Renk KPBV190 2013 11 19

REPORT
REPORT NUMBER: OCL - RAJGANGPUR 05-242-01.78

Gear Reducer RENK KPBV 190
Serial-No.: 03-03-01661
Time Period: 2013-07-31 - 2013-11-16
Date of Report: 2013-11-19

Reported by: Dipl.-Ing. (FH) B. Tetzlaff
Checked by: Dipl.-Ing. H. Brodherr
Plant:
RAJGANGPUR
Page:
2/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
Page 002
Contents Report
Page 003
Gearbox Condition Display
Page 004
Condition Summary Comments
Page 005
SENSOR 3 Acceleration - Vibration Condition Indicator: Bevel Gear
Page 006
SENSOR 4 Acceleration - Vibration Condition Indicator: Planetary Gear Stage 1
Page 007
SENSOR 5 Acceleration - Vibration Condition Indicator: Planetary Gear Stage 2
Page 008
SENSOR 6 and 7 Vibration Velocity Condition Indicator: near Grinidng Bed / Bottom
Page 009
SENSOR 8 to 13 Temperature: Bearing Gearbox
Page 010
SENSOR 14 to 17 Temperature: Axial Thrust Bearing
Page 011
SENSOR 18 Displacement: Input Shaft
Page 012
SENSOR 19 to 20 Temperature and Pressure: Gearbox Oil Parameters
Page 013
Bevel Gear Faults Gear Mesh Frequencies GMF
Page 014
Shaft Anomaly Indicators: Torque and Envelope
Page 015
Planetary Gear Faults Stage 1
Page 016
Planetary Gear Faults Stage 2
Page 017
Torque Progress over measurement Period
Page 018
Torque Alarm - Process Mode - Events I October 2013
Page 019
Torque Alarm - Process Mode - Events II November 2013
Page 020
Torque Alarm - Process Mode - Events III Year 2013
Page 021
Torque Alarm - Start Up Mode - Events I October 2013
Page 022
Torque Alarm - Start Up Mode - Events II November 2013
Page 023
Torque Alarm - Start Up Mode - Events III Year 2013
Page 024
How to read this Report 1
Page 025
Page 026
DALOG Diagnosesysteme GmbH

Siemensstrasse 2a
86356 Neusaess
Tel. +49 (0) 821 - 74777-10
Fax +49 (0) 821 - 74777-19
E-Mail:
Bernhard.Tetzlaff@dalog.net
Horst.Brodherr@dalog.net
Franz.Muschaweck@dalog.net
Plant:
RAJGANGPUR
Page:
3/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
See
comments
Point
RENK ID
Name
Sensor 1
570
Speed Sensor - Input Shaft
Ok
Sensor 2
530
Torque Sensor - Input Shaft
Ok
Sensor 3
511 / 3
Acceleration Sensor - Bevel Gear
Ok
Sensor 4
511 / 1
Acceleration Sensor - Planetary Gear Stage 1
Ok
Sensor 5
511 / 2
Acceleration Sensor - Planetary Gear Stage 2
Ok
Sensor 6
515
Vibration Velocity Sensor - X-Direction near Grinding Bed
Ok
Sensor 7
520
Vibration Velocity Sensor - Housing / Gearbox Foundation
Ok
Sensor 8
28 / 1
Temperature Sensor - Input Shaft Outer Bearing
Ok
Sensor 9
28 / 2
Temperature Sensor - Input Shaft Inner Bearing
Ok
Sensor 10
28 / 3
Temperature Sensor - Input Shaft Inner Bearing
Ok
Sensor 11
28 / 4
Temperature Sensor - Sun Shaft Lower Bearing
Ok
Sensor 12
28 / 5
Temperature Sensor - Sun Shaft Upper Bearing
Ok
Sensor 13
28 / 6
Temperature Sensor - Planetary Guide Bearing
Ok
Sensor 14...17 21 / 1...4
Condition
Temperature Sensor - Thrust Pads Axial Bearing 1...4
Ok
Sensor 18
580
Displacement Sensor - Axial Input Shaft
Ok
Sensor 19
13
Temperatur Sensor - Oil Inlet
Ok
Sensor 20
Pressure Sensor - Oil Filter Differential
Ok
Sensor 21
500
Pressure Sensor - Oil Inlet
Ok
Legend
Vibration conditions Ok
Indication
Ok
Remarkable trend or sensor faults
Indication
ALERT
Trend over Alert level
DANGER
ALERT
Trend over Danger level

Sensor fault
DANGER
Ok
Sensor
Plant:
RAJGANGPUR
Page:
4/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
CONDITION SUMMARY
Comments:
1. Condition of the Bearings:
No remarkable trend is observed
2. Condition of the Bevel Gears:

