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2009<br />
<strong>Gearless</strong> <strong>Mill</strong> <strong>Drives</strong><br />
Machinery Risk Solutions<br />
Practice<br />
Matt Dugalic P.Eng., MARSH – MRSP Risk Consultant, VP<br />
Kurt Tischler Dipl.-Ing., Siemens – Product Manager, Mining<br />
www.marsh.ca www.marsh.com
WHY shift to the gearless drives in mineral processing ???<br />
� <strong>Mill</strong> size – grinding economies of scale<br />
� Relative lifecycle cost<br />
� Lower power consumption<br />
� Robust design<br />
� Avoiding critical open gear power trains<br />
� Variable speed<br />
� Compatibility with processing plants<br />
� Engineering design efficiencies<br />
� Availability<br />
� Minimal downtime<br />
Marsh<br />
1
Marsh<br />
However,<br />
from the machinery breakdown<br />
underwriting perspective, this<br />
often creates a<br />
critical, single point exposure !!!<br />
2
Significant Mining Industry Property Losses (Jan 2006 – Jul 2009)<br />
Class Loss Type Gross Claim<br />
Marsh<br />
(MM US$)<br />
Coal Flood +/- 603<br />
Coal Flood +/- 550<br />
Coal Flood +/- 450<br />
Iron Storm / Flooding +/- 180<br />
Manganese Smelter Explosion +/- 170<br />
Platinum Flood +/- 140.3<br />
Iron / Salt Typhoon (Glenda) +/- 122.4<br />
Copper & Zinc Electrical Flashovers of SAG <strong>Mill</strong> Stator +/- 115<br />
Iron / Salt Typhoon (Emma) +/- 107.7<br />
. . .<br />
Siemens<br />
3
www.marsh.ca www.marsh.com
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Mastertextformat bearbeiten<br />
Zweite Ebene<br />
Dritte Ebene<br />
Vierte Ebene<br />
Fünfte Ebene<br />
Siemens’ <strong>Gearless</strong> Drive Technology<br />
Performance<br />
Facts & Figures<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Performance<br />
Content<br />
� Experience & References (5 minutes)<br />
� Maintenance, Service (2 minutes)<br />
� Major Problems and their Solutions (25 minutes)<br />
Cadia, Repairs, Lessons learned<br />
Chilean plant, Rotor failure<br />
� Performance: Downtime; Availability (10 minutes)<br />
Page 2 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Experience First <strong>Gearless</strong> Drive in Mining<br />
Sydvaranger Norway<br />
<strong>Gearless</strong> Drive 8200 kW<br />
for a Ballmill<br />
of 21.3 ft ID<br />
Start-up:<br />
1980<br />
Page 3 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Experience<br />
Sydvaranger Norway<br />
<strong>Gearless</strong> Drive 8200 kW<br />
for a Ballmill<br />
of 21.3 ft ID<br />
Start-up:<br />
1980<br />
History:<br />
1997: Shutdown of plant<br />
due to low iron prices<br />
2005:<br />
<strong>Mill</strong> and <strong>Gearless</strong> Drive<br />
sold to Zinifex Australia<br />
Page 4 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Experience<br />
Sydvaranger Norway<br />
<strong>Gearless</strong> Drive 8200 kW<br />
for a Ballmill<br />
of 21.3 ft ID<br />
Start-up:<br />
1980<br />
History:<br />
1997: Shutdown of plant<br />
due to low iron prices<br />
2005:<br />
<strong>Mill</strong> and <strong>Gearless</strong> Drive<br />
sold to Zinifex Australia<br />
2008: Restart in Zinifex’<br />
Century Zinc Plant<br />
Page 5 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
CODELCO Chuquicamata, 2 GD 8210kW, 32’<br />
First SAG-<strong>Mill</strong> <strong>Gearless</strong> <strong>Drives</strong><br />
Start-up:<br />
1988<br />
Altitude:<br />
3000 m<br />
Page 6 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
CODELCO El Teniente, GD 12000 kW<br />
First 36’ SAG-<strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Start-up:<br />
1991<br />
Page 7 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Freeport II; Indonesia, 20400 kW<br />
First 38’ SAG-<strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Start-up:<br />
1997<br />
Altitude:<br />
2700 m<br />
Page 8 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia Australia, GD 20000 kW,<br />
First 40’ SAG-<strong>Mill</strong> <strong>Gearless</strong> <strong>Drives</strong><br />
Start-up:<br />
1998<br />
Page 9 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
References<br />
Plant<br />
SYDVARANGER<br />
CHUQUICAMATA 1<br />
CHUQUICAMATA 2<br />
