An international steel manufacturer was experiencing bearing failures on a rotary coal valve in their ore preparation plant. Failures were occuring twice per year resulting in significant lost production costs and damage to associated components. An application review identifying the current bearing design was inadequate for the applications high temperatures. NSK recommended a customized HLT bearing insert within a Self-Lube cast iron FC housing and a special heat isolating spacer. Testing of the NSK recommendation was conducted with NSK Applications Engineers overseeing the correct fitting of the bearing units within the application. The NSK bearings ran for over 12 months with no bearing failure resulting in a large overall cost saving.
|Before||Cost p.a.||NSK Solution||Cost p.a.|
|Replacement costs x 2 times per year||$135||Replacement cost once a year||$68|
|$95/hr x 7 hours per breakdown for 2 engineers x 2 times per year||$1330||$95/hr x 7 hours fitting for 2 engineers once a year||$665|
|$9,581/hr x 7 hours per breakdown x 2 times per year||$134,134||Downtime eliminated||€ 0|
|$2,738 per month for shutdown to relubricate||$32,856||$1,051 per month for shutdown to re-lubricate||$12,612|