WORLD COAL AUGUST VOLUME 20 NUMBER World Leader in Material Handling and Coal Preparation

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1 WORLD COAL AUGUST 2011 AUGUST VOLUME 20 NUMBER 08 Wrld Leader in Material Handling and Cal Preparatin

2 Smth peratins, n s r a L d i v Da., C n t r e t s e A.W. Chnes a simple US, utlti imprving appracahring reliability. be T he cal industry is cnstantly striving t imprve plant reliability and lwer perating csts. One particularly gd place t make savings is in bearing maintenance. Bearing failure can cause unplanned shutdwns, lst prductin and increased csts fr parts and labur. Mst maintenance persnnel are aware f the primary reasns fr shrtened bearing life, but d nt have the time, budget r slutins available t extend the mean time between failure (MTBF). By addressing the primary causes f premature failure, it is pssible t significantly imprve bearing life and reliability, while lwering perating csts. Imprving bearing reliability is a subject that is much discussed and dcumented. This article cnsiders what can be dne t reduce cmmn bearing failures when the tls, time r budget fr an in-depth analysis and slutin implementatin are limited r unavailable. This paper discusses ne example, f hw simple changes fr the re-greasing f piw blck bearings n a cal cnveyr reduced bearing failure by 90%. The specific example was imprving bearing reliability f cal cnveyrs at a cal preparatin plant; hwever, the apprach wuld apply t a brad range f applicatins. Sme basics n bearing reliability may be helpful. A frequently asked questin is: Hw lng shuld bearings last? The simple answer is that they shuld last a lt lnger than mst d. A mre specific answer is that mst bearings are typicay designed t last at least 50,000 perating hurs, r abut 6 years f cntinuus peratin. August 2011 Wrld Cal

3 The bearing design, instaatin and perating cnditins wi, f curse, directly impact bearing life, smetimes severely. Mst bearing manufacturers prvide a list f reasns fr premature bearing failure. They usuay cnclude that less than 10% f bearings reach their L 10 design life. 1 In ther wrds, mre than 90% f bearings fail prematurely. Significant imprvements in bearing reliability can be achieved if the rt cause(s) f bearing failure can be identified and addressed. There are many causes f early bearing failure and these are we dcumented. Bearing manufacturers and their trubleshting guides can be a great tl fr failure analysis. While sme causes are quite difficult t identify, the primary reasns are usuay basic, easy t determine and reslve. One study by a bearing manufacturer gruped failure causes int tw categries: l Mechanical prblems (20%). l Lubricant failure r cntaminatin (80%). The lubricant-related causes were further expanded, prviding an interesting insight and clear pprtunities fr imprvement (Figure 1). Aged lubricant (20%) This is ften caused by a failure t peridicay re-lubricate, limited xidative stability f the grease and/r envirnmental cnditins. The slutin is t chse a grease with suitable thermal stability and re-lubricate at crrect intervals. Unsuitable lubricant (20%) The lubricant des nt have the prperties needed t maintain a lubricating film under the perating cnditins f the bearing. The apprach in this case is t chse a grease with perfrmance that better matches the perating cnditins and envirnment. Pr lubricatin (15%) T much r t little grease generay results in reduced bearing life. The re-lubricatin time and amunt needs t match the recmmendatins fr the specific bearing. Hard cntaminants (20%) Failure f the bearing prtectin t prevent ingress f dirt r dust, r failure t clean the grease nipple befre manual re-greasing. In the cal handling industries, cal dust presents a cntinuus chaenge t bearing life. Hard particles, such as cal dust, mix with the grease frming an abrasive paste. In additin, the cal ften brings with it crrsive elements such as sulfur r chlrides. The mst cmmn bearing prtectin is a spring laded rubber lip seal. The standard rubber lip seal has a design life f 3000 hurs r less. Bearing prtectin can be upgraded, and/r mre frequent re-lubricatin can be emplyed t help expel cntaminants. Figure 1. Lubricants cause up t 80% f bearing failures, brken dwn int: aged lubricant (20%); unsuitable lubricant (20%); pr lubricatin (15%); hard cntaminants (20%); liquid cntaminants (5%). Figure 2. Cmparisn f manual vs autmatic re-lubricatin. Liquid cntaminants (5%) Water cntaminatin frm rain r misture cndensing wi thin mst greases. The result is a pr lubricating film causing crrsin, increased wear and ptentiay awing the lubricant t flw ut f the bearing. The direct slutin is t imprve the bearing prtectin, r upgrade t a grease that prvides superir crrsin prtectin and is designed t accept water withut thinning ut. Once the specific causes f reduced bearing life are identified, the mst cmmn issues are straightfrward t minimise. Gals include: l Extending bearing life. l Increasing prductivity. l Reducing grease cnsumptin. l Reducing peratinal csts. Wrld Cal August 2011

