REPORT

REPORT NUMBER: HOLCIM SHUROVO-08-339-01.09

Gear Reducer: FLENDER KMPP 601 Line: 361-MD1.M1

Serial No.: 44 36 182 - 0040 -1

Report Period: 2010-09-23 - 2012-06-18

Date of Report: 2012-06-19

Reported by: Dipl.-Ing. Horst Brodherr

Checked by: Dipl.-Ing. (FH) Bernhard Tetzlaff

 Plant: SHUROVO Page: 2/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB

Page 002 Contents Report

Page 003 Gearbox Condition and Sensor Positions

Page 004 Condition Summary Comments

Page 005 SENSOR 3 Acceleration - Vibration Diagnostic Indicators: Bevel Gear Stage

Page 006 SENSOR 4 Acceleration - Vibration Diagnostic Indicators: Planetary Gear Stage 1

Page 007 SENSOR 5 Acceleration - Vibration Diagnostic Indicators: Planetary Gear Stage 2

Page 008 SENSOR 6 + 7 Velocity - Vibration Condition Indicators Grinding Bed: X - Y Direction

Page 009 SENSOR 8 - 13 Temperatures Slide Bearing No. 150 - 151 - 451 - 450

Page 010 SENSOR 14 + 15 Displacement Sun Shaft Planetary Gear Stage 1 X ( 0°) - Y (90°) Direction

Page 011 Bevel Gear Stage Faults: Gear Mesh Frequency and Sideband Energy

Page 012 Planetary Gear Faults Stage 1: Planetary Fault Frequencies

Page 013 Planetary Gear Faults Stage 2: Planetary Fault Frequencies

Page 014 Mill Operating Parameter MOP1

Page 015 Mill Operating Parameter MOP2

Page 016 Torque Progress over Measurement Period

Page 017 Torque Alarm - Process Mode - Events I May 2012

Page 018 Torque Alarm - Process Mode - Events II June 2012

Page 019 Torque Alarm - Process Mode - Events III Year 2012

Page 020 Torque Alarm - Start Up Mode - Events I May 2012

Page 021 Torque Alarm - Start Up Mode - Events II June 2012

Page 022 Torque Alarm - Start Up Mode - Events III Year 2012

Page 023 How to read this Report 1

Page 024 How to read this Report 2

Page 025 How to read this Report 3

DALOG Diagnosesysteme GmbH

Siemensstrasse 2a
86356 Neusaess
Tel. +49 (0) 821 - 74777-10
Fax +49 (0) 821 - 74777-19
E-Mail:

[email protected]
[email protected]
[email protected]
 Plant: SHUROVO Page: 3/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB

z-dir
x-dir

y-dir

451

150 151

450

150 - 451

See
Sensor Point Flender Sensor No. Measurement Name Bearing No. Condition
comments
Sensor 1 Speed Input Shaft Ok
Sensor 2 Torque Input Shaft Ok
Sensor 3 Acceleration Bevel Gear Stage Ok
Sensor 4 Acceleration Planetary Gear Stage 1 Ok
Sensor 5 Acceleration Planetary Gear Stage 2 Ok
Sensor 6 Vibration Velocity Grinding Bed X - dir Defect Sensor
Sensor 7 Vibration Velocity Grinding Bed Y - dir Ok
Sensor 8 No 823.1 Temperature Slide Bearing Vertical 150 Ok
Sensor 9 No 821.1 Temperature Slide Bearing Vertical 151 Ok
Sensor 10 No 825.1 Temperature Slide Bearing Horizontal 451 Ok
Sensor 11 No 824.1 Temperature Slide Bearing Horizontal 450 Ok
Sensor 12 No 822.1 Temperature Slide Bearing Horizontal 151 Ok
Sensor 13 No 826.1 Temperature Slide Bearing Vertical 451 Ok
Sensor 14+15 Displacement Sun Shaft Stage 1 Ok
Sensor 16 Oil Pressure Bearing 150 and 151 Ok
MOP 1 Mill Operating Parameter 1 Ok
MOP 2 Mill Operating Parameter 2 Ok
Legend
Vibration conditions Ok Ok
Remarkable trend or sensor faults Indication
Trend over Alert level ALERT
Trend over Danger level DANGER
Sensor defect or not connected Sensor
 Plant: SHUROVO Page: 4/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB

CONDITION SUMMARY
Comments :

1.Condition of Bearings:
Notice : No remarkable trend is observed.

2.Condition of the Bevel Gears:

Notice : No remarkable trend is observed.

3.Condition of the Planetary Gears:

Notice : No remarkable trend is observed.

4.Torque measurements:
Notice : No remarkable trend is observed.

5.Remark :
Findings:
Sensor no.6 - grinding bed - shows faulty signals.
Please check sensor mounting and cable connection.
 Plant: SHUROVO Page: 5/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB

Fig.1 Sensor 3
Raw Signal
40 1
RMS3 [g]

30
0.8 Basis 0.67
Current 0.64
0.6
20 Alert 1.07
0.4 REF_Corr 0.06
10
0.2
Black Line as Reference Value: Torque Average CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Fig.2 Sensor 3
Raw Signal
40 4
PtoP3 [g]

30 3
Basis 2.64
Current 2.64
20 2 Alert 4.22
REF_Corr 0.53
10 1

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Fig.3 Sensor 3
Envelope
40
0.3 RMS_ENV3 [g]

30
Basis 0.19
0.2 Current 0.23
20 Alert 0.34
REF_Corr 0.71
0.1
10

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Fig.4 Sensor 3

0.8 Envelope
40
PtoP_ENV3 [g]

30 0.6 Basis 0.37

Current 0.40
20 0.4 Alert 0.80
REF_Corr 0.44
10 0.2

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Basis - Range Days 30 2010-10-16 - 2011-07-19 Title SENSOR 3 - Vibration Diagnostic Indicators
Current - Range Days 1 2012-06-17 - 2012-06-18 Bevel Gear Stage
Gearbox Hours Date Data conditions Compress 12 hr
Operation Time 2916 2010-09-23 - 2012-06-18 Sample Rate 10 1/hr Standstill Removed
 Plant: SHUROVO Page: 6/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB

Fig.1 Sensor 4
0.8 Raw Signal
40
RMS4 [g]
0.6 Basis 0.44
30
Current 0.48
0.4
20 Alert 0.77
REF_Corr 0.87
10 0.2

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Fig.2 Sensor 4
6
Raw Signal
40
PtoP4 [g]

30 4
Basis 3.18
Current 3.54
20 Alert 5.57
2 REF_Corr 0.88
10

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Fig.3 Sensor 4
1.5 Envelope
40
RMS_ENV4 [g]

30
Basis 0.79
1
Current 0.85
20 Alert 1.46
0.5 REF_Corr 0.76
10

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Fig.4 Sensor 4

2.5
Envelope
40
PtoP_ENV4 [g]
2 Basis 1.50
30
1.5 Current 1.45
20 Alert 2.58
1
REF_Corr -0.50
10
0.5
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Basis - Range Days 30 2010-10-16 - 2011-07-19 Title SENSOR 4 - Vibration Diagnostic Indicators
Current - Range Days 1 2012-06-17 - 2012-06-18 Planetary Gear Stage 1
Gearbox Hours Date Data conditions Compress 12 hr
Operation Time 2916 2010-09-23 - 2012-06-18 Sample Rate 10 1/hr Standstill Removed
 Plant: SHUROVO Page: 7/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB

Fig.1 Sensor 5
0.4
Raw Signal
40
RMS5 [g]
0.3
30
Basis 0.20
Current 0.21
0.2
20 Alert 0.38
REF_Corr 0.65
10 0.1

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Fig.2 Sensor 5

3
Raw Signal
40
PtoP5 [g]

30
Basis 1.63
2
Current 1.78
20 Alert 3.05
1 REF_Corr 0.71
10

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Fig.3 Sensor 5
0.3
Envelope
40 0.25 RMS_ENV5 [g]

30 0.2 Basis 0.14

Current 0.17
0.15
20 Alert 0.27
0.1 REF_Corr 0.93
10
0.05
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Fig.4 Sensor 5
Envelope
40
1.5 PtoP_ENV5 [g]

30
Basis 0.82

1 Current 0.99
20 Alert 1.70
REF_Corr 0.85
0.5
10

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Basis - Range Days 30 2010-10-16 - 2011-07-19 Title SENSOR 5 - Vibration Diagnostic Indicators
Current - Range Days 1 2012-06-17 - 2012-06-18 Planetary Gear Stage 2
Gearbox Hours Date Data conditions Compress 12 hr
Operation Time 2916 2010-09-23 - 2012-06-18 Sample Rate 10 1/hr Standstill Removed
 Plant: SHUROVO Page: 8/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB

Fig.1 Sensor6 x-dir

Sensor 6 shows faulty signals
RMS Value
40
20 VEL_AVG1 [mm/s]

30
Basis 2.63
15
Current 0.46
20 10 Alert 9.76
REF_Corr 0.03
10 5
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm mm/s

Fig.2 Sensor6 x-dir

MAX Value
40
20 VEL_MAX1 [mm/s]

30
Basis 3.72
15
Current 0.71
20 10 Alert 14.14
REF_Corr -0.01
10 5
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm mm/s

Fig.3 Sensor7 y-dir

6
RMS Value
40
5 VEL_AVG2 [mm/s]

30 4 Basis 3.01
Current 2.82
3
20 Alert 5.47
2 REF_Corr -0.40
10
1
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm mm/s

Fig.4 Sensor7 y-dir

MAX Value
40
6 VEL_MAX2 [mm/s]