3. Condition of the Planetary Gear Stage 1:

4. Condition of the Planetary Gear Stage 2:

5. Torque measurements:
6. Remark:
- none -
Plant:
RAJGANGPUR
Page:
5/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
Fig.1
50
1.2
40
Bevel
0.8
30
0.6
20
0.4
10
0
kNm
0.2
RMS3
[g]
Basis
0.65
Current
0.64
Alert
1.15
REF_Corr
0.97
Trend
0.08
100
200
300
400
500
600
700
800
900
1000
1100
1200
REF:
T530avg
Fig.2
Sensor 3
1300 hr
50
Bevel
5
40
4
30
20
10
0
kNm
3
2
1
PtoP3
[g]
Basis
3.05
Current
3.12
Alert
5.21
REF_Corr
0.90
Trend
0.17
100
200
300
400
500
600
700
800
900
1000
1100
1200
REF:
T530avg
Fig.3
Sensor 3
1300 hr
50
Bevel
0.08
40
0.06
30
20
10
Ok
CONDITION
0
0
g
Ok
CONDITION
0
0
g
Sensor 3
0.04
0.02
RMS_ENV3
[g]
Basis
0.04
Current
0.03
Alert
0.08
REF_Corr
0.20
Trend
0.23
Ok
CONDITION
0
kNm
0
0
g
100
200
300
400
500
600
700
800
900
1000
1100
1200
REF:
T530avg
Fig.4
Sensor 3
1300 hr
0.4
50
Bevel
0.35
40
0.3
0.25
30
0.2
20
0.15
0.1
10
0.05
0
kNm
Basis - Range
[g]
Basis
0.14
Current
0.08
Alert
0.36
REF_Corr
-0.18
Trend
0.57
Ok
CONDITION
REF:
0
0
g
PtoP_ENV3
100
Days
200
300
400
500
600
700
800
900
1000
30
2013-07-31 - 2013-09-26
Title
Current - Range Days
2013-11-09 - 2013-11-10
Gearbox
Hours
Date
Data conditions
Operation Time
1308
2013-07-31 - 2013-11-16
Sample Rate
1100
1200
T530avg
1300 hr
SENSOR 3 Condition Indicator:

Bevel Gear
10 1/hr
Compress
12 hr
Standstill
Removed
Plant:
RAJGANGPUR
Page:
6/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
Fig.1
50
Stage 1
2
40
1.5
30
1
20
10
Sensor 4
0.5
RMS4
[g]
Basis
1.26
Current
1.20
Alert
2.07
REF_Corr
0.39
Trend
0.06
Ok
CONDITION
0
kNm
50
40
30
0
0
g
100
200
300
400
500
600
700
800
900
1000
1100
1200
kNm
Fig.2
Sensor 4
12
Stage 1
10
PtoP4
[g]
Basis
7.34
Current
7.16
Alert
12.03
REF_Corr
0.52
Trend
0.05
T530avg
1300 hr
20
10
REF:
CONDITION
REF:
T530avg
Fig.3
Sensor 4
0
g
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300 hr
50
Stage 1
0.2
40
0.15
30
20
10
Ok
0.1
0.05
RMS_ENV4
[g]
Basis
0.12
Current
0.12
Alert
0.21
REF_Corr
0.82
Trend
0.11
Ok
CONDITION
0
kNm
0
0
g
100
200
300
400
500
600
700
800
900
1000
1100
1200
REF:
T530avg
Fig.4
Sensor 4
1300 hr
50
Stage 1
0.5
40
30
20
10
0.4
0.3
0.2
PtoP_ENV4
[g]
Basis
0.27
Current
0.27
Alert
0.50
REF_Corr
0.81
Trend
0.11
0.1
Ok
CONDITION
0
kNm
REF:
0
0
g
Basis - Range
100
Days
200
300
400
500
600
700
800
900
1000
30
2013-07-31 - 2013-09-26
Title
2013-11-09 - 2013-11-10
Gearbox
Hours
Date
Data conditions
Operation Time
1308
2013-07-31 - 2013-11-16
Sample Rate
1100
1200
T530avg
1300 hr

Planetary Gear Stage 1
10 1/hr
Compress
12 hr
Standstill
Removed
Plant:
RAJGANGPUR
Page:
7/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
Fig.1
50
Stage 2
0.5
40
0.4
30
20
10
0
kNm
0.3
0.2
0.1
RMS5
[g]
Basis
0.31
Current
0.30
Alert
0.52
REF_Corr
0.97
Trend
0.09
100
200
300
400
500
600
700
800
900
1000
1100
1200
REF:
T530avg
Fig.2
Sensor 5
1300 hr
50
Stage 2
4
40
3
30
20
10
Ok
CONDITION
0
0
g
Sensor 5
PtoP5
[g]
Basis
2.40
Current
2.40
Alert
4.14
REF_Corr
0.95
Trend
0.13
Ok
CONDITION
0
kNm
0
0
g
100
200
300
400
500
600
700
800
900
1000
1100
1200
REF:
T530avg
Fig.3
Sensor 5
1300 hr
50
Stage 2
0.4
40
0.3
30
20
10
0.2
0.1
RMS_ENV5
[g]
Basis
0.24
Current
0.24
Alert
0.42
REF_Corr
0.59
Trend
0.01
Ok
CONDITION
0
kNm
50
40
30
0
0
g
100
200
300
400
500
600
700
800
900
1000
1100
1200
kNm
Fig.4
Sensor 5
Stage 2
1.2
PtoP_ENV5
[g]
Basis
0.57
0.8
Current
0.58
0.6
Alert
1.19
REF_Corr
0.08
Trend
0.01
0.4
T530avg
1300 hr
20
10
REF:
0.2
REF:
0
0
g
Basis - Range
Ok
CONDITION
100
Days
200
300
400
500
600
700
800
900
1000
30
2013-07-31 - 2013-09-26
Title
2013-11-09 - 2013-11-10
Gearbox
Hours
Date
Data conditions
Operation Time
1308
2013-07-31 - 2013-11-16
Sample Rate
1100
1200
T530avg
1300 hr

Planetary Gear Stage 2
10 1/hr
Compress
12 hr
Standstill
Removed
Plant:
RAJGANGPUR
Page:
8/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
Fig.1
50
40
30
Vib. X-Dir
RMS avg
1.5
20
0.5
10
R515-1
[mm/sec]
Basis
0.68
Current
0.78
Alert
1.76
REF_Corr
-0.46
Trend
0.00
Ok
CONDITION
0
0
kNmmm/sec
100
200
300
400
500
600
700
800
900
1000
1100
1200
REF:
T530avg
Fig.2
Vib. X-Dir
1300 hr
3.5
50
RMS max
3
40
2.5
30
2
1.5
20
1
10
0
0.5
[mm/sec]
Basis
0.92
Current
1.15
Alert
3.04
REF_Corr
-0.44
Trend
0.01
100
200
300
400
500
600
700
800
900
1000
1100
1200
REF:
T530avg
Fig.3
Vib. Y-Dir
1300 hr
3
50
RMS avg
2.5
40
2
30
1.5
20
10
0
1
0.5
R515-2
[mm/sec]
Basis
1.37
Current
1.47
Alert
2.70
REF_Corr
-0.42
Trend
0.00
Ok
CONDITION
0
kNmmm/sec
100
200
300
400
500
600
700
800
900
1000
1100
1200
REF:
T530avg
Fig.4
Vib. Y-Dir
1300 hr
50
RMS max
4
40
3
30
2
20
10
Ok
CONDITION
0
kNmmm/sec
R515-1max
R515-2max
[mm/sec]
Basis
1.72
Current
1.94
Alert
4.04
REF_Corr
-0.45
Trend
0.00
Ok
CONDITION
0
REF:
0
kNmmm/sec
Basis - Range
100
Days
200
300
400
500
600
700
800
900
1000
30
2013-07-31 - 2013-09-26
Title
2013-11-09 - 2013-11-10
Gearbox
Hours
Date
Data conditions
Operation Time
1308
2013-07-31 - 2013-11-16
Sample Rate
1100
1200
T530avg
1300 hr
SENSOR 6 and 7 Vibration Velocity

near Grinding Bed / Bottom
10 1/hr
Compress
12 hr
Standstill
Removed
Plant:
RAJGANGPUR
Page:
9/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
125
125
125
125
125
125
120
120
120
120
120
120
115
115
115
115
115
115
110
110
110
110
110
110
105
105
105
105
105
105
100
100
100
100
100
100
95
95
95
95
95
95
90
90
90
90
90
90
85
85
85
85
85
85
80
80
80
80
80
80
75
75
75
75
75
75
70
70
70
70
70
70
65
65
65
65
65
65
60
60
60
60
60
60
55
55
55
55
55
55
50
50
50
50
50
50
45
45
45
45
45
45
40
40
40
40
40
40
35
35
35
35
35
35
30
30
30
30
30
30
25
25
25
25
25
25
20
20
20
20
20
20
15
15
15
15
15
15
10
10
10
10
10
10
0
C
Feature
01 T530avg
02 R28-1
03 R28-2
04 R28-3
05 R28-4
06 R28-5
07 R28-6
Days
50
45
40
35
30
25
20
15
10
0
100
200
300
Phys.Unit
kNm
[C]
[C]
[C]
[C]
[C]
[C]
01 T530avg
02 R28-1
03 R28-2
04 R28-3
05 R28-4
06 R28-5
07 R28-6
Basis - Range
55
400
500
600
max
42.26
84.73
87.69
84.02
73.36
69.01
70.61
700
800
900
min
32.95
81.68
84.21
80.97
71.08
66.02
67.79
1000
1100
mean
38.47
83.32
86.37
82.27
72.07
67.50
69.18
1200
1300 hr
kNm
sdev
1.90
0.61
0.64
0.65
0.49
0.58
0.62
Torque average values as correlation reference

Temperature 28/1B - Bearing near Bevel Gear
Temperature 28/5B - Bearing near Sun Gear
30
Title
Gearbox
Hours
Date
Data conditions
Operation Time
1308
2013-07-31 - 2013-11-16
Sample Rate
SENSOR 8 to 13 Temperature
Bearing Gearbox
10 1/hr
Compress
12 hr
Standstill
Removed
Rcorr
1.00
-0.14
0.28
0.74
0.30
0.07
-0.08
105
105
105
105
100
100
100
100
95
95
95
95
90
90
90
90
85
85
85
85
80
80
80
80
75
75
75
75
70
70
70
70
65
65
65
65
60
60
60
60
55
55
55
55
50
50
50
50
45
45
45
45
40
40
40
40
35
35
35
35
30
30
30
30
25
25
25
25
20
20
20
20
15
15
15
15
10
10
10
10
0
C
Plant:
RAJGANGPUR
Page:
10/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
55
50
45
40
35
30
25
20
15
10
0
100
Feature
01 T530avg
02 R21-1
03 R21-2
04 R21-3
05 R21-4
Days
300
400
Phys.Unit
kNm
[C]
[C]
[C]
[C]
01 T530avg
02 R21-1
03 R21-2
04 R21-3
05 R21-4
Basis - Range
200
500
600
700
max
42.26
55.81
56.25
57.87
55.08
800
900
min
32.95
51.98
52.33
53.90
50.97
1000
1100
mean
38.47
53.80
54.19
55.82
52.94
1200
1300 hr
kNm
sdev
1.90
0.92
0.96
0.92
0.96

