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Novexa’s Presentation*: The wear maintenance approach of
rotating tubes driveline
This document is the sole property of NOVEXA and must not be
copied, issued or reproduced without authorisation 1
Average shutdown period reduction (days)
Strategy Preventive approach development
Business On site machining specialist
Headquarters Valence (26) – Near Lyon (FRANCE)
Experience 15 years of worldwide experience and more than 500
rotating tubes assistance
Life span extension (years) Cost reduction (€)
Cost / efficiency ratio (i.e: Kiln / mill girth gear
reprofiling)
Strategy Conditional Preventive maintenance of major rotating
equipments (kilns, mills)
Business On site machining specialist (gears, gearboxes, kiln
tyres & rollers)
Experience 15 years of worldwide experience and more than 500
rotating tubes assistance
*Headquarters Valence (26) – Near Lyon (France)
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be copied, issued or reproduced without authorisation
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Novexa’s Presentation
This document is the sole property of NOVEXA and must not be
copied, issued or reproduced without authorisation 2
1st level: The training program
2nd level: The maintenance and wear monitoring project – NOVEXA
toolkit
3rd level: The online wear calculation module
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be copied, issued or reproduced without authorisation
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Conditional Preventive approach - The Training Program – 2
Days
This document is the sole property of NOVEXA and must not be
copied, issued or reproduced without authorisation 3
How to transfer our knowledge
Bringing wear analysis awarness
Transferring essential and technical knowledges to follow the
wear evolution
Providing high technology methods and a preventive maintenance
program to manage the gear wear
Bringing huge and short term maintenance operations savings
Meshing model (NOVEXA’s development)
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be copied, issued or reproduced without authorisation
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Summary of the Training Program
This document is the sole property of NOVEXA and must not be
copied, issued or reproduced without authorisation 4
Introduction 1 Novexa business
Drive analysis
Gears 2
Operational characteristics
12 Key parameters to know
Wear analysis
Wear speed calculation, profile deformation and thickness
remaining
Data sheet and meshing modification
Gear damages
Maintenance solutions
Bearings 3 Lubrication
Level, reliefs and clearances
Scrapping method
Bearings damages
Vibration 4
Lubrication 6
Lubrication methods
Lubricants (Specification and selection)
The preventive approach 7 Wear control program of gear
Oil analysis, temperature and print control
Drive alignment
Non destructive testing
Axial/Radial runout
Success story
Gear meshing effect (horizontal, vertical, axial analysis)
Drive analysis
Tyres / rollers 5
Tyres damages
Balance / translation
Maintenance solutions
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be copied, issued or reproduced without authorisation
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Conditional Preventive approach – The NOVEXA toolkit
Providing a high level technique
approach different from usual solutions
Giving access to objective values
to analyze by yourself the wear of gears
Bringing important savings with:
- Wear speed calculation : how to increase significantly the
life span
- Remaining thickness calculation : decide between flipping,
reprofiling, or changing
- Profile deformation calculation: give us target to avoid and
reduce vibration
This document is the sole property of NOVEXA and must not be
copied, issued or reproduced without authorisation 5
The wear monitoring project of gears
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be copied, issued or reproduced without authorisation
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Conditional Preventive approach – Online wear calculation
module
This document is the sole property of NOVEXA and must not be
copied, issued or reproduced without authorisation 6
Your secure access to NOVEXA reports and the gear wear
calculation module
Providing a free access and usefull wear
calculation module
Helping to organize your own data base
- Including automatic calculation and analysis
of the wear level of gears
Overall correct condition
Close monitoring recommended
Excessive wear of gears – an intervention
is needed
Important risks of breakage / irreversible
damages
Providing close technical assistance by
phone/ email
Equipments characteristics
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be copied, issued or reproduced without authorisation
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Business
On site reprofiling and welding repair of gears
Defects corrected: high vibrations,
teeth breakage / cracking,
bad load distribution,
shock when meshing or at junction,
profile deformation
On site machining and welding repair of kiln tyres and
rollers
This document is the sole property of NOVEXA and must not be
copied, issued or reproduced without authorisation 7
To anticipate and solve wear problems on rotating tubes
driveline as a whole
tolerance at 0.07mm – on pitch, flatness, profile
Defects corrected: facetting,
scratches,
spalling and all surface deteriorations,
thrust tyre defects,
material discharge and flatness defects,
conicity in rolling components,
runout, humps, cracks
This whole document is the sole property of NOVEXA and must not
be copied, issued or reproduced without authorisation
Before After
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Business
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copied, issued or reproduced without authorisation 8
To anticipate and solve wear problems on rotating tubes
driveline as a whole
All types
mill trunnions bearings,
pinions bearings, kiln rollers
All types of pads
brass, lead sleeve bearings,
others.
