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Introduction

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. 

Key Facts

  • Air Recirculation Fan
  • Overheating of bearings
  • Incorrect fitting
  • Incorrect lubrication amounts and frequencies
  • NSK Solution: NSKHPS Spherical Roller Bearings within NSK SNN Plummer blocks and Labyrinth seals
  • Significant cost saving generated by removing the need for compressed air cooling
  • Air Recirculation Fan
  • NSK HPS SRB and NSK SNN Plummer Block

Value Proposals

  • NSK engineering conducted an Application Review including a Temperature Survey and a Bearing Condition Report
  • NSK engineers recommended NSKHPS Spherical Roller Bearings in combination with SNN Plummer Blocks and Labyrinth seals and suggested changes in the lubrication amount and intervals
  • Trial conducted, with NSK Engineering overseeing the installation and implementation of NSK recommendations
  • The customer benefited from increased productivity, reduced maintenance costs and the removal of compressed air resulting in a significant cost saving

Product Features

  • Highest load rating SRB's
  • Optimum raceway design & surface finishing
  • Brass cage design (CAM) or strengthened steel cage (EA)
  • High cleanliness Z-steel
  • Temperature stability: up to 200° C
  • 40 mm to 260 mm bore size
  • Up to twice the operating life
  • Up to 20% higher limiting speed
  • Dynamic load rating: 25% higher
  • Lower maintenance cost and improved productivity
  • High load rating enables downsizing

Cost Saving Breakdown

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
Total Costs $423,450 $1,524

Reference:SS-E-2052

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