EL TENIENTE<br />
GOLDFIELDS 1<br />
GOLDFIELDS 2<br />
KENNECOTT<br />
NORILSK NICKEL 1<br />
NORILSK NICKEL 2<br />
CANDELARIA 1<br />
FREEPORT 1<br />
ALUMBRERA 1<br />
ALUMBRERA 2<br />
FREEPORT 2<br />
CANDELARIA 2<br />
CADIA<br />
ANDINA<br />
OLYMPIC DAM<br />
PELAMBRES 1<br />
PELAMBRES 2<br />
20 <strong>Gearless</strong> <strong>Drives</strong><br />
Country<br />
Norway<br />
Chile<br />
Chile<br />
Chile<br />
South Africa<br />
South Africa<br />
USA<br />
Russia<br />
Russia<br />
Chile<br />
Indonesia<br />
Argentina<br />
Argentina<br />
Indonesia<br />
Chile<br />
Australia<br />
Chile<br />
Australia<br />
Chile<br />
Chile<br />
Type of <strong>Mill</strong><br />
Ball-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
AG-<strong>Mill</strong><br />
AG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
AG-<strong>Mill</strong><br />
AG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
AG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
ID of <strong>Mill</strong> (ft)<br />
Total Power<br />
233,542<br />
Page 10 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009<br />
21.3<br />
32<br />
32<br />
36<br />
16.4<br />
16.4<br />
36<br />
21.3<br />
21.3<br />
36<br />
34<br />
36<br />
36<br />
38<br />
36<br />
40<br />
36<br />
38<br />
36<br />
36<br />
Rated Power (kW) Start-up<br />
8,200<br />
8,210<br />
8,210<br />
11,200<br />
4,000<br />
4,000<br />
12,000<br />
9,650<br />
9,650<br />
12,000<br />
10,600<br />
13,400<br />
13,400<br />
20,400<br />
12,000<br />
20,000<br />
12,000<br />
18,000<br />
13,311<br />
13,311<br />
1980<br />
1988<br />
1989<br />
1990<br />
1990<br />
1990<br />
1991<br />
1991<br />
1991<br />
1993<br />
1995<br />
1997<br />
1997<br />
1997<br />
1997<br />
1998<br />
1998<br />
1998<br />
1999<br />
1999<br />
kW
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
References<br />
Plant<br />
20 above<br />
SAN CRISTOBAL<br />
SAN CRISTOBAL<br />
SAN CRISTOBAL<br />
EL TENIENTE<br />
EL TENIENTE<br />
EL TENIENTE<br />
EL TENIENTE<br />
Barrick Cowal<br />
Barrick Cowal<br />
Equinox Lumwana<br />
Equinox Lumwana<br />
RPM Kinross<br />
Peñasquito<br />
Peñasquito<br />
Los Pelambres<br />
Los Pelambres<br />
Las Brisas<br />
Las Brisas<br />
ANGLO Los Bronces<br />
39 <strong>Gearless</strong> <strong>Drives</strong><br />
Country<br />
Bolivia<br />
Bolivia<br />
Bolivia<br />
Chile<br />
Chile<br />
Chile<br />
Chile<br />
Australia<br />
Australia<br />
Zambia<br />
Zambia<br />
Brazil<br />
México<br />
México<br />
Chile<br />
Chile<br />
Venezuela<br />
Venezuela<br />
Chile<br />
Type of <strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
Ball-<strong>Mill</strong><br />
Ball-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
Ball-<strong>Mill</strong><br />
Ball-<strong>Mill</strong><br />
Ball-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
Ball-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
Ball-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
Ballmill<br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
ID of <strong>Mill</strong> (ft)<br />
Total Power<br />
520,310<br />
Scheduled 2011<br />
Page 11 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009<br />
36<br />
22<br />
22<br />
38<br />
24<br />
24<br />
24<br />
36<br />
22<br />
38<br />
26<br />
38<br />
38<br />
38<br />
36<br />
26<br />
38<br />
38<br />
40<br />
Rated Power (kW) Start-up<br />
233,542<br />
13,050<br />
7,830<br />
7,830<br />
19,400<br />
11,186<br />
11,186<br />
11,186<br />
12,500<br />
10,500<br />
18,000<br />
15,000<br />
20,000<br />
18,300<br />
18,300<br />
15,000<br />
15,500<br />
20,000<br />
20,000<br />
22,000<br />
2007<br />
2007<br />
2007<br />
2003<br />
2003<br />
2003<br />
2006<br />
2006<br />
2006<br />
2008<br />
2008<br />
2008<br />
Scheduled 2009<br />
Scheduled 2010<br />
Scheduled 2010<br />
Scheduled 2010<br />
Project stopped<br />
Project stopped<br />
kW
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
References<br />
Plant<br />
39 above<br />
ANGLO Los Bronces<br />
CP –Mining<br />
CP –Mining<br />
CP –Mining<br />
CP –Mining<br />
CP –Mining<br />
CP –Mining<br />
CP –Mining<br />
Xstrata Las Bambas<br />
Xstrata Las Bambas<br />