Temperature 21 / 1 - Axial Trust Bearing
30
Title
Gearbox
Hours
Date
Data conditions
Operation Time
1308
2013-07-31 - 2013-11-16
Sample Rate
SENSOR 14 to 17 Temperature
Axial Thrust Bearing
10 1/hr
Compress
12 hr
Standstill
Removed
Rcorr
1.00
-0.28
-0.31
-0.29
-0.30
2.45
2.45
0.4
2.4
2.4
0.38
2.35
2.35
2.3
2.3
Plant:
RAJGANGPUR
Page:
11/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
55
0.36
50
0.34
2.25
2.25
2.2
2.2
0.32
2.15
2.15
0.3
2.1
2.1
2.05
2.05
1.95
1.95
0.24
1.9
1.9
0.22
1.85
1.85
1.8
1.8
1.75
1.75
0.18
1.7
1.7
0.16
1.65
1.65
45
40
0.28
0.26
35
30
0.2
25
20
0.14
1.6
1.6
1.55
1.55
1.5
1.5
0.1
1.45
1.45
0.08
1.4
1.4
1.35
1.35
0.12
10
0.06
5
0.04
1.3
1.3
1.25
1.25
0.02
mm
0
mm
mm
15
0
100
200
Feature
01 T530avg
02 DISPL_mean
03 DISPL_max
04 DISPL_PtoP
Days
400
500
Phys.Unit
kNm
[mm]
[mm]
[mm]
01 T530avg
02 DISPL_mean
03 DISPL_max
04 DISPL_PtoP
Basis - Range
300
600
700
800
max
42.26
1.79
1.84
0.13
900
min
32.95
1.70
1.76
0.11
1000
1100
1200
mean
38.47
1.75
1.80
0.13
1300 hr
kNm
sdev
1.90
0.02
0.02
0.00

Displacement mean values
Displacement maximum values
Displacement peak to peak values
30
Title
Gearbox
Hours
Date
Data conditions
Operation Time
1308
2013-07-31 - 2013-11-16
Sample Rate
SENSOR 18
Displacement: Input Shaft
10 1/hr
Compress
12 hr
Standstill
Removed
Rcorr
1.00
0.20
0.20
-0.09
Plant:
RAJGANGPUR
Page:
12/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
80
55
5.5
5.5
50
45
4.5
4.5
40
35
3.5
3.5
75
70
65
60
55
50
45
30
25
2.5
2.5
20
40
35
30
25
15
1.5
1.5
10
20
15
10
0.5
0.5
5
0
C
bar
0
bar
0
100
200
Feature
01 T530avg
02 R13
03 R500-0
04 R3_C
Days
400
500
Phys.Unit
kNm
[C]
[bar]
[bar]
01 T530avg
02 R13
03 R500-0
04 R3_C
Basis - Range
300
600
700
800
max
42.26
47.10
2.40
1.04
900
min
32.95
42.65
2.20
0.90
1000
1100
1200
mean
38.47
44.80
2.30
0.98
1300 hr
kNm
sdev
1.90
1.07
0.05
0.04

Oil Inlet Temperatur
Oil Inlet Pressure
Differntial Pressure
30
Title
Gearbox
Hours
Date
Data conditions
Operation Time
1308
2013-07-31 - 2013-11-16
Sample Rate
SENSOR 19 to 20
Gearbox Oil Parameters
10 1/hr
Compress
12 hr
Standstill
Removed
Rcorr
1.00
-0.32
0.30
0.23
Plant:
RAJGANGPUR
Page:
13/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
55
Fig.1
50
Sensor 3
SB_Bevel
0.025
45
SBs_BEV
[g]
Basis
0.00
Current
0.00
Alert
0.02
REF_Corr
0.27
15
Trend
0.02
10 0.005
CONDITION
40
0.02
35
30
0.015
25
20
0.01
5
0
kNm
55
50
45
Ok
REF:
T530avg
Fig.2
Sensor 3
0
0
g
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300 hr
1.1
1
GMF_Bevel
0.9
GMFs_BEV
[g]
Basis
0.55
Current
0.54
Alert
0.97
0.4
REF_Corr
0.97
15
0.3
Trend
0.08
10
0.2
CONDITION
0.1
REF:
T530avg
Fig.3
Sensor 3
40
0.8
35
0.7
30
0.6
25
0.5
20
kNm
0
g
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300 hr
55
50
45
Ok
0.055
GMF_Bevel
0.05
ENV3_BEV
[g]
Basis
0.00
Current
0.00
Alert
0.05
REF_Corr
0.00
15 0.015
Trend
0.00
10
CONDITION
40
0.045
0.04
35
0.035
30
25
20
0.03
0.025
0.02
0.01
5 0.005
0
kNm
REF:
Ok
T530avg
0
0
g
Basis - Range
100
Days
200
300
400
500
600
700
800
900
1000
30
2013-07-31 - 2013-09-26
Title
2013-11-09 - 2013-11-10
Gearbox
Hours
Date
Data conditions
Operation Time
1308
2013-07-31 - 2013-11-16
Sample Rate
1100
1200
1300 hr
Bevel Gear Faults

Gear Mesh Frequencies GMF
10 1/hr
Compress
12 hr
Standstill
Removed
Plant:
RAJGANGPUR
Page:
14/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
Fig.1
50 0.012
40
30
Bevel Shaft
0.01
0.008
0.006
20
0.004
10
0
kNm
0.002
ENV3_shft1
[g]
Basis
0.00
Current
0.00
Alert
0.01
REF_Corr
0.11
Trend
0.07
100
200
300
400
500
600
700
800
900
1000
1100
1200
REF:
T530avg
Fig.2
Envelope 3
1300 hr
50 0.025
40
Sun Shaft
0.02
30 0.015
20
Ok
CONDITION
0
0
g
Envelope 3
0.01
10 0.005
ENV3_shft2
[g]
Basis
0.00
Current
0.00
Alert
0.02
REF_Corr
0.00
Trend
0.40
Ok
CONDITION
0
kNm
50
40
0
0
g
100
200
300
400
500
600
700
800
900
1000
1100
1200
1.2
0
kNm
50
40
20
[kNm]
Basis
0.65
0.68
Alert
1.09
0.4
REF_Corr
0.45
Trend
0.30
0.2
0
0
kNm
100
200
300
400
500
600
700
800
900
1000
1100
1200
REF:
T530avg
Fig.4
Torque
1300 hr
3.5
Sun Shaft
2
1.5
0.5
Basis - Range
TRQ_shaft2
[kNm]
Basis
1.66
Current
1.82
Alert
3.35
REF_Corr
0.03
Trend
0.06
Ok
CONDITION
REF:
0
0
kNm
Ok
CONDITION
10
kNm
TRQ_shaft1
Current
Torque
0.6
2.5
30
Fig.3
Bevel Shaft
1
30
10
T530avg
1300 hr
0.8
20
REF:
100
Days
200
300
400
500
600
700
800
900
1000
30
2013-07-31 - 2013-09-26
Title
2013-11-09 - 2013-11-10
Gearbox
Hours
Date
Data conditions
Operation Time
1308
2013-07-31 - 2013-11-16
Sample Rate
1100
1200
T530avg
1300 hr
Shaft Faults:
Torque and Envelope
10 1/hr
Compress
12 hr
Standstill
Removed
Plant:
RAJGANGPUR
Page:
15/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
0.7
Fig.1
50
GMF Stg 1
0.6
40
30
GMFs_PL1
[g]
Basis
0.34
0.4
Current
0.33
0.3
Alert
0.61
REF_Corr
0.91
Trend
0.02
0.5
20
0.2
10
0
kNm
0.1
0
0
g
100
200
300
400
500
600
700
800
900
1000
1100
1200
REF:
T530avg
Fig.2
Sensor 4
1300 hr
Planet Stg 1
0.012
D_PL1
[g]
Basis
0.00
Current
0.00
Alert
0.01
REF_Corr
0.47
0.004
Trend
0.00
0.002
CONDITION
0.01
30
0.008
20 0.006
10
0
kNm
0
0
g
100
200
300
400
500
600
700
800
900
1000
1100
1200
40
0.01
30 0.008
0.006
0.004
0
kNm
0.002
Fig.3
Sensor 4
D_RI1
[g]
Basis
0.00
Current
0.00
Alert
0.01
REF_Corr
0.45
Trend
0.00
100
200
300
400
500
600
700
800
900
1000
1100
1200
REF:
T530avg
Fig.4
Sensor 4
1300 hr
50
Sun Stg 1
40 0.0015
30
Ok
CONDITION
0
0
g
T530avg
Ring Stg 1
0.012
10
Ok
REF:
1300 hr
50 0.014
20
Ok
CONDITION
50 0.014
40
Sensor 4
0.001
20
0.0005
10
D_SUN1
[g]
Basis
0.00
Current
0.00
Alert
0.00
REF_Corr
0.20
Trend
0.02
Ok
CONDITION
0
kNm
REF:
0
0
g
Basis - Range
100
Days
200
300
400
500
600
700
800
900
1000
30
2013-07-31 - 2013-09-26
Title
2013-11-09 - 2013-11-10
Gearbox
Hours
Date
Data conditions
Operation Time
1308
2013-07-31 - 2013-11-16
Sample Rate
1100
1200
T530avg
1300 hr
Planetary Gear Faults