4 Bearing prtectin In general, permanent envirnmental bearing prtectin in general is thught t be a myth. With regards t bearing prtectin, it is cmmnly believed that if n lubricant can be seen leaking ut, the seal is effective. This is nt true, because it des nt cnsider the ingress f misture, crrsive chemicals r abrasive particles. Cnventinal rubber lip seals are cmmnly used t prtect bearings frm envirnmental cntaminants. Studies indicate that a nrmal lip seal prtects fr less than 3000 hurs (< 4 mnths), even thugh bearings are designed fr 50,000 hurs f peratin. The gap is mre than cnsiderable. There are many alternative designs fr imprved bearing prtectin. A simple replacement upgrade wuld be lip seal types that use newer designs and materials technlgies. They have been shwn t prvide up t 10 times lnger life. Sme designs are split, awing easy instaatin withut disassembly. Grease chice Lubricatin frequency and quantity Grease technlgy has dramaticay imprved since the develpment f basic lithium grease. The industry nw has a wide spectrum f perfrmance t address specific perating cnditins. With the nrmal lip seal ptentiay prviding limited life, the grease is effectively the last line f bearing prtectin. With the crrect base il viscsity, and grease hardness specified, the primary prperties t cnsider might include: Lad bearing capability, EP. Anti-wear ability. Figure 3. Cal cnveyrs. Water washut resistance. Crrsin prtectin. Temperature range. Tlerance t cntaminatin with water. Ideay, the crrect amunt f grease shuld be maintained in the bearing at a times. Equipment such as ultrasnic bearing mnitring ffers an exceent tl t determine when the bearing has the crrect amunt f grease. The mst cmmn apprach is t re-lubricate the bearings at a predetermined interval. Re-lubricatin can be dne manuay r autmaticay. Cmmn net differences between these tw appraches are represented in Figure 2. The benefit f autmatic re-lubricatin is clear. It is designed t frequently supply a sma amunt f grease t maintain a cnsistent quantity in the bearing. A central system is ideal, but nt always practical. Increasingly cmmn are single pint lubricatrs. The advantage is that they can be cst effectively used t upgrade frm manual lubricatin f bearings in remte, dangerus lcatins. Nt nly d they imprve the lubricatin quality, but significantly reduce the labur. In additin, they ften reduce the amunt f grease used by a factr f tw, cnfirming that ver-lubricatin was ccurring befre. They can be actuated by a spring, gas pressure r electr-mechanical mechanism. Case study The chaenge Figure 4. Single pint grease lubricatrs feeding primary bearings. At a cal preparatin plant, frequent bearing failures n the tail rer cnveyr system were due t incnsistent lubricatin practices, average quality greases and pr bearing seal prtectin. The typical chaenges were what type f grease shuld be used, cncerns f ver- r under-lubricatin, the vlume f grease needed, the frequency f lubricatin, the dangerus lcatin f grease pints and limited manpwer. A these factrs cntributed t incnsistent bearing lubricatin, August 2011 Wrld Cal

5 resulting in premature bearing failures and cstly dwntime. The slutin A high perfrmance calcium sulfnate grease with extremely lw water washut, high EP and crrsin prtectin was cmbined with a gas-perated, single pint lubricatr. Standardising n ne lubricant eliminated the need fr multiple types f greases fr different applicatins. The single pint lubricatrs slved the ther issues by being user friendly and simple t perate, having a variable dispensing rate, a sealed micrprcessr/lgic circuit fr dependable peratin and, mst imprtantly, prvided an affrdable system apprach t lubricatin maintenance. The replaceable lubricatrs were lcated between 5 10 ft frm the bearings where they were remved frm rtating parts, making it easy t inspect and maintain the units withut interrupting the peratin f the cnveyr line. A single lubricatr was used fr each bearing t maximise the intervals between replacement. The unit chsen culd als be turned ff during extended line shutdwns. The grease feed rate depends n the bearing diameter and revlutins per minute (RPM). The dispenser suppliers nrmay prvide charts t determine the feed rate setting. In this case, 250 cc f grease prvided lubricatin fr each bearing fr 6 mnths. At this pint, the units wuld be shut ff and replaced withut interrupting prductin. Annual savings Materials l Tail drive puey (4), 4 7 / 16 in. HD piw blcks bearings. l Take-up puey (4), 3 in. piw blcks bearings. l Snubber puey (4), 3 in. piw blcks bearings. Labur Three mechanics fr a minimum f 6 hurs each. The results The cst fr bearing replacement n this cnveyr alne was US$ 10,800/year, while the cst f lubricatrs with grease is US$ 2200/year. This represents annual savings f US$ This des nt include eliminating the time and labur previusