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Introduction

A steel maker was experiencing problems with their continuous casting machine. The life of a Cylindrical Roller Bearing mounted on a continuous cast roller was only about one to two months. The casting machine had a very complicated cooling and lubricating piping system. High maintenance costs was the biggest problem because of the necessary process to reconnect the piping system. NSK proposed to assemble the rollers of one segment with Sealed Spherical Roller Bearings equipped with high temperature grease. This resulted in significant improvement of the bearing performance along with reduced maintenance cost.

Key Facts

  • Continuous Casting Machine
  • Long replacement time for Cylindrical Roller Bearing with oil lubrication due to complicated piping system
  • NSK Solution: Sealed Spherical Roller Bearings specifically designed for the application
  • Significant increase in operating life
  • Improved bearing protection
  • Eco-friendly due to lack of contamination from the equipment
  • Reduction in maintenance time and cost
  • Continuous Casting Machine
Sealed Spherical Roller Bearing
  • Sealed Spherical Roller Bearing

Value Proposals

  • NSK analyzed the application and proposed to assemble Sealed Spherical Roller Bearings in one segment
  • With the new bearings, a dismantling and re-installation of the oil piping system was not necessary
  • Eco-friendly system reducing the oil consumption as bearings included high-temperature grease
  • Required time for replacement of the roller in segments was reduced from 20 to 10 hours
  • The operating life was increased from 2 to 4 months

Product Features

  • Special “outward-extending, spring loaded lip seal”
  • Nitride rubber seal – or differing seals depending on temperature needs
  • Special long-life grease: heat & pressure resistant
  • Symmetrical roller & raceway design to prevent edge loading problems
  • Special chamfer configuration for smooth axial movement
  • Seal retains grease offering longer running time with improved efficiency
  • Reduction in grease consumption & no  leaks due to special seal offer cleaner working environments
  • Increased uptime

Cost Saving Breakdown

Before Cost p.a. NSK Solution Cost p.a.
6 Sets of bearings per segment per year $27,016 3 Sets of bearings per segment per year $30,393
6 Replacements per year x 3 hours $19,297 3 Replacements per year x 3 hours $9,647
6 Replacements x 20 hours $12,865 3 Replacements x 10 hours $3,216
Total Costs $59,178 $43,256

Reference:SS-E-7005

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