30
Basis 3.52
4 Current 3.33
20 Alert 6.72
REF_Corr -0.48
2
10

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm mm/s

Basis - Range Days 30 2010-10-16 - 2011-07-19 Title Vibration Velocity Grinding Bed
Current - Range Days 1 2012-06-17 - 2012-06-18 X - Y Direction
Gearbox Hours Date Data conditions Compress 12 hr
Operation Time 2916 2010-09-23 - 2012-06-18 Sample Rate 10 1/hr Standstill Removed
 Plant: SHUROVO Page: 9/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB

140 100

130
90
120

80
110
Warning Level: 105°C
100
70

90
60
80

70 50

60
40
50

30
40

30
20

20
10
10

0 0

0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 hr
°C kNm

Feature Phys.Unit max min mean sdev Rcorr

TRQavg kNm 41.03 15.64 30.54 4.17 1.00
TEMP_8 [°C] 73.03 54.75 67.02 2.95 0.86
TEMP_9 [°C] 80.29 63.08 73.96 2.70 0.68
TEMP_10 [°C] 73.73 62.33 67.92 1.80 0.49
TEMP_11 [°C] 72.25 59.84 66.33 1.99 0.50
TEMP_12 [°C] 74.36 59.92 67.72 2.40 0.60
TEMP_13 [°C] 78.52 67.27 73.50 1.68 0.63

TRQavg Torque Average as Reference Values

TEMP_8 Temperature Bearing 150 Radial 823.1
TEMP_9 Temperature Bearing 151 Radial 821.1
TEMP_10 Temperature Bearing 451 Radial 825.1
TEMP_11 Temperature Bearing 450 Radial 824.1
TEMP_12 Temperature Bearing 151 Axial 822.1
TEMP_13 Temperature Bearing 451 Axial 826.1

Basis - Range Days 30 Title Slide Bearing Temperatures 821 - 826

Current - Range Days 1 Bearing No.150 - 151 - 451 - 450
Gearbox Hours Date Data conditions Compress 12 hr
Operation Time 2916 2010-09-23 - 2012-06-18 Sample Rate 10 1/hr Standstill Removed
 Plant: SHUROVO Page: 10/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB

Fig.1 Sensor 14
X-dir
40 11
Average [mm]

30 10 Basis 7.46
Current 7.48
20 9 Alert 11.29
REF_Corr 0.64
10 8

CONDITION Ok
0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm mm

Fig.2 Sensor 14
X-dir
40 0.3 Peak to Peak [mm]
Basis 0.14
30
0.2 Current 0.11
20 Alert 0.33
REF_Corr -0.55
0.1
10

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm mm

Fig.3 Sensor 15
12 Y-dir
40
Average [mm]

30
Basis 7.13
10
Current 7.12
20 Alert 10.78
8 REF_Corr -0.48
10

CONDITION Ok
0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm mm

Fig.4 Sensor 15

0.3
Y-dir
40
Peak to Peak [mm]

30
Basis 0.12
0.2
Current 0.12
20 Alert 0.30
0.1 REF_Corr -0.50
10

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm mm

Basis - Range Days 30 2010-10-16 - 2011-07-19 Title Displacement X ( 0°) - Y (90°) Direction
Current - Range Days 1 2012-06-17 - 2012-06-18 Sun Shaft Planetary Gear Stage 1
Gearbox Hours Date Data conditions Compress 12 hr
Operation Time 2916 2010-09-23 - 2012-06-18 Sample Rate 10 1/hr Standstill Removed
 Plant: SHUROVO Page: 11/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB

Fig.1 Bevel Gear

Gear Mesh
40
1 GMFs_BEV [g]

30
Basis 0.44
Current 0.54
20 0.5 Alert 1.13
REF_Corr 0.27
10

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Fig.2 Bevel Gear

0.5
Sidebands
40
0.4 SBs_BEV [g]

30
Basis 0.08
0.3
Current 0.02
20 Alert 0.46
0.2
REF_Corr -0.26
10 0.1
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Fig.3 Pinion Shaft

0.03 Amplitude
40
ENVshft1 [g]

30
Basis 0.02
0.02
Current 0.02
20 Alert 0.03
0.01 REF_Corr 0.23
10

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Fig.4 Wheel Shaft

0.05
Amplitude
40
0.04 ENVshft2 [g]

30
Basis 0.02
0.03 Current 0.02
20 Alert 0.05
0.02
REF_Corr 0.27
10 0.01
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Basis - Range Days 30 2010-10-16 - 2011-07-19 Title Bevel Gear Stage Faults
Current - Range Days 1 2012-06-17 - 2012-06-18 GMF + SB and Shaft Faults
Gearbox Hours Date Data conditions Compress 12 hr
Operation Time 2916 2010-09-23 - 2012-06-18 Sample Rate 10 1/hr Standstill Removed
 Plant: SHUROVO Page: 12/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB

Fig.1 Planet Stg.1

0.25
Raw Signal
40
0.2 GMF Planet [g]

30
Basis 0.09
0.15
Current 0.14
20 Alert 0.23
0.1
REF_Corr 0.85
10 0.05
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Fig.2 Planet Stg.1

Envelope
40 0.2
Fault Planet [g]

30 0.15 Basis 0.11

Current 0.09
20 0.1 Alert 0.21
REF_Corr -0.82
10 0.05

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Fig.3 Planet Stg.1

Envelope
40
Fault Sun [g]
0.1
30
Basis 0.07
Current 0.07
20 Alert 0.12
0.05
REF_Corr 0.08
10

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Fig.4 Planet Stg.1

0.2 Envelope
40
Fault Ring [g]
0.15 Basis 0.10
30
Current 0.08
20 0.1 Alert 0.20
REF_Corr -0.83
10 0.05

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Basis - Range Days 30 2010-10-16 - 2011-07-19 Title Planetary Gear Faults Stage 1
Current - Range Days 1 2012-06-17 - 2012-06-18 Planetary Fault Frequencies
Gearbox Hours Date Data conditions Compress 12 hr
Operation Time 2916 2010-09-23 - 2012-06-18 Sample Rate 10 1/hr Standstill Removed
 Plant: SHUROVO Page: 13/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB

Fig.1 Planet Stg.2

0.05
RAW Signal
40
0.04 GMF Planet [g]

30
Basis 0.02
0.03
Current 0.02
20 0.02 Alert 0.05
REF_Corr 0.03
10 0.01
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Fig.2 Planet Stg.2

0.04 Envelope
40
Fault Planet [g]

30 0.03 Basis 0.02

Current 0.01
20 0.02 Alert 0.04
REF_Corr -0.02
10 0.01

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Fig.3 Planet Stg.2

Envelope
40 0.04 Fault Sun [g]

30
Basis 0.02
0.03
Current 0.02
20 0.02 Alert 0.04
REF_Corr 0.17
10 0.01

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Fig.4 Planet Stg.2

0.04 Envelope
40
Fault Ring [g]
0.03 Basis 0.02
30
Current 0.01
0.02 Alert 0.04
20
REF_Corr -0.08
10 0.01

CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g

Basis - Range Days 30 2010-10-16 - 2011-07-19 Title Planetary Gear Faults Stage 2
Current - Range Days 1 2012-06-17 - 2012-06-18 Planetary Fault Frequencies
Gearbox Hours Date Data conditions Compress 12 hr
Operation Time 2916 2010-09-23 - 2012-06-18 Sample Rate 10 1/hr Standstill Removed
 Plant: SHUROVO Page: 14/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB

7
140 140
5500 550 550 17 60
6.5
130 130
16
5000 500 500 55
6
120 120 15
50
4500 450 450 14 5.5
110 110
13 45
5
4000 100 400 400 100
12
4.5 40
90 90
3500 350 350 11

4
80 80 10 35
3000 300 300
9 3.5
70 70 30
8
2500 250 250 3
60 60
7 25

2000 50 200 200 50 2.5

6
20
40 40 5 2
1500 150 150
15
4 1.5
30 30
1000 100 100 3 10
20 20 1
2
500 50 50 5
10 10 0.5
1

0 0 0 0 0 0 0 0

0 500 1000 1500 2000 2500 hr

kW mbar t/h °C °C m³/h bar kNm

Feature Phys.Unit max min mean sdev Rcorr

TRQavg kNm 41.03 15.64 30.54 4.17 1.00
361-MD1_J1_T [kW] 3904.54 1500.00 2897.51 389.63 0.99
361-RM1_PD_T [mbar] 56.21 29.28 46.25 6.33 0.60
361-WF0_Q1_T [t/h] 514.81 212.66 363.52 53.13 0.70
361-RM1_T1_T [°C] 291.17 172.19 218.83 27.12 0.05
361-RM1_T2_T [°C] 94.50 64.81 83.79 4.29 0.19
361-WI1_F1_T [m³/h] 11.00 0.00 3.15 4.14 0.25
Press_T [bar] 1.39 1.00 1.25 0.09 0.21

TRQavg Torque Average Values as Reference

361-MD1_J1_T Mill Main Drive Motor Power Mean Values
361-RM1_PD_T Mill Differential Pressure
361-WF0_Q1_T Mill Feed Rate
361-RM1_T1_T Mill Hot Gas Inlet Temperature
361-RM1_T2_T Mill Hot Gas Outlet Temperature
361-WI1_F1_T Water Injection Rate
Press_T Oil Pressure at Bearings A and B

Basis - Range Days 30 Title Mill Operating Parameter

Current - Range Days 1 MOP1
Gearbox Hours Date Data conditions Compress 12 hr
Operation Time 2916 2010-09-23 - 2012-06-18 Sample Rate 10 1/hr Standstill Removed
 Plant: SHUROVO Page: 15/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB

75 15000 55
1800 1800
70 350 350 14000
50
65 13000
1600 1600
45
60 300 300 12000

1400 1400
55 11000 40

50 250 250 10000

1200 1200 35
45 9000

40 1000 200 1000 200 8000 30

35 7000
25
800 800
30 150 150 6000
20
25 5000
600 600

20 100 100 4000 15

400 400
15 3000
10

10 50 50 2000
200 200
5
5 1000

0 0 0 0 0 0 0

0 500 1000 1500 2000 2500 hr

mm/s 1/min bar 1/min mm m³/h kNm

Feature Phys.Unit max min mean sdev Rcorr

TRQavg kNm 41.03 15.64 30.54 4.17 1.00
361-RM1_N1_T [mm/s] 2.54 1.49 1.99 0.23 -0.25
361-SR1_S1_T [1/min] 1751.56 1318.83 1613.42 72.69 -0.10
361-HS1_P1_T [bar] 168.73 44.98 124.22 21.22 0.91
361-FN1_S1_T [1/min] 946.76 803.22 875.85 26.04 0.65
361-HS1_L1_T [mm] 86.51 30.89 53.33 11.56 -0.30
361-RM1_F1_T [m³/h] 6253.12 3.97 2589.35 2406.27 -0.27

TRQavg Torque Average Values as Reference

361-RM1_N1_T Mill Vibration
361-SR1_S1_T Seperator Speed
361-HS1_P1_T Hydraulic Pressure
361-FN1_S1_T Mill Fan Speed
361-HS1_L1_T Grinding Bed Depth
361-RM1_F1_T Mill Air Flow

Basis - Range Days 30 Title Mill Operating Parameter

Current - Range Days 1 MOP2
Gearbox Hours Date Data conditions Compress 12 hr
Operation Time 2916 2010-09-23 - 2012-06-18 Sample Rate 10 1/hr Standstill Removed
 Plant: SHUROVO Page: 16/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB

80 80 80

75 75 75
8000
70 70 70
7500
65 65 65
7000

60 60 60 6500

55 55 55 6000

50 50 50 5500
200

45 45 45 5000
180
4500
40 40 40 160
4000
35 35 35 140
3500
30 30 30 120
3000
25 25 25 100
2000 2500
20 20 20 80
2000
1500
15 15 15 60 Speed Sensor Fault
1500
1000
10 10 10 40 1000

5 5 5 20 500
500

0 0 0 0 0 0

0 500 1000 1500 2000 2500 hr

kNm kNm kNm kNm 1/min kW

Feature Phys.Unit max min mean sdev Rcorr

TORQ_MEAN kNm 40.76 15.43 30.19 4.09 1.00
TORQ_MAX1 [kNm] 54.32 25.27 42.13 4.47 0.91
TORQ_PTOP1 [kNm] 28.69 13.54 22.75 3.50 0.03
TORQ_SDV1 [kNm] 6.10 2.74 4.85 0.81 -0.00
361-MD1_J1_T [kW] 3890.09 1469.80 2874.19 387.51 0.99
Speed_mean [1/min] 1445.71 0.00 452.74 511.07 -0.33

TORQ_MEAN Torque Average Values as Reference

TORQ_MAX1 Torque Max Values
TORQ_PTOP1 Torque Peak to Peak Values
TORQ_SDV1 Torque Standard Deviation Values
361-MD1_J1_T Mill Main Drive Motor Power
Speed_mean Input Speed