Xstrata Las Bambas<br />
Aurox Balla Balla<br />
Aurox Balla Balla<br />
Antamina<br />
Antamina<br />
Escondida<br />
Escondida<br />
Escondida<br />
Escondida<br />
58 <strong>Gearless</strong> <strong>Drives</strong><br />
Country<br />
Chile<br />
Australia<br />
Australia<br />
Australia<br />
Australia<br />
Australia<br />
Australia<br />
Australia<br />
Peru<br />
Peru<br />
Peru<br />
Australia<br />
Australia<br />
Peru<br />
Peru<br />
Chile<br />
Chile<br />
Chile<br />
Chile<br />
Type of <strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
SAG-<strong>Mill</strong><br />
Ballmill<br />
Ballmill<br />
SAG-<strong>Mill</strong><br />
Ballmill<br />
SAG-<strong>Mill</strong><br />
Ballmill<br />
SAG-<strong>Mill</strong><br />
Ballmill<br />
Ballmill<br />
Ballmill<br />
ID of <strong>Mill</strong> (ft)<br />
Scheduled 2011<br />
Page 12 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009<br />
26<br />
40<br />
40<br />
40<br />
40<br />
40<br />
40<br />
40<br />
40<br />
26<br />
26<br />
34<br />
26<br />
38<br />
24<br />
40<br />
26<br />
26<br />
26<br />
Total Power<br />
Rated Power (kW) Start-up<br />
520,310 above<br />
16,400<br />
28,000<br />
28,000<br />
28,000<br />
28,000<br />
28,000<br />
28,000<br />
28,000<br />
24,000<br />
16,400<br />
16,400<br />
14,000<br />
17,000<br />
20,142<br />
11,190<br />
22,000<br />
15,700<br />
15,700<br />
15,700<br />
892,942<br />
Scheduled 2011<br />
Scheduled 2009<br />
Scheduled 2009<br />
Scheduled 2010<br />
Scheduled 2010<br />
Scheduled 2010<br />
Scheduled 2010<br />
Scheduled 2011<br />
Scheduled 2011<br />
Scheduled 2011<br />
Project stopped<br />
Project stopped<br />
Scheduled 2011<br />
Scheduled 2011<br />
Project stopped<br />
Project stopped<br />
Project stopped<br />
Project stopped<br />
kW
Plant<br />
SIMINE CIS <strong>Mill</strong> gearless drives<br />
References<br />
58 above<br />
Escondida<br />
Escondida<br />
Escondida<br />
Xstrata 2<br />
Xstrata 2<br />
Xstrata 2<br />
64 <strong>Gearless</strong> <strong>Drives</strong><br />
Country<br />
Chile<br />
Chile<br />
Chile<br />
Peru or Chile<br />
Peru or Chile<br />
Peru or Chile<br />
Type of <strong>Mill</strong><br />
Ballmill<br />
Ballmill<br />
Ballmill<br />
SAG-<strong>Mill</strong><br />
Ballmill<br />
Ballmill<br />
ID of <strong>Mill</strong> (ft)<br />
in operation: 33<br />
in fabrication or installation: 21<br />
project stopped: 4<br />
order cancelled: 6<br />
Project stopped<br />
Page 13 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009<br />
26<br />
26<br />
26<br />
40<br />
26<br />
26<br />
Total Power<br />
Rated Power (kW) Start-up<br />
892,942 above<br />
15,700<br />
15,700<br />
15,700<br />
24,000<br />
16,400<br />
16,400<br />
1’003,920<br />
Project stopped<br />
Project stopped<br />
Scheduled 2011<br />
Scheduled 2011<br />
Scheduled 2011<br />
kW
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Clarification<br />
No flashovers in Siemens’ SAG-<strong>Mill</strong> Stators<br />
Page 14 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Clarification<br />
Collahuasi Chile: 40’ <strong>Gearless</strong> <strong>Mill</strong> Drive NOT Siemens supply<br />
Escondida Chile: 38’ <strong>Gearless</strong> <strong>Mill</strong> Drive NOT Siemens supply<br />
Escondida Chile: 25’ <strong>Gearless</strong> <strong>Mill</strong> <strong>Drives</strong> NOT Siemens supply<br />
Antamina Peru: 38’ <strong>Gearless</strong> <strong>Mill</strong> Drive NOT Siemens supply<br />
Antamina Peru: 24’ <strong>Gearless</strong> <strong>Mill</strong> <strong>Drives</strong> NOT Siemens supply<br />
Page 15 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
10<br />
9<br />
8<br />
7<br />
6<br />
5<br />
4<br />
3<br />
2<br />
1<br />
SIMINE <strong>Mill</strong> GD<br />
Experience<br />
Number<br />
11<br />
Goldfields<br />
Ball-<strong>Mill</strong>s SAG-<strong>Mill</strong>s<br />
Antamina<br />
El<br />
Kolskaya San Teniente<br />
Cristobal<br />
Syd- Cowal<br />
varanger<br />
Xstrada 2<br />
Antapaccay<br />
Pelambres<br />
Los Bronces<br />
Lumwana<br />
Pelambres<br />
San Cristobal<br />
Cowal<br />
Pelambres<br />
Andina<br />
Alumbrera<br />
Candelaria<br />
Kennecott<br />
El Teniente<br />
Chuquicamata<br />
Balla Balla<br />
Freeport<br />
Antamina<br />
Las Brisas<br />
Paracatu<br />
Peñasquito<br />
Lumwana<br />
El Teniente<br />
Olympic Dam<br />
Freeport<br />
16’ 21’ 22’ 24’ 26’<br />
32’ 34’ 36’ 38’ 40’<br />
Xstrada 2<br />
Antapaccay<br />
CP-Mining<br />
Los Bronces<br />
Cadia<br />
Page 16 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009<br />
<strong>Mill</strong><br />
Diameter
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Experience<br />
Total Operation hours<br />
SIMINE <strong>Mill</strong> GD in Mining:<br />
307<br />
Machine years<br />
until September 2009<br />
Page 17 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Experience<br />
Total Operation hours<br />
SIMINE <strong>Mill</strong> GD in Mining:<br />
105,000<br />
Machine days<br />
until September 2009<br />
Page 18 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Performance<br />
Content<br />
� Experience & References (5 minutes)<br />
� Maintenance, Service (2 minutes)<br />
� Major Problems and their Solutions (25 minutes)<br />
Cadia, Repairs, Lessons learned<br />
Chilean plant, Rotor failure<br />
Performance: Downtime; Availability (10 minutes)<br />
Page 19 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Maintenance, Service<br />
Preventive Maintenance of <strong>Gearless</strong><br />
Drive is performed during downtime<br />
for <strong>Mill</strong> Maintenance<br />
No additional downtime for preventive<br />
Maintenance of <strong>Gearless</strong> Drive<br />
Page 20 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Recommended Maintenance Schedule<br />
Page 21 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Recommended Maintenance Schedule<br />
Preventive maintenance recommended<br />
� Four (4) actions (in total 13 minutes) once per month, during operation,<br />
� Eleven (11) actions (in total 247 minutes) once per 3 months, during operation,<br />
� Two (2) actions (in total 130 minutes) once per 6 months,<br />
during downtime for maintenance of mill,<br />
� 27 actions (in total 25 hours and 46 minutes) once per year,<br />
during downtime for maintenance of mill,<br />
� Five (5) actions (in total 8 hours) once per 3 years,<br />
during downtime for maintenance of mill,<br />
� Five (5) actions (in total 9 hours) once per 5 years,<br />
during downtime for maintenance of mill,<br />
Page 22 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Maintenance, Service<br />
� Minimum work for maintenance of <strong>Gearless</strong> Drive,<br />
average of 37 hours per year,<br />
� Normal electricians and engineers are requested for scheduled<br />
maintenance,<br />
�Siemens offers maintenance and service contracts<br />
Page 23 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Performance<br />
Content<br />
� Experience & References (5 minutes)<br />
� Maintenance, Service (2 minutes)<br />
� Major Problems and their Solutions (25 minutes)<br />
Cadia, Repairs, Lessons learned<br />
Chilean plant, Rotor failure<br />
Performance: Downtime; Availability (10 minutes)<br />
Page 24 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia; Australia<br />
<strong>Gearless</strong> Drive 20 000 kW for a 40 ft. SAG-<strong>Mill</strong><br />
Observed Phenomena<br />
at the Motor of Cadia<br />
Commissioning in<br />
May 1998<br />
Elastic Deflections<br />
During Startup<br />
Vibrations<br />
during operation<br />
Page 25 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia: Investigation<br />
P [MW]<br />
20<br />
10<br />
0<br />
Resonance frequency of the stator system<br />
Operating<br />
range ran range ge<br />
7 Hz = 9.5 rpm<br />
Rated speed: 9.01 rpm<br />
Rated frequency: 6.6 Hz<br />
Maximum speed: 10.36 rpm<br />
Max. frequency: 7.6 Hz<br />
0 1 2 3 4 5 6 7 8 9 10 11 12<br />
f [Hz]<br />
Page 26 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia:<br />
Resonance of the stator system<br />
The resonance already appeared during commissioning in July 1998<br />
The problems occurred at cold<br />
condition of the motor.<br />
Reaching the operation temperature<br />
of the Ring motor the vibrations<br />
disappeared<br />
and the <strong>Gearless</strong> Drive was operated<br />
using the complete speed range<br />
Page 27 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia: Resonance of the stator system;<br />
PRELIMINARY MEASURES<br />
During commissioning stage Siemens provided preliminary measures to<br />
enable the operation of <strong>Gearless</strong> Drive and SAG-<strong>Mill</strong> also at cold condition.<br />
Pedestals with hydraulic jacks were installed at<br />
the stator bottom to increase stiffness of stator.<br />
Page 28 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia: Resonance of the stator system;<br />
PRELIMINARY MEASURES<br />
The preliminary measures allowed the operation in the complete speed range<br />
also in cold condition.<br />
The preliminary measures were so successful that Cadia<br />
operated the SAG-<strong>Mill</strong> continuously at full throughput.<br />
As a consequence Cadia allowed<br />
access for investigation<br />
only during liner change,<br />
six months after start of<br />
commercial operation.<br />
Page 29 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia: Resonance of the stator system;<br />
INVESTIGATION<br />
During liner change was performed the deflection measurement taken on<br />
the motor of Cadia with photogrammetric system<br />
Page 30 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia: Lessons learned<br />
Improved FE model, considering non-linear air gap behavior<br />
� Special airgap elements<br />
allow a direct input of<br />
excitation current<br />
� Reaction forces are<br />
calculated on deformed<br />
structure<br />
� Dynamic reaction of<br />
structure is calculated<br />
with direct time integration<br />
Foundation<br />
stiffness<br />
Stator modeled<br />
with beam<br />
elements<br />
<strong>Mill</strong><br />
stiffness<br />
<strong>Mill</strong> modeled<br />
as rigid body<br />
on springs<br />
Air gap<br />
elements<br />
Non-linear air gap force<br />
vs. deflection<br />
relation<br />
Page 31 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia: Lessons learned<br />
Improved FE model, considering non-linear air gap behavior<br />
3 rd mode shape:<br />
Ovalization<br />
Page 32 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia: Lessons learned<br />
Improved FE model, considering non-linear air gap behavior<br />
4 th mode shape:<br />
Twisting<br />
Page 33 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia: Repairs<br />
Modification of stator<br />
Modified form of the stator<br />
Additional stiffener built<br />
on the stator<br />
Page 34 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia: Resonance of the stator system;<br />
End of 1999 the stiffener was installed on the stator<br />
The installation of the<br />
stiffener was performed<br />
during a<br />
downtime of 7 days<br />
parallel to a liner change of<br />
five days.<br />
Page 35 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia: Resonance of the stator system;<br />
Final solution: Stator with stiffener<br />
Since installation of the stiffener, end of 1999, the Ring motor of Cadia<br />
does not show any vibrations any more.<br />
Page 36 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia: Rotor Pole Segments<br />
Cracks at support ribs<br />
Rotor poles<br />
Lamination core<br />
Rotor support<br />
Rotor flange<br />
<strong>Mill</strong> flange<br />
Page 37 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia: Rotor Pole Segments<br />
Cracks at support ribs<br />
Change of airgap at several<br />
spots was detected in 2003.<br />
The problem was investigated<br />
during liner change.<br />
Engineering analysis and repair<br />
concept was developed by<br />
Siemens together with Cadia and<br />
EAnD.<br />
Cadia published a paper on the SAG-conference 2006 in Vancouver.<br />
Please find more details there.<br />
Page 38 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia: Rotor Pole Segments<br />
Repair<br />
Repair was performed during a scheduled downtime of 15 days in<br />
June 2005 in parallel to a liner change, which normally needs four<br />
days.<br />
Page 39 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia <strong>Gearless</strong> Drive<br />
AVAILABILITY<br />
Start-up July 1998 to 2003 mechanical & electrical: 98.5 %<br />
From 2003 to 2005 electrical: 98.5 %<br />
2005 Repair of rotor electrical: 95.5 %<br />
2005 to date electrical: higher than 99 %<br />
Ring motor: 100 %<br />
Page 40 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia: Cracks of welding beams at rotor support<br />
Design Change<br />
Lamination<br />
Weld<br />
Pressure plate<br />
Flange plate<br />
Pressure bolt<br />
Divided rib<br />
Page 41 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia: Cracks of welding beams at rotor support<br />
Design Change<br />
Magnetic pull<br />
Magnetic pull<br />
Tensile<br />
Tensile<br />
load<br />
load<br />
Stator core<br />
Stress concentration<br />
Page 42 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia: Cracks of welding beams at rotor support<br />
Design Change<br />
Magnetic pull<br />
Tensile load<br />
Stator core<br />
The magnetic pull<br />
tries to bend the<br />
lamination and the rib<br />
welded on to it.<br />
Through this a tensile<br />
load arises in the<br />
lower edge of the rib.<br />
There is no stress<br />
concentration since<br />
the rib cross section<br />
is undisturbed.<br />
Page 43 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Cadia: Cracks of welding beams at rotor support<br />
Design Change<br />
Design Change was implemented 2005<br />
and is in operation in all Siemens <strong>Gearless</strong> <strong>Drives</strong> since then.<br />
Page 44 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
38’ <strong>Gearless</strong> <strong>Mill</strong> Drive, Chile<br />
Cracked Weld at rotor support<br />
� The 38’ SAG-<strong>Mill</strong> is in operation since<br />
September 2003<br />
� During the weekend of August 31, 2008 the SAG-<strong>Mill</strong><br />
stopped several times and was restarted.<br />
Finally the air gap supervision tripped the motor and did not permit to<br />
restart it again on September 1, at 4:48 a.m.<br />
� Air gap and rotor were revised and there was found a crack of a weld<br />
of the rotor segment support (Picture next page)<br />
� Specialists from Siemens Germany arrived on September 3 at site and<br />
investigated the motor. They found another crack at the same segment<br />
and another segment with cracks.<br />
� They started the repair on September 4 and the mill restarted on<br />
September 8, 2008 at 9:10 a.m.<br />
Page 45 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Chilean Plant<br />
Cracked Weld at rotor support<br />
Page 46 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Chilean Plant<br />
Origin: Fatigue by mechanical stress<br />
The mechanical stress is caused by three effects<br />
� Constant stress by constant magnetic force, (does not cause fatigue)<br />
Fatigue is caused by variable stress<br />
� Variable stress by gravity,<br />
� Variable stress by changing magnetic force over the circumference,<br />
due to air gap deformation<br />
Page 47 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Chilean Plant<br />
Variable Stress around the circumference<br />
Small air gap<br />
higher force<br />
Normal air gap deformation during operation<br />
Large air gap<br />
smaller force<br />
Page 48 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Chilean Plant<br />
Provisional Repair of Rotor Segment<br />
Page 49 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Chilean Plant<br />
Provisional Repair of Rotor Segment<br />
Page 50 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Chilean Plant,<br />
Provisional Repair of Rotor Segment<br />
Page 51 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Defect of rotor segments;<br />
Consequences for other users<br />
� Siemens investigated the possibility of similar damages in other<br />
Ring Motors and informed in September 2008 three other users to<br />
inspect the rotors:<br />
� Other Chilean Plant<br />
Inspection was performed during mill maintenance in February 2009:<br />
no findings<br />
� Australian plant<br />
Inspections were performed during plant maintenance in November<br />
2008 and February 2009:<br />
cracks were found and provisionally repaired;<br />
2 additional days of downtime;<br />
� Indonesian plant<br />
Inspection was performed during plant maintenance in April 2009<br />
cracks were found and provisionally repaired;<br />
12 additional hours of downtime;<br />
Page 52 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Chilean Plant<br />
Final Repair of Rotor Segment<br />
The final repair of the rotor segments were planned from<br />
June 30, 2009 to July 14, 2009,<br />
parallel to a mill maintenance (liner change) .<br />
After replacing 4 segments, turning of motor for positioning was<br />
interrupted by earth fault.<br />
There were found foreign objects in the air gap, which had damaged<br />
stator windings and rotor coils.<br />
Repair of windings and coils was finished August 10, 2009<br />
without completion of rotor segments.<br />
A failure of the feeding switchgear delayed the restart of production for<br />
another two days.<br />
Caused Downtime: 43 days minus 4 days for mill maintenance<br />
Page 53 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Performance<br />
Content<br />
� Experience & References (5 minutes)<br />
� Maintenance, Service (2 minutes)<br />
� Major Problems and their Solutions (25 minutes)<br />
Cadia, Repairs, Lessons learned<br />
Chilean Plant, Rotor failure<br />
Performance: Downtime; Availability (10 minutes)<br />
Page 54 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Downtime, Availability<br />
Major downtimes for repair:<br />
� Cadia, Vibrations,<br />
� Cadia, defect at the rotor segments,<br />
� Chilean Plant, defect at the rotor segments,<br />
� Australian plant, defect at the rotor segments<br />
� Indonesian plant, defect at the rotor segments<br />
Page 55 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Downtime, Availability<br />
Cadia; Vibrations<br />
� Downtime for repair: 7 days minus 5 days for liner change<br />
Cadia; Defect of rotor segments<br />
� During 2003 Cracks of welds at rotor support were found and<br />
provisionally repaired.<br />
Downtime: 5 days for investigation and repair<br />
minus 4 days for liner change.<br />
� In 2005 the final repair was performed with a downtime of 15 days.<br />
� Downtime for repair: 15 days minus 4 days for liner change<br />
Page 56 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Downtime, Availability<br />
Chilean plant; Defect of rotor segments<br />
� September 1, 2008 the air gap supervision of the 38’ Ring<br />
motor tripped the mill. Cracks were detected and provisionally<br />
repaired. September 8, 2008 the 38’ mill was restarted.<br />
9 days of unscheduled downtime<br />
� First part of final repair in 2009 including repair of occurred damages:<br />
Downtime: 43 days minus 4 days for mill maintenance<br />
� Scheduled completion of final repair in 2010:<br />
Downtime: 15 days minus 4 days for liner change<br />
Page 57 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Downtime, Availability<br />
Major downtimes for repair:<br />
� Cadia, Vibrations: 2 days<br />
� Cadia, defect at the rotor segments: provisional repair: 1 day….<br />
final repair: 11 days<br />
� Chilean plant, defect at the rotor segments: 2008: 9 days<br />
First part of repair in including repair of damages 2009: 39 days<br />
final repair, scheduled 2010: 11 days<br />
� Australian plant, defect at the rotor segments: 2009: 2 days<br />
final repair, scheduled 2010: 14 days<br />
� Indonesian plant, defect at rotor segments: 2009: 0.5 days<br />
final repair, date to be defined: 10 days<br />
Total sum 99.5 days<br />
Page 58 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
SIMINE <strong>Mill</strong> <strong>Gearless</strong> Drive<br />
Performance<br />
Total Operation hours<br />
SIMINE <strong>Mill</strong> GD in Mining:<br />
105,000<br />
Machine days<br />
until September 2009<br />
With major downtimes of in total 99.5 machine days<br />
Page 59 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009
Thank you for your attention!<br />
Contact:<br />
Kurt Tischler<br />
Siemens AG<br />
Metals Technologies<br />
Mining Industry<br />
W-v-Siemens-Str. 50<br />
91052 Erlangen / Germany<br />
Phone: +49 (9131) 7-42420<br />
Mail: kurt.tischler@siemens.com<br />
Page 60 October 2009 Kurt Tischler<br />
I IS MT MI<br />
Confidential / Copyright © Siemens AG 2009