Measurement up to 60 meters /
accuracy 0.2mm
This whole document is the sole property of NOVEXA and must not
be copied, issued or reproduced without authorisation
Alignment controls of
horizontal kilns, mills
Bearing scraping
in 4/5 hours
Spectral vibration analysis,
ultrasonic testing,
magnetic inspection
Full range of non
destructive testing
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Business
This document is the sole property of NOVEXA and must not be
copied, issued or reproduced without authorisation 9
To anticipate and solve wear problems on rotating tubes
driveline as a whole
Non exhaustive list
of products’ supply
pinions, kiln rollers, etc.
This whole document is the sole property of NOVEXA and must not
be copied, issued or reproduced without authorisation
Full range of products’
supply
Supply of girth gear
and adjustment
Partnership with 3 main gears’
manufacturers in Europe
Supply of lubricants and
centralized system
Lubrication advices
supply of centralized system
large range of lubricants supply
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copied, issued or reproduced without authorisation 10
Business cases among our 500 interventions
OCEANIA New Caledonia – CM 2 gear reprofiling + bearing scraping
– January 2011
EUROPE United Kingdom – Mill Girth gear reprofiling – April
2007
MIDDLE EAST Jordan – Kiln tyres cracks repair – April 2010
CARRIBEAN Martinique plant – Mill pinion bearings scraping –
October 2008
ASIA South Corea – Kiln 2&3 girth gears reprofiling – August
2008 / Sept 2009
THE GLOBAL PROJECT Brazil - Kiln revamping – August 2010
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be copied, issued or reproduced without authorisation
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Business case – New Caledonia – CM 2 gear reprofiling + bearing
scraping
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copied, issued or reproduced without authorisation 11
405 mm : input/output clearance
220 000€ + 7 days of production
+ 11 000 € / year of energy saving
Return on investment 3 years (energy saving)
Pitch control after reprofiling Scraping operation
CM situation
-Bad lubrication + high temperature
on trunnion
-High vibration level on pinion/gear
Engineering proposal
-250 000€ for 1 new girth gear
investment
-14 days of shutdown including 2
bearings scraping
NOVEXA operation
-2 bearings scraping in 3 days (including dismantling +
reassembling)
-10 years of life span extension
after reprofiling
-5% energy consumption saving
SAVINGS
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be copied, issued or reproduced without authorisation
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Business case – Europe UK - Mill 2 girth gear reprofiling
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copied, issued or reproduced without authorisation 12
Before
150 000€ / year for maintenance operations
3 000 000€ / year due to non production (150 000€/days saved
during 20 days)
After NOVEXA reprofiling
Mill situation
-mill reliability 86%
-150 000€ / year for maintenance
operations
Engineering proposal
-900 000€ for 1 new girth gear
investment
-14 days of shutdown
NOVEXA operation
-mill reliability 95%
-10 years of life span extension
after reprofiling
SAVINGS
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be copied, issued or reproduced without authorisation
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Business case - Middle East Jordan - Kiln tyre cracks repair
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copied, issued or reproduced without authorisation 13
Blanket + flamme installation Situation after 6 days of
welding
405 000€ + 4 days of production (compared to investment)
Tyre situation
-cracks: 55% of the tyres width
-risk of cracks extension +
unexpected shut-down
Engineering proposal
-1 new shell under tyre and the
corresponding tyre investment
-12 days of shutdown
-investment cost 500 000€
NOVEXA operation
-strict respect of the customer
welding procedure
-welding operation in 8 days
-operation cost 95 000€
SAVINGS
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be copied, issued or reproduced without authorisation
Diameter adjustment after welding operation
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Business case - Caribbean Martinique plant – Bearings
scraping
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copied, issued or reproduced without authorisation 14
Bearings dismantling During scraping, a line is traced
each 35/40 mm
Scraping in 4 hours – diam 1400 mm, width 350 mm