Basis - Range Days 30 Title Torque Progress

Current - Range Days 1 Over Measurement Period
Gearbox Hours Date Data conditions Compress 12 hr
Operation Time 2904 2010-09-23 - 2012-06-18 Sample Rate 10 1/hr Standstill Removed
 Plant: SHUROVO Page: 17/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB
TORQUE ALARM-EVENTS (Exclude start processing) 05.2012
1 2 3 4 5 6 7 Alarm Production
Month Tmax Tavg Timpact Tneg Tdyn Tavg2 Timpact2 Sum Hours
01.05.2012 0 0 0 0 5 0 0 5 18
02.05.2012 0 0 0 0 1 0 0 1 17
03.05.2012 0 0 0 0 0 0 0 0 13
04.05.2012 0 0 0 0 0 0 0 0 3
05.05.2012 1 0 0 0 0 0 0 1 6
06.05.2012 1 0 0 0 3 0 0 4 14
07.05.2012 0 0 0 0 1 0 0 1 4
08.05.2012 0 0 0 0 34 0 0 34 15
09.05.2012 0 0 0 1 10 0 0 11 16
10.05.2012 0 0 0 1 0 0 0 1 4
11.05.2012 0 0 0 0 1 0 0 1 14
12.05.2012 1 0 0 0 4 0 0 5 11
13.05.2012 1 0 1 0 1 0 0 3 17
14.05.2012 1 0 0 0 0 0 0 1 15
15.05.2012 0 0 0 1 1 0 0 2 8
16.05.2012 0 0 0 0 1 0 0 1 18
17.05.2012 1 0 0 0 1 0 0 2 14
18.05.2012 0 0 0 0 0 0 0 0 10
19.05.2012 0 0 0 0 1 0 0 1 1
20.05.2012 1 0 0 0 1 0 0 2 13
21.05.2012 1 0 1 1 3 0 0 6 19
22.05.2012 1 0 0 0 0 0 0 1 14
23.05.2012 0 0 0 0 0 0 0 0 3
24.05.2012 2 0 0 0 10 0 0 12 9
25.05.2012 1 0 1 0 2 0 0 4 8
26.05.2012 0 0 0 0 1 0 0 1 15
27.05.2012 0 0 1 0 1 0 0 2 19
28.05.2012 2 0 1 0 0 0 0 3 13
29.05.2012 1 0 0 0 14 0 0 15 14
30.05.2012 0 0 0 0 0 0 0 0 4
31.05.2012 0 0 0 0 0 0 0 0 0
Tmax Tavg Timpact Tneg Tdyn Tavg2 Timpact2 Total Hours
Sum May 15 0 5 4 96 0 0 120 349

Alarm-Sum and Production Time

45
40 24
35 21
19 19
30 18 17 17
18 18
16
25 15 15 15 15
14 14 14 14 14
13 13 13
20 12
11
10
15 9 9
8 8
10 6 6
4 4 4
5 3 3 3
0 1
0 0
01.05.12
02.05.12
03.05.12
04.05.12
05.05.12
06.05.12
07.05.12
08.05.12
09.05.12
10.05.12
11.05.12
12.05.12
13.05.12
14.05.12
15.05.12
16.05.12
17.05.12
18.05.12
19.05.12
20.05.12
21.05.12
22.05.12
23.05.12
24.05.12
25.05.12
26.05.12
27.05.12
28.05.12
29.05.12
30.05.12
31.05.12

Prodc
Alarm
t.
hrs
 Plant: SHUROVO Page: 18/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB
TORQUE ALARM-EVENTS (Exclude start processing) 06.2012
1 2 3 4 5 6 7 Alarm Production
Month Tmax Tavg Timpact Tneg Tdyn Tavg2 Timpact2 Sum Hours
01.06.2012 0 0 0 0 0 0 0 0 0
02.06.2012 0 0 0 0 0 0 0 0 0
03.06.2012 2 0 0 0 1 0 0 3 3
04.06.2012 0 0 0 0 0 0 0 0 0
05.06.2012 0 0 0 0 0 0 0 0 0
06.06.2012 0 0 0 0 0 0 0 0 0
07.06.2012 0 0 0 0 0 0 0 0 0
08.06.2012 1 0 0 0 4 0 0 5 17
09.06.2012 1 0 0 0 7 0 0 8 11
10.06.2012 0 0 0 0 0 0 0 0 0
11.06.2012 0 0 0 0 0 0 0 0 0
12.06.2012 0 0 0 0 0 0 0 0 0
13.06.2012 0 0 0 0 1 0 0 1 2
14.06.2012 1 0 0 0 0 0 0 1 19
15.06.2012 0 0 0 0 4 0 0 4 14
16.06.2012 0 0 0 0 0 0 0 0 14
17.06.2012 0 0 0 0 2 0 0 2 21
18.06.2012 1 0 1 0 0 0 0 2 6
19.06.2012 0 0 0 0 0 0 0 0 0
20.06.2012 0 0 0 0 0 0 0 0 0
21.06.2012 0 0 0 0 0 0 0 0 0
22.06.2012 0 0 0 0 0 0 0 0 0
23.06.2012 0 0 0 0 0 0 0 0 0
24.06.2012 0 0 0 0 0 0 0 0 0
25.06.2012 0 0 0 0 0 0 0 0 0
26.06.2012 0 0 0 0 0 0 0 0 0
27.06.2012 0 0 0 0 0 0 0 0 0
28.06.2012 0 0 0 0 0 0 0 0 0
29.06.2012 0 0 0 0 0 0 0 0 0
30.06.2012 0 0 0 0 0 0 0 0 0

Tmax Tavg Timpact Tneg Tdyn Tavg2 Timpact2 Total Hours

Sum Jun 6 0 1 0 19 0 0 26 107

Alarm-Sum and Production Time

9
8 24
7 21 21
19
6 17 18
5 14 14 15
4 12
11
3 9
2 6 6
1 3 3
2
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
01.06.12
02.06.12
03.06.12
04.06.12
05.06.12
06.06.12
07.06.12
08.06.12
09.06.12
10.06.12
11.06.12
12.06.12
13.06.12
14.06.12
15.06.12
16.06.12
17.06.12
18.06.12
19.06.12
20.06.12
21.06.12
22.06.12
23.06.12
24.06.12
25.06.12
26.06.12
27.06.12
28.06.12
29.06.12
30.06.12

