Customer Success Story
An unplanned downtime occurred in a Spenner tube mill. The plant was at a standstill for three weeks. After repairing the cost-intensive damage, an Schaeffler online monitoring system was installed. In use, the system detected gear damage on the gearbox during operation. It was possible to replace the gearbox during a planned shutdown.
Savings: Around 27,000 euro.
Benefits
Customer benefits
Less unplanned downtime and consequential damage.
Lower repair costs
Multiple benefits – The solution can be applied to all tube mills and coal mills in fossil-fuel power plants.
Challenge
Solution
Schaeffler employees from the Service area installed an online monitoring system with a total of five sensors on the gearbox and layshaft. Following three months of support from Schaeffler experts in data evaluation, the customer‘s Schaeffler-trained employees operated the system unaided. After just a short period of use, the online measuring system detected tooth damage on the gearbox, which was confirmed by the customer following a visual inspection. The gearbox was replaced during a planned shutdown. Wear to the tooth system on the layshaft gear pinion was also detected and remedied during this period.
What’s special
Monitoring a tooth set on a slowly rotating assembly is an extremely demanding process in diagnostic terms. Following its proven success, Spenner has expanded the monitoring system further and confirmed the diagnostic success to the technical journal “Automation & Drives”. This application can be transferred to almost all tube mills for raw material processing and coal mills in fossil-fuel power plants worldwide.
Savings
In the event of severe gearbox damage, Spenner would be faced with repair costs of between 50,000 and 100,000 euro. Production losses amounting to 10,000 euro or more would also have to be included.
Following the introduction of an online monitoring system
The investment in the condition monitoring solution amounted to approx. 18,000 euro. Consequential damage that was detectable at an early stage cost the cement works approx. 5,000 euro in repairs. For the first damage case, savings of at least 27,000 euro are achieved, based on damage occurring without the use of an online monitoring system to the amount of 50,000 euro.
Technical Details
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