A customer experienced bearing failure on an Air Recirculation Fan application within an ore preparation plant. This had been a regular problem. Compressed air cooling was applied to try and reduce the bearings high running temperature.
NSK Engineers carried out an Application Review including a temperature survey of the fan and bearings, revealing major issues with incorrect fitting of the bearings, over lubrication and inadequate sealing arrangement. NSK recommended using NSKHPS Spherical Roller Bearings within NSK SNN Plummer Blocks and NSK Labyrinth seals. In addition recommendations were given for correct fitting and correct lubrication intervals and quantities.
A trial was conducted resulting in no bearing failure for more than 12 months. The compressed air cooling was also removed adding additional savings.
|Before||Cost p.a.||NSK Solution||Cost p.a.|
|$9,002/hour x 36hours shift due to bearing failure||$324,072||No downtime||$0|
|$45/hr x 36hours x 2 persons due to bearing failure||$3,240||Manpower, fitting of NSK bearing $45/hr x 8hours x 2 persons||$720|
|Annual cost of compressed air||€ 88.954||Removal of compressed air||$0|
|Bearing cost||$804||Bearing cost||$804|