Prodc
Alarm
t.
hrs
 Plant: SHUROVO Page: 19/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB

TORQUE ALARM-EVENTS (Exclude start processing) 2012

1 2 3 4 5 6 7 Alarm Production
Month Tmax Tavg Timpact Tneg Tdyn Tavg2 Timpact2 Sum Hours
Jan 0 0 0 0 0 0 0 0 0
Feb 0 0 0 0 0 0 0 0 0
Mar 0 0 0 0 15 0 0 15 13
Apr 6 0 0 0 156 0 0 162 250
May 15 0 5 4 96 0 0 120 348
Jun 6 0 1 0 19 0 0 26 107
Jul 0 0 0 0 0 0 0 0 0
Aug 0 0 0 0 0 0 0 0 0
Sep 0 0 0 0 0 0 0 0 0
Oct 0 0 0 0 0 0 0 0 0
Nov 0 0 0 0 0 0 0 0 0
Dec 0 0 0 0 0 0 0 0 0
Tmax Tavg Timpact Tneg Tdyn Tavg2 Timpact2 Total Hours
Sum 2012 27 0 6 4 286 0 0 323 718

Annual Sum of Alarms and Production Time

220
400
200
348 350
180
160 300
140 250 250
120
100 200
80 150
60 107 100
40
20 50
13
0 0 0 0 0 0 0 0 0 0

Alarm Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov DecProdct. hrs

Split Up Annual Torque Alarms

220
200
180
160
140
120
100
80
60
40
20
0

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Tmax Tavg Timpact Tneg Tdyn Tavg2 Timpact2
 Plant: SHUROVO Page: 20/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB
TORQUE ALARM-EVENTS (Starting processing) 05.2012
1 2 3 4 5 6 7 Alarm Production
Month Tmax Tavg Timpact Tneg Tdyn Tavg2 Timpact2 Sum Hours
01.05.2012 0 0 0 0 6 0 0 6 18
02.05.2012 1 0 0 0 6 0 0 7 17
03.05.2012 0 0 0 0 2 0 0 2 13
04.05.2012 0 0 0 0 2 0 0 2 3
05.05.2012 0 0 0 0 6 0 0 6 6
06.05.2012 2 0 0 0 8 0 0 10 14
07.05.2012 0 0 0 0 3 0 0 3 4
08.05.2012 0 0 0 0 17 0 0 17 15
09.05.2012 0 0 0 0 14 0 0 14 16
10.05.2012 0 0 0 0 0 0 0 0 4
11.05.2012 0 0 0 0 1 0 0 1 14
12.05.2012 0 0 0 0 8 0 0 8 11
13.05.2012 0 0 2 0 2 0 0 4 17
14.05.2012 0 0 0 0 1 0 0 1 15
15.05.2012 0 0 0 0 0 0 0 0 8
16.05.2012 0 0 0 0 3 0 0 3 18
17.05.2012 0 0 0 0 0 0 0 0 14
18.05.2012 0 0 0 0 3 0 0 3 10
19.05.2012 0 0 0 0 3 0 0 3 1
20.05.2012 0 0 0 0 6 0 0 6 13
21.05.2012 0 0 0 0 4 0 0 4 19
22.05.2012 0 0 0 0 0 0 0 0 14
23.05.2012 0 0 0 0 0 0 0 0 3
24.05.2012 1 0 0 0 7 0 0 8 9
25.05.2012 0 0 0 0 1 0 0 1 8
26.05.2012 0 0 0 0 1 0 0 1 15
27.05.2012 0 0 0 0 1 0 0 1 19
28.05.2012 0 0 0 0 8 0 0 8 13
29.05.2012 1 0 0 0 5 0 0 6 14
30.05.2012 0 0 0 0 0 0 0 0 4
31.05.2012 0 0 0 0 0 0 0 0 0
Tmax Tavg Timpact Tneg Tdyn Tavg2 Timpact2 Total Hours
Sum May 5 0 2 0 118 0 0 125 349

Alarm-Sum and Production Time

18
16 24
14 21
19 19
12 18 17 17
18 18
16
10 15 15 15 15
14 14 14 14 14
13 13 13
8 12
11
10
6 9 9
8 8
4 6 6
4 4 4
2 3 3 3
0 1
0 0
01.05.12
02.05.12
03.05.12
04.05.12
05.05.12
06.05.12
07.05.12
08.05.12
09.05.12
10.05.12
11.05.12
12.05.12
13.05.12
14.05.12
15.05.12
16.05.12
17.05.12
18.05.12
19.05.12
20.05.12
21.05.12
22.05.12
23.05.12
24.05.12
25.05.12
26.05.12
27.05.12
28.05.12
29.05.12
30.05.12
31.05.12