entry clearance 3 mm
900 000€ + 6 days of production (compared to the engineering
proposal)
Bearings situation
-bad lubrication + high
temperature
-risk of damages + unexpected
shut-down
Engineering proposal
-2 bearings scraping in 9 days
(including dismantling and
reassembling)
Novexa operation
-2 Bearings scraping in 3 days (including dismantling +
reassembling)
-22 000€ for scraping + mill
alignment + logistics
SAVINGS
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be copied, issued or reproduced without authorisation
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Business case – Sth Corea - 2 kilns girth gear reprofiling
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copied, issued or reproduced without authorisation 15
Before (kiln#2) After (kiln#2)
860 000 € (2 girth gears) + 5 days of production / kiln
(compared to the engineering proposal)
NOVEXA reprofiling
In 2008, the company decision
was to invest on 5 new girth
gears: Malaysia (kiln), Corea (2
kilns), Philippines (2 girth gears)
Engineering proposal
-1 000 000€ for 2 new girth gears
investment
-14 days of shutdown / kiln
Mr X (technical center in Asia in
2008) drove inspections in each
plants with NOVEXA. Conclusion:
no need to replace any of these 5
girth gears
SAVINGS
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be copied, issued or reproduced without authorisation
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The saving program 1/3
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NOVEXA global project Kiln revamping - Brazil - August 2010
2.25 millions € (compared to investment)
20 000 € / year (energy consumption)
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be copied, issued or reproduced without authorisation
Engineering proposal
35 days of shutdown
- 2 new shells under tyres and the 2
corresponding tyres investment
- 1 new girth gear investment
- Supply of a new pinion
-Supply of new pinion bearings
Costs 2.5 millions €
NOVEXA solution
8 days of shutdown
- On site machining of 3 tyres
- On site machining of 6 rollers
- Girth gear reprofiling
- Supply of a new pinion
- Pinion bearings scraping
-Kiln Alignment
NOVEXA costs 250 000€
Return on investment 4 years
SAVINGS +
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The saving program 2/3
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NOVEXA global project Kiln revamping - Brazil - August 2010
Before intervention
- Most of suppliers recommendation was to
invest on a new kiln installation
- Gear profile deformation : 1.6 mm
- Shocks when meshing
- 3/4 flats on tyres (1 meter each)
- Runout at 15 mm on 2 tyres
- Flatness distorsion up to 2 mm on rollers
- Intensity variation –
from 230 to
400 Amp
After intervention
- Gears accuracy tolerance
0.15mm (pitch, flatness, profile) – same
tolerance as a new gear
after girth gear
reprofiling
- Tyres/rollers cutting tolerance: 0.07mm
flatness, ovality below 1mm, diam dif R/L below
0.3mm
- Intensity variation
falls down –
from 235 to 260
Amp
10 years of life
span extension
(on average)
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The saving program 3/3
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NOVEXA global project Kiln revamping - Brazil - August 2010
Gears
0.15mm accuracy tolerance
After girth gear reprofiling
Pinion supply by NOVEXA
Tyres / rollers
Tyre grinding Bearing scraping
by NOVEXA
Bearing scraping
Blue print contact
after scraping Roller diameter control
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This document is the sole property of NOVEXA and must not be
copied, issued or reproduced without authorisation
Conclusion
This whole document is the sole property of NOVEXA and must not
be copied, issued or reproduced without authorisation
Customized saving strategy
High level technique solutions
Rotating tubes global wear
monitoring approach
NOVEXA’S STRENGHTS
Worldwide references
Unique wear monitoring method
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This whole document is the sole property of NOVEXA and must not
be copied, issued or reproduced without authorisation
Office
7 rue Arturo Toscanini
26 000 Valence
FRANCE
Tel: +33 (0)4 75 25 14 18
Fax: +33 (0)4 75 25 16 14
[email protected]
www.novexa.com
Fabrice ZIEGLER Managing director
7 rue Arturo Toscanini
26 000 Valence
FRANCE
Tel: +33 (0)4 75 25 14 18
Mob: +33 (0)6 75 08 11 26
Fax: +33 (0)4 75 25 16 14
[email protected]
Gaylor CHAPUT Account manager
7 rue Arturo Toscanini
26 000 Valence
FRANCE
Tel: +33 (0)4 75 25 14 18
Fax: +33 (0)4 75 25 16 14
[email protected]
