Condition Monitoring Report

Location:

Shah Cement, Bangladesh

Contact person:

Mr Sengupta

Date of measurement: 22 September 2002

Type of service:

Condition monitoring of 5 Flender gear units

Order nr.:

Reg. 88 827

Application:

Cement mill

Gear unit data:

Flender SZN 800, s/n : 0021.5041.001-2, P = 2475 kW,

n1 = 990 rpm, n2 = 108.92 rpm

Motor:

s/n : 40297X 422-11-01, Pm = 2500kW, n = 993 rpm

Measuring technology:
Content:

Mobile GearController und Notebook

9 pages, 7 pictures and 1 annex

Herne, 25 Oct 2002

Head of department: Dr.Becker

CM engineer / Report written by:

Chaterjee/Lelich

Bankverbindung:
Commerzbank AG, Bochum
BLZ:
430 400 36
Konto:
2 125 672

Sitz der Gesellschaft: Herne

Registergericht Herne
HR B 761

Niederlassung Dresden:
Bautzener Str. 147a
D-01199 Dresden
Tel.: (0351) 81407-31

Niederlassung Penig:
Thierbacher Str. 24
D-09320 Penig
Tel.: (037381) 6-437

Niederlassung Bocholt:
Alfred-Flender-Str.77
D-46395 Bocholt
Tel.:(02871) 92-2402

Geschftsfhrer:
Dipl.-Ing. K.-P. Deppermann

Summary
Gear condition
The gear mesh frequency of the output stage in axial direction is harder than normal, cause external stresses. The gear contact pattern has to be verified and the alignment between gear unit
and drive shaft. These external stresses can even be monitored in the input gear stage.
Bearing condition
The measured frequency of 85.3 Hz at measurement points 6 & 7 are close to the excitation
frequency of the bearing outer ring of bearing SL 182980 C3. Apart from this exciation frequency are various modulations present of the rotation- and wobbling frequency of the intermediate shaft. It is not clear whether a bearing damage is present due to the presence of the
external stresses.
General Condition of Gear Unit and Recommendations
Overloads effect the complete gear unit and are even transmitted to the electrical motor. A
comparison vibration measurement has to be taken after the re-alignment. The rather strong
axial vibrations in the output gear stage are caused by stresses from the mill onto the gear unit.
The alignment of the mill girth gear to the mill pinion should be checked, in order to analyse
the condition of the bearings. Continuous operation under these conditions may lead to operating damages.

Content
1

Initial situation and task ....................................................................................................2

Kinematics and Measuring Technology .................................................................................3

Measurement results..........................................................................................................4

Condition Monitoring Report of Cement Mill Drive installed at Shah Cement, Bangladesh

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1. Initial situation and task

Flender Service Condition Monitoring received the order from Flender Limited India to analyse the collected vibration data at Shah Cement. These are the results from the first measurement and should be used as a reference for future successive vibration measurements.
The gear unit condition has been analysed by use of narrow-band vibration collected and analysed. The following text reports about these results.

2. Kinematik und Messtechnik

Vibration analysis is mainly based upon the comparison of measured vibrations to theoretical calculated
excitation frequencies of the gearing and bearings. The table with calculated excitation frequencies for
the gear unit is attached in as annex 1.
The input speed of the SZN 800 has been assumed at 990 rpm. This is as first gear mesh frequency
280.5 Hz and 99.8 Hz as the second gear mesh frequency. The vibration spectras have been collected at
the measurement point as indicated in picture 1.
Vibration measurements were carried out with a mobile FLENDER GearController-system with 2
FLENDER-type accelerometers attached. The resolution is 8,200 lines. Sensitivity of the device is
102 dB. Measurement modules were chosen with longer measurement times for the gear unit output
shaft.
The FLENDER GearController-system calculates vibration velocity, acceleration and envelope frequency spectra to analyse the condition of the bearings and gears. Velocity spectra give a global overview of the gear unit condition. For in-depth analysis, envelope spectra are used to detect and monitor
any initial bearing- and gear problems. These initial frequency excitations cannot be detected in the
velocity spectra. Acceleration spectra are used to monitor bearing and/or gear resonance.
All measured data are stored separately on a computer system at Flender Service, Herne Germany, and
may be available for later measurements and analyses. The data shown within this report were chosen to
point out characteristic problems of the different gear units.
With respect to the carrying out of the measurement, the inspection and the reporting please refer to our
general conditions for mobile services.

Condition Monitoring Report of Cement Mill Drive installed at Shah Cement, Bangladesh

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Picture 1 : Overview of the measurement points and applied measurement modules

Measurement results

3.1. General behaviour and particulars

It is a standard to check also the outer appearance of the gear unit and additional operation parameters.
Following particulars have been found :

a) The measured temperature at the motor DE bearing was 56C and 43C at the motor
NDE bearing.
b) The gear unit temperatures at the input shaft was 65C at the input side and 63C at the
output side. At the intermediate shaft range the temperatures from 56C, input side, to
59C on the output side. At the output shaft were the temperatures 53C, input side and
51C on the output side. These temperatures are acceptable.
c) Oil leaks have been observed at one pump and at the in- and output shaft seals.
d) Increased vibration levels up to 27 mm/s have been measured on the output housing
wall have been measured. This is caused by a housing resonance. On the bearing points,
motor side is a max. 4.5 mm/s vibration and 5.5 mm/s on the output side..
Condition Monitoring Report of Cement Mill Drive installed at Shah Cement, Bangladesh

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e) The size of breather is not suitable for this type of gear unit as oil foaming has been observed.
3. 2. Analyse of the velocity vibration spectras of gear unit and motor
Initially are with the GearController narrow-band vibration frequency spectras been taken at
the gear unit and motor, in nominal operation condition.
Picture shows the frequency spectras taken at the measurement points 1 & 2, horizontal at the
input gear stage. Dominant and pronounced is the gear mesh frequency of the output gear stage
at a frequency of 100.6 Hz with some harmonics. The input gear mesh frequency is also present
at 282.8 Hz, although with normal amplitudes. Stresses work on the output gear stage, resulting
in high vibrations. This is supported by the presence of increased vibration levels on the gear
unit housing. We recommend to verify the gear contact pattern of the output gear stage and realign in radial and axial direction the gear unit with the drive shaft.

Input gear mesh frequency

Output gear mesh

frequency with

mp 1

mp 2
Picture 2: Velocity vibration spectras taken at the input shaft, horizontal direction

The output gear mesh frequency dominates and has an amplitude of 6.3 mm/s at measurement
point 10. The frequency excitations of the input shaft are also relatively strong and have an
amplitude of 3 mm/s. This is been caused by stresses of the cement mill on gear unit. Continuous operation under these conditions may lead to gear unit damage.
The gear mesh frequency of the output gear stage is also dominating at the electrical motor.
These effects, stresses coming from the cement mill, transmit through the gear unit all the way
in to the motor. Rotational frequencies with some harmonics can be allocated. These have a
maximum amplitude of 0.5 mm/s and are acceptable. The motor alignment is OK.

Condition Monitoring Report of Cement Mill Drive installed at Shah Cement, Bangladesh

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mp 9

mp 10
Picture 3: Frequency spectras taken in axial direction at measurement points 9 & 10

mp 2

mp 1
Picture 4: Frequency spectras taken at motor measurement points 1 & 2

3. 3 Analysis of the envelope- and acceleration frequency spectras

Condition Monitoring Report of Cement Mill Drive installed at Shah Cement, Bangladesh

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For in-depth analysis, envelope spectra are used to detect and monitor any initial bearing- and
gear problems. The envelope spectras taken at measurement points 1 & 2 on the gear unit are
shown in picture 5. Remarkable is the presence of many rotational excitation frequencies. The
gear mesh frequency of the input gear stage has harmonics and sidebands equal to the input
rotation frequency. This means a hard gear mesh, caused by an increased bearing clearance
and/or previous mentioned stresses from the cement mill working on the complete gear unit.
In the envelope spectras taken at measurement points 6 & 7, shown in picture 6, are some discrete frequency excitations present at 38.7 Hz and 85,3 Hz. Apart of these frequencies occur
various modulations of the rotation- and wobbling frequency of the intermediate shaft at 4.8 Hz
and 9.6 Hz. The discrete frequency of 85.3 Hz is very close to the excitation frequency of the
outer ring of bearing SL 182930 C3. This means an increased bearing clearance and initial
bearing damage. The acceleration spectras show not yet resonances in the high frequency
range, picture 7. There for the alignment has to be checked and corrected, followed by successive vibration analysis to analyse the bearing vibrations. The reference condition of the gear
unit is attached to this report and stored at a computer system for future comparison analyses.

Input gear mesh frequency

with harmonics and side-

mp 1

mp 2
Picture 5: Envelope spectra taken at measurement points 1 & 2

Condition Monitoring Report of Cement Mill Drive installed at Shah Cement, Bangladesh

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mp 6
Rotation- and wobbling frequencies of the
intermediate shaft at 4.8 Hz and 9.6 Hz

mp 7
Picture 6: Envelope spctras taken at measurement points 6 & 7

mp 6

mp 7
Picture 7: Acceleartion frequency spectras taken at measurement points 6 & 7

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Condition Monitoring Report of Cement Mill Drive installed at Shah Cement, Bangladesh

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