Prodc
Alarm
t.
hrs
 Plant: SHUROVO Page: 21/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB
TORQUE ALARM-EVENTS (Starting processing) 06.2012
1 2 3 4 5 6 7 Alarm Production
Month Tmax Tavg Timpact Tneg Tdyn Tavg2 Timpact2 Sum Hours
01.06.2012 0 0 0 0 0 0 0 0 0
02.06.2012 0 0 0 0 0 0 0 0 0
03.06.2012 0 0 0 0 4 0 0 4 3
04.06.2012 0 0 0 0 0 0 0 0 0
05.06.2012 0 0 0 0 0 0 0 0 0
06.06.2012 0 0 0 0 0 0 0 0 0
07.06.2012 0 0 0 0 0 0 0 0 0
08.06.2012 0 0 0 0 4 0 0 4 17
09.06.2012 0 0 0 0 2 0 0 2 11
10.06.2012 0 0 0 0 2 0 0 2 0
11.06.2012 0 0 0 0 0 0 0 0 0
12.06.2012 0 0 0 0 0 0 0 0 0
13.06.2012 0 0 0 0 7 0 0 7 2
14.06.2012 0 0 0 0 2 0 0 2 19
15.06.2012 0 0 0 0 1 0 0 1 14
16.06.2012 0 0 0 0 2 0 0 2 14
17.06.2012 0 0 0 0 1 0 0 1 21
18.06.2012 0 0 0 0 0 0 0 0 6
19.06.2012 0 0 0 0 0 0 0 0 0
20.06.2012 0 0 0 0 0 0 0 0 0
21.06.2012 0 0 0 0 0 0 0 0 0
22.06.2012 0 0 0 0 0 0 0 0 0
23.06.2012 0 0 0 0 0 0 0 0 0
24.06.2012 0 0 0 0 0 0 0 0 0
25.06.2012 0 0 0 0 0 0 0 0 0
26.06.2012 0 0 0 0 0 0 0 0 0
27.06.2012 0 0 0 0 0 0 0 0 0
28.06.2012 0 0 0 0 0 0 0 0 0
29.06.2012 0 0 0 0 0 0 0 0 0
30.06.2012 0 0 0 0 0 0 0 0 0

Tmax Tavg Timpact Tneg Tdyn Tavg2 Timpact2 Total Hours

Sum Jun 0 0 0 0 25 0 0 25 107

Alarm-Sum and Production Time

9
8 24
7 21 21
19
6 17 18
5 14 14 15
4 12
11
3 9
2 6 6
1 3 3
2
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
01.06.12
02.06.12
03.06.12
04.06.12
05.06.12
06.06.12
07.06.12
08.06.12
09.06.12
10.06.12
11.06.12
12.06.12
13.06.12
14.06.12
15.06.12
16.06.12
17.06.12
18.06.12
19.06.12
20.06.12
21.06.12
22.06.12
23.06.12
24.06.12
25.06.12
26.06.12
27.06.12
28.06.12
29.06.12
30.06.12

Prodc
Alarm
t.
hrs
 Plant: SHUROVO Page: 22/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB

TORQUE ALARM-EVENTS (Starting processing) 2012

1 2 3 4 5 6 7 Alarm Production
Month Tmax Tavg Timpact Tneg Tdyn Tavg2 Timpact2 Sum Hours
Jan 0 0 0 0 0 0 0 0 0
Feb 0 0 0 0 0 0 0 0 0
Mar 1 0 0 0 30 0 0 31 13
Apr 3 0 0 0 125 0 0 128 250
May 5 0 2 0 118 0 0 125 348
Jun 0 0 0 0 25 0 0 25 107
Jul 0 0 0 0 0 0 0 0 0
Aug 0 0 0 0 0 0 0 0 0
Sep 0 0 0 0 0 0 0 0 0
Oct 0 0 0 0 0 0 0 0 0
Nov 0 0 0 0 0 0 0 0 0
Dec 0 0 0 0 0 0 0 0 0
Tmax Tavg Timpact Tneg Tdyn Tavg2 Timpact2 Total Hours
Sum 2012 9 0 2 0 298 0 0 309 718

Annual Sum of Alarms and Production Time

160 400
348 350
140
120 300
250 250
100
80 200
60 150
107 100
40
20 50
13
0 0 0 0 0 0 0 0 0 0

Alarm Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov DecProdct. hrs

Split Up Annual Torque Alarms

160
140
120
100
80
60
40
20
0

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Tmax Tavg Timpact Tneg Tdyn Tavg2 Timpact2
Plant: SHUROVO Page: 23/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB
Plant: SHUROVO Page: 24/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB
Plant: SHUROVO Page: 25/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB