An international steel manufacturer was experiencing regular failures on a bearing fitted to a rotary coal valve in an ore preparation plant. This occured 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 high temperatures involved, NSK recommended a customised HLT bearing insert within a Self-Lube cast iron FC housing together with a special heat isolating spacer. A trial was conducted with NSK Applications Engineers overseeing the correct fitting of the bearing units within the application. The NSK bearings fitted ran for over 12 months with no bearing failure which resulted in a large overall cost saving for the customer.
|Before||Cost p.a.||NSK Solution||Cost p.a.|
|Cost of bearings x 2 times per year||€ 126||Costs of bearings once per year||€ 63|
|€89/hr x 7 hours per breakdown for 2 engineers x 2 times per year||€ 1.246||€89/hr x 7 hours fitting for 2 engineers x 1 times per year||€ 623|
|€8.938/hr x 7 hours per breakdown x 2 times per year||€ 125.132||No downtime costs||€ 0|
|€2.554 per month for shutdown to relubricate||€ 30.648||€981 per month for shutdown to re-lubricate||€ 11.772|
|Total Costs||€ 157.152||€ 12.458|