Stage 1
10 1/hr
Compress
12 hr
Standstill
Removed
Plant:
RAJGANGPUR
Page:
16/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
0.08
50
40
Fig.1
GMF Stg 2
0.07
GMFs_PL2
[g]
Basis
0.04
Current
0.04
Alert
0.07
0.03
REF_Corr
0.92
0.02
Trend
0.09
0.01
CONDITION
0.06
0.05
30
0.04
20
10
0
kNm
0
0
g
100
200
300
400
500
600
700
800
900
1000
1100
1200
T530avg
Fig.2
Sensor 5
1300 hr
Planet Stg 2
0.03
40
0.025
0.02
20 0.015
0.01
10
0
kNm
50
0.005
100
200
300
400
500
600
700
800
900
1000
1100
1200
30
20
0.035
0
kNm
Basis
0.01
Current
0.01
Alert
0.03
REF_Corr
0.08
Trend
0.15
T530avg
Fig.3
Sensor 5
0.025
0.02
0.015
0.005
[g]
Basis
0.01
Current
0.01
Alert
0.03
REF_Corr
0.07
Trend
0.15
100
200
300
400
500
600
700
800
900
1000
1100
1200
REF:
T530avg
Fig.4
Sensor 5
1300 hr
Sun Stg 2
0.04
40
0.03
30
10
Ok
CONDITION
0
0
g
D_RI2
50
20
Ok
REF:
Ring Stg 2
0.01
10
[g]
1300 hr
0.03
40
D_PL2
CONDITION
0
0
g
Ok
REF:
50 0.035
30
Sensor 5
0.02
0.01
D_SUN2
[g]
Basis
0.02
Current
0.02
Alert
0.04
REF_Corr
0.16
Trend
0.10
Ok
CONDITION
0
kNm
REF:
0
0
g
Basis - Range
100
Days
200
300
400
500
600
700
800
900
1000
30
2013-07-31 - 2013-09-26
Title
2013-11-09 - 2013-11-10
Gearbox
Hours
Date
Data conditions
Operation Time
1308
2013-07-31 - 2013-11-16
Sample Rate
1100
1200
T530avg
1300 hr
Planetary Gear Faults

Stage 2
10 1/hr
Compress
12 hr
Standstill
Removed
80
80
80
80
80
75
75
75
75
75
70
70
70
70
70
65
65
65
65
65
60
60
60
60
60
55
55
55
55
55
50
50
50
50
50
45
45
45
45
45
40
40
40
40
40
35
35
35
35
35
30
30
30
30
30
25
25
25
25
25
20
20
20
20
20
15
15
15
15
15
10
10
10
10
10
Plant:
RAJGANGPUR
Page:
17/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
1200
1150
1100
1050
1000
950
900
850
800
750
700
650
600
550
500
450
400
350
300
250
200
150
100
50
0
kNm
kNm
kNm
0
0
kNm
kNm
Feature
01 T530avg
02 T530max
03 T530min
04 T530ptp
05 T530sdv
06 SPEEDavg
Days
200
300
400
Phys.Unit
kNm
[kNm]
[kNm]
[kNm]
[kNm]
[1/min]
01 T530avg
02 T530max
03 T530min
04 T530ptp
05 T530sdv
06 SPEEDavg
Basis - Range
0
100
500
600
700
max
42.26
54.02
32.37
25.20
3.77
998.83
800
900
min
32.95
44.22
22.73
18.83
2.66
988.23
1000
1100
mean
38.47
49.81
28.27
21.52
3.10
995.10
1200
1300 hr
1/min
sdev
1.90
2.02
1.99
1.37
0.21
1.47

Torque maximum values
Torque minimum values
Torque peak to peak values
Torque standard deviation values
Input Shaft Speed mean values
30
Title
Gearbox
Hours
Date
Data conditions
Operation Time
1308
2013-07-31 - 2013-11-16
Sample Rate
Torque Progress
over measurement Period
10 1/hr
Compress
12 hr
Standstill
Removed
Rcorr
1.00
0.93
0.94
-0.00
-0.05
-0.07
Day
01.10.2013
02.10.2013
03.10.2013
04.10.2013
05.10.2013
06.10.2013
07.10.2013
08.10.2013
09.10.2013
10.10.2013
11.10.2013
12.10.2013
13.10.2013
14.10.2013
15.10.2013
16.10.2013
17.10.2013
18.10.2013
19.10.2013
20.10.2013
21.10.2013
22.10.2013
23.10.2013
24.10.2013
25.10.2013
26.10.2013
27.10.2013
28.10.2013
29.10.2013
30.10.2013
31.10.2013
Sum Oct
Plant:
RAJGANGPUR
Page:
18/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
TORQUE ALARM-EVENTS (Exclude start processing) 10.2013

2
3
4
5
6
7
T--neg
T--dyn
T--max
T--avg
Vibr.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
T--neg
T--dyn
T--max
T--avg
Vibr.
0
0
0
0
0
1
T--impct
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
T--impct
0
Alarm
Sum
Production
Hours
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Total
0
4
19
4
0
1
10
23
20
21
8
16
0
0
0
11
14
24
14
0
12
20
3
14
24
24
24
24
4
11
21
22
Hours
392
Alarm-Sum and Production Time

9
8
24
23
20
19
24 24 24 24
21
21
20
22
6
14
14
15
14
12
11
10
11
6
4
3
0
0 0 0
01.10.13
02.10.13
03.10.13
04.10.13
05.10.13
06.10.13
07.10.13
08.10.13
09.10.13
10.10.13
11.10.13
12.10.13
13.10.13
14.10.13
15.10.13
16.10.13
17.10.13
18.10.13
19.10.13
20.10.13
21.10.13
22.10.13
23.10.13
24.10.13
25.10.13
26.10.13
27.10.13
28.10.13
29.10.13
30.10.13
31.10.13
Alarm
12
9
21
18
16
24
3
0
Prodct.
hrs
Plant:
RAJGANGPUR
Page:
19/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
Day
01.11.2013
02.11.2013
03.11.2013
04.11.2013
05.11.2013
06.11.2013
07.11.2013
08.11.2013
09.11.2013
10.11.2013
11.11.2013
12.11.2013
13.11.2013
14.11.2013
15.11.2013
16.11.2013
17.11.2013
18.11.2013
19.11.2013
20.11.2013
21.11.2013
22.11.2013
23.11.2013
24.11.2013
25.11.2013
26.11.2013
27.11.2013
28.11.2013
29.11.2013
30.11.2013
1
T--impct
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
TORQUE ALARM-EVENTS (Exclude start processing) 11.2013

2
3
4
5
6
7
T--neg
T--dyn
T--max
T--avg
Vibr.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Sum Nov
T--impct
0
T--neg
0
T--dyn
0
T--max
0
T--avg
0
Vibr.
0
Alarm
Sum
Production
Hours
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
18
7
23
5
0
19
23
10
10
17
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Total
0
Hours
132

9
8
23
24
23
21
19
6 18
18
17
15
12
10 10
30.11.13
29.11.13
28.11.13
27.11.13
26.11.13
25.11.13
24.11.13
23.11.13
22.11.13
21.11.13
20.11.13
19.11.13
18.11.13
17.11.13
16.11.13
15.11.13
14.11.13
13.11.13
12.11.13
10.11.13
09.11.13
08.11.13
07.11.13
06.11.13
05.11.13
04.11.13
03.11.13
02.11.13
01.11.13
Alarm
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11.11.13
0
Prodct.
hrs
Plant:
RAJGANGPUR
Page:
20/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
TORQUE ALARM-EVENTS (Exclude start processing) 2013

1
Month
T--impct
T--neg
T--dyn
T--max
T--avg
Vibr.
Alarm
Sum
Production
Hours
Jan
Feb
Mar
Apr
May
Jun
Jul
12
Aug
278
Sep
497
Oct
389
Nov
130
Dec
T--impct
T--neg
T--dyn
T--max
T--avg
Vibr.
Total
Hours
1306
Sum 2013
Annual Sum of Alarms and Production Time

10
9
497
8
7
389
6
5
278
4
3
130
2
1
0
Alarm
600
550
500
450
400
350
300
250
200
150
100
50
0
12
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
DecProdct.
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
10
9
8
7
6
5
4
3
2
1
0
T--impct
T--neg
T--dyn
T--max
T--avg
Vibr.
hrs
Day
01.10.2013
02.10.2013
03.10.2013
04.10.2013
05.10.2013
06.10.2013
07.10.2013
08.10.2013
09.10.2013
10.10.2013
11.10.2013
12.10.2013
13.10.2013
14.10.2013
15.10.2013
16.10.2013
17.10.2013
18.10.2013
19.10.2013
20.10.2013
21.10.2013
22.10.2013
23.10.2013
24.10.2013
25.10.2013
26.10.2013
27.10.2013
28.10.2013
29.10.2013
30.10.2013
31.10.2013
Sum Oct
1
T--impct
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
T--impct
0
Plant:
RAJGANGPUR
Page:
21/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
2
T--neg
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
T--neg
1
TORQUE ALARM-EVENTS (Starting processing) 10.2013

3
4
5
6
T--dyn
T--max
T--avg
Vibr.
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
T--dyn
T--max
T--avg
Vibr.
2
0
0
0
Alarm
Sum
Production
Hours
1
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Total
3
4
19
4
0
1
10
23
20
21
8
16
0
0
0
11
14
24
14
0
12
20
3
14
24
24
24
24
4
11
21
22
Hours
392

9
8
24
23
20
19
24 24 24 24
21
21
20
22
6
14
14
15
14
12
11
10
11
6
4
3
0
0 0 0
01.10.13
02.10.13
03.10.13
04.10.13
05.10.13
06.10.13
07.10.13
08.10.13
09.10.13
10.10.13
11.10.13
12.10.13
13.10.13
14.10.13
15.10.13
16.10.13
17.10.13
18.10.13
19.10.13
20.10.13
21.10.13
22.10.13
23.10.13
24.10.13
25.10.13
26.10.13
27.10.13
28.10.13
29.10.13
30.10.13
31.10.13
Alarm
12
9
21
18
16
24
3
0
Prodct.
hrs
Plant:
RAJGANGPUR
Page:
22/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
Day
01.11.2013
02.11.2013
03.11.2013
04.11.2013
05.11.2013
06.11.2013
07.11.2013
08.11.2013
09.11.2013
10.11.2013
11.11.2013
12.11.2013
13.11.2013
14.11.2013
15.11.2013
16.11.2013
17.11.2013
18.11.2013
19.11.2013
20.11.2013
21.11.2013
22.11.2013
23.11.2013
24.11.2013
25.11.2013
26.11.2013
27.11.2013
28.11.2013
29.11.2013
30.11.2013
1
T--impct
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
2
T--neg
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Sum Nov
T--impct
0
T--neg
0
TORQUE ALARM-EVENTS (Starting processing) 11.2013

3
4
5
6
T--dyn
T--max
T--avg
Vibr.
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
T--dyn
1
T--max
0
T--avg
0
Vibr.
0
Alarm
Sum
Production
Hours
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
18
7
23
5
0
19
23
10
10
17
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Total
1
Hours
132

9
8
23
24
23
21
19
6 18
18
17
15
12
10 10
30.11.13
29.11.13
28.11.13
27.11.13
26.11.13
25.11.13
24.11.13
23.11.13
22.11.13
21.11.13
20.11.13
19.11.13
18.11.13
17.11.13
16.11.13
15.11.13
14.11.13
13.11.13
12.11.13
10.11.13
09.11.13
08.11.13
07.11.13
06.11.13
05.11.13
04.11.13
03.11.13
02.11.13
01.11.13
Alarm
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11.11.13
0
Prodct.
hrs
Plant:
RAJGANGPUR
Page:
23/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
TORQUE ALARM-EVENTS (Starting processing) 2013

1
Month
T--impct
T--neg
T--dyn
T--max
T--avg
Vibr.
Alarm
Sum
Production
Hours
Jan
Feb
Mar
Apr
May
Jun
Jul
12
Aug
278
Sep
497
Oct
389
Nov
130
Dec
T--impct
T--neg
T--dyn
T--max
T--avg
Vibr.
Total
Hours
1306
Sum 2013
Annual Sum of Alarms and Production Time

10
9
497
8
7
389
6
5
278
4
3
130
2
1
0
Alarm
600
550
500
450
400
350
300
250
200
150
100
50
0
12
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
DecProdct.
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
10
9
8
7
6
5
4
3
2
1
0
T--impct
T--neg
T--dyn
T--max
T--avg
Vibr.
hrs
Plant:
RAJGANGPUR
Page:
24/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
Plant:
RAJGANGPUR
Page:
25/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT
Plant:
RAJGANGPUR
Page:
26/26
Type:
RENK KPBV 190
Date:
2013-11-19
Data:
5400kW / 990rpm / 52.1kNm
Name:
BeT

Renk KPBV190 2013 11 19

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REPORT

REPORT NUMBER: OCL - RAJGANGPUR 05-242-01.78

Date of Report: 2013-11-19

RENK KPBV 190

5400kW / 990rpm / 52.1kNm

Gearbox Condition Display

Condition Summary Comments

SENSOR 3 Acceleration - Vibration Condition Indicator: Bevel Gear

SENSOR 4 Acceleration - Vibration Condition Indicator: Planetary Gear Stage 1

SENSOR 5 Acceleration - Vibration Condition Indicator: Planetary Gear Stage 2

SENSOR 8 to 13 Temperature: Bearing Gearbox

SENSOR 14 to 17 Temperature: Axial Thrust Bearing

SENSOR 18 Displacement: Input Shaft

SENSOR 19 to 20 Temperature and Pressure: Gearbox Oil Parameters

Bevel Gear Faults Gear Mesh Frequencies GMF

Shaft Anomaly Indicators: Torque and Envelope

Planetary Gear Faults Stage 1

Planetary Gear Faults Stage 2

Torque Progress over measurement Period

Torque Alarm - Process Mode - Events I October 2013

Torque Alarm - Process Mode - Events II November 2013

Torque Alarm - Process Mode - Events III Year 2013

Torque Alarm - Start Up Mode - Events I October 2013

Torque Alarm - Start Up Mode - Events II November 2013

Torque Alarm - Start Up Mode - Events III Year 2013

How to read this Report 1

How to read this Report 2

How to read this Report 3

DALOG Diagnosesysteme GmbH

RENK KPBV 190

5400kW / 990rpm / 52.1kNm

Speed Sensor - Input Shaft

Torque Sensor - Input Shaft

Acceleration Sensor - Bevel Gear

Acceleration Sensor - Planetary Gear Stage 1

Acceleration Sensor - Planetary Gear Stage 2

Vibration Velocity Sensor - X-Direction near Grinding Bed

Vibration Velocity Sensor - Housing / Gearbox Foundation

Temperature Sensor - Input Shaft Outer Bearing

Temperature Sensor - Input Shaft Inner Bearing

Temperature Sensor - Input Shaft Inner Bearing

Temperature Sensor - Sun Shaft Lower Bearing

Temperature Sensor - Sun Shaft Upper Bearing

Temperature Sensor - Planetary Guide Bearing

Sensor 14...17 21 / 1...4

Temperature Sensor - Thrust Pads Axial Bearing 1...4

Displacement Sensor - Axial Input Shaft

Temperatur Sensor - Oil Inlet

Pressure Sensor - Oil Filter Differential

Pressure Sensor - Oil Inlet

Remarkable trend or sensor faults

Trend over Alert level

Trend over Danger level

RENK KPBV 190

5400kW / 990rpm / 52.1kNm

2. Condition of the Bevel Gears:

3. Condition of the Planetary Gear Stage 1:

4. Condition of the Planetary Gear Stage 2:

RENK KPBV 190

5400kW / 990rpm / 52.1kNm

Current - Range Days

SENSOR 3 Condition Indicator:

RENK KPBV 190