed productivity and profitability
Continued customer satisfaction
Enhanced reliability
WPU: The Gear Drive System
Mill thrust bearing

Thrust pads Thrust bearings lined with
babbitt metal
The WPU Gear System
Roller Mill
Mill thrusts
Annulus
WPU gear reducer
Schematical Design Concept
Spiral bevel gear set
Set of instrumentation for trend analysis
Set of instrumentation continue
Process signals directly wired to CS

51.1: T1 Bearing temperature (self-aligning roller bearing bevel pinion, coupling
side)
51.2: T2 Bearing tempersature (axial self-aligning roller bearing bevel pinion,
gearing side)
51.3: T3 Bearing temperature (self-aligning roller bearing bevel pinion, gearing
side)
51.4: T4 Bearing temperature (roller bearing bevel wheel, below wheel)
51.5: T5 Bearing temperature (roller bearing bevel wheel, above wheel)
50.1: T11 Bearing temperature Segment of axial thrust bearing
46: T12 Oil temperature at gearbox outlet
Vibration Sensors directly wired to CS
86.1: VS1 Ring Gear (Annulus) of the planetary stage
86.2: VS2 Ring Gear (Annulus) of the planetary stage (perpendicular to 86.1)
Note: Wiring between gearbox and centre control room shall be done
by the customer
WPV sectional drawing
Selection chart for vertical mill gearbox
350
320
298
300
275
WPU WPV 254
250 233
212
200
Maximum 191
P/nt
P/nt
170
155
150 140
125
110
97
100 84
72
61
51
50 42
35
28
22
0
26 35 43 54 64 78 92 107 125 142 161 182 200 222 242 274 302 332 360 390 420
Gearbox type
WPV - Concept
Main advantages:
Torque split 30% to 70%,
=> 2nd stage with smaller dimension
5 Planets on the 2nd PV-Stage,
=> smaller dimension of the stage
Planets on the 2nd Stage with flex pin,
=> much better load distribution
No housing integrated Planetary stage
=> standard components possible
=> casing optimised to the axial load
Only slide bearings used
=> unlimited lifetime of bearings
Adjustment of bevel gear
=> No need of gearbox disassembly
Slide bearings in the bevel gear stage
Advantages of the slide bearings:
Short delivery time

Unlimited lifetime => high availability of plant
Higher damping compared to antifriction bearings => less vibration
easy installation and highly service friendly
high know-how basis at MAAG Gear through an enormous amount of deliveries for
the Cement, Turbo, and Marine applications
Easy adjustment of bevel gear
Advantages of the improved adjustment method:

Tooth contact easy to adjust
Bevel pinion is adjustable from outside
Bevel gear wheel is adjustable through conic shoe
Fast removal of bevel pinion, without need to remove gear
Service friendly through large dimensioned man hole

=> short maintenance stops
=> no pull out of the gearbox
WPV 360 Bevel Gear Stage
Summary
MAAG new developed WPV gearbox show several important

advantages in investment and operation:
First Test run results and assembly show very encouraging results
High potential for optimisation of investment cost
Improvement on maintenance and service friendliness increasing
the gearbox availability
Lower transport weight and consequently easier erection and
reduced transport costs
The independent gearbox modules allow a more flexible and faster
production
Lower delivery time for spares due to the smaller gear parts
The gearbox is build up with long term approved technologies
Maintenance philosophy
- Permanent surveillance, daily checks (by site personnel)
- Checks after every 1000 h of operation (by site personnel)
- Checks after every 6000 h and 12000 h of operation (annually)

(under supervision of MAAG Service personnel)
- Special checks after approx. 80000h of operation, or 12 years

(under supervision of MAAG personnel)
Daily checks
Permanent surveillance/daily checks (by site personnel)
- Quick check of the whole drive group
- Checking and recording of operating data
- Checking of drive group and accessories for eventual leaks

(reducer, couplings, lube oil supply unit, etc.)
- Checking of oil level in lube oil reservoir
- Check p of lube oil filter (if not monitored)
Routine 1000 h checks
Checks every 1000h of operation (by site personnel), (additionally to

the aforementioned daily checks)
- Record and check operating data (complete checklist 1 of the

instruction manual)
- Check lube oil filter and filter/breather for contamination, cleaning

or replacing at need
Regular 6000 h check
Checks every 6000h of operation (under supervision of MAAG

service personnel), (additionally to the aforementioned routine
checks)
- Check all important bolt connections (reducer, lube oil supply unit,
coupling, etc.)
- Check and if necessary re-tighten gearbox anchoring
- Check lube oil for water content/contamination, Analysis of lube oil

by the supplier (replacement according to recommendation)
- Visual check of lube oil-sample from axial bearing casing
Regular 12000 h check
Checks every 12000h of operation (under supervision of MAAG service

personnel), (additionally to the aforementioned regular checks)
- Checking of alignment to driving- and driven machine
- Inspection of central bearing no. 1 (input shaft)
- Check of instruments and interlocks, record setting points (complete

checklist no. 2)
- Inspect and clean lube oil cooler (if required)
- Partial disassembly and inspection of in- and output coupling, replacing of

lubricants and seals
- Functional and alignment check of auxiliary drive
- Inspection of spare parts (if available), special tools
Special checks - Overhaul
Special checks, overhaul after approx. 80000 h of operation, or 12

years (under supervision of MAAG personnel)
- Disassembly of the entire reducer, inspection of all parts.
Ultrasonic bonding test of all bearings. (replacement of parts if
required)
- Maintenance of components (motors, instruments, etc.)

(according to the individual supplier)
Estimated shutdown time 2 weeks, depending upon accessibility,
availability of facilities as well as findings and results of the
inspection.
Customer Service Products
Overview Customer Service Products
Service & Spare Parts Contracts

Easy Training Concept
Performance Gear Box upgrade
Prevention Security thanks obviating
Speed Security thanks fast information flow
32
Customer Service Products
Easy Training Concept

- training of customers service personnel
Challenge Gear Box upgrade

- exchange of an existing gear box, incl. gear boxes from
competitors
Prevention Security thanks obviating

- checks via vibration measuring, incl. gear boxes from competitors
Speed Security thanks fast information flow

- 24 h/day vibration measurement thanks direct access of
customers datas via internet.
33
MAAG Gear AG
Gearbox Damage
How to handle
material availability
August 09
Source of information and procedures
Emergency situation:
a) Customer contacts Field Service Dept: Emergency
description, detailed information
b) Customer contacts Sales: availability of spare parts, delivery
schedules
Service report at customer
Sales travel report at MAAG Gear
Customer / Agency request once procedure defined
Monitoring system
Material planning for repair (1)
1. Emergency case:
Damage assessment and evaluation
Material selection (parts, spares)
Availability at customer site
2. Service report:
History of the gearbox
Detect background of failure
Recommendations for repair
3. Sales travel report:
Spare parts already delivered
Identification of spares required
Contact persons
Express delivery
Quotes
Material planning for repair (2)
4. Customer / Agency request:

Contact Field Service Dept. for details / history
Proceed standard spare parts quotation
5. Monitoring system
Data exchange
Analysis
Recommendations
Follow up after repair
Information flow
Customer address
Service
Contact name; e-mail; phone No.
Report Basic Info
Plant code name
Gearbox type & ex. Order No.
Parts description
Drawing No.
SAP No. (If available)
Material Info
Quantity
Reason for material request

Time frame
Gen. Info
Repair options (1)
1. On site repair by MAAG Gear Field Service Engineers

Field Service Dept. to contact customer & make proposal for
service intervention (material inspection on site)
If damage material is already specified, then standard part
quotation is issued
If defective material is already inspected, then procedure
according to inspection report recommendations
Repair options (2)
2. In house repair at MAAG Gear production site

Delivery of damaged parts
Quote for damage assessment and inspection
Quote for repair
3. Repair by 3rd. Party

Cooperation under customer responsability
MAAG Gear locations and service centers
MAAG Gear locations for development, production and sales

Winterthur, Switzerland / Elblag, Poland
Bethlehem, North America / sales office
Beijing, China / sales office
Service Centers including agents and FLS partner offices world wide
(MAAG Gear service centers in USA, Mexico, Poland and Denmark)
MAAG Gears in operation around the world
Algeria India Spain

Angola Indonesia Sudan
Argentina Iran Sweden
Austria Ireland Switzerland
Bangladesh Israel Syria
Belgium Italia Taiwan
Bolivia Japan Thailand
Brazil Jordan Togo
Bulgaria South Korea Turkey
Canada Kuwait UAE
China Lebanon Ukraine
Colombia Malaysia Uruguay
Costa Rica Mexico USA
Croatia Nigeria Vietnam
Denmark Pakistan Yemen
Ecuador Peru
Egypt Philippines
El Salvador Poland
France Russia
Germany Saudi Arabia
Greece Senegal
Honduras South Africa
MAAG Gears vision
Core Elements of our Corporate Strategy

Sustainable sales growth
Dynamic, relevant innovation pipeline
Operational excellence
Winning organization
Ensure we have the right people and the right
working environment to deliver our vision
Constant willingness to innovate and close
collaboration with our customer

MAAG GEAR - Techinal and Commercial Considerations Related To The Cement Mill Production

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MAAG Gear AG

The mills gearbox

1913 Foundation of MAAG Zahnrderfabrik in Zurich, Switzerland

MAAG Gear is a leading global player and belongs to FLSmidth

Turnover: 115 mio CHF

Engineering experts Supporting tools

FLSmidth & Co.

FLSmidth Project Division FLSmidth Minerals Division

FLSmidth Customer Services FLSmidth Dorr-Oliver EIMCO

FLSmidth Airtech FLSmidth Krebs

Pfister FLSmidth Buffalo

Ventomatic FLSmidth Koch / MVT

MAAG Gear FLSmidth Mller

Excel Foundry & Machine

WPU/WPV WPU PPU CPU/CPV/LGD

Roller mills Roller mills Ball mills Ball mills

Installation and commissioning Experienced and skilled service engineers

Troubleshooting 24/7 Hotline Tel +41 79 619 91 00

Customer training During installation and commissioning

Expert reports Vibration and operating readings

Service packages Better performance for longer periods

Mill thrust bearing

WPU gear reducer

Spiral bevel gear set

Process signals directly wired to CS

Advantages of the slide bearings:

Short delivery time

Advantages of the improved adjustment method:

Bevel pinion is adjustable from outside

Bevel gear wheel is adjustable through conic shoe

Fast removal of bevel pinion, without need to remove gear

Service friendly through large dimensioned man hole

MAAG new developed WPV gearbox show several important

- Permanent surveillance, daily checks (by site personnel)

- Checks after every 1000 h of operation (by site personnel)

- Checks after every 6000 h and 12000 h of operation (annually)

- Special checks after approx. 80000h of operation, or 12 years

Permanent surveillance/daily checks (by site personnel)

- Quick check of the whole drive group

- Checking and recording of operating data

- Checking of drive group and accessories for eventual leaks

- Checking of oil level in lube oil reservoir

- Check p of lube oil filter (if not monitored)

Checks every 1000h of operation (by site personnel), (additionally to

- Record and check operating data (complete checklist 1 of the

- Check lube oil filter and filter/breather for contamination, cleaning

Checks every 6000h of operation (under supervision of MAAG

- Check lube oil for water content/contamination, Analysis of lube oil

- Visual check of lube oil-sample from axial bearing casing

Checks every 12000h of operation (under supervision of MAAG service

- Inspection of central bearing no. 1 (input shaft)

- Check of instruments and interlocks, record setting points (complete

- Inspect and clean lube oil cooler (if required)

- Partial disassembly and inspection of in- and output coupling, replacing of

- Functional and alignment check of auxiliary drive

- Inspection of spare parts (if available), special tools

Special checks, overhaul after approx. 80000 h of operation, or 12

- Maintenance of components (motors, instruments, etc.)

Overview Customer Service Products

Service & Spare Parts Contracts

Easy Training Concept

Challenge Gear Box upgrade

Prevention Security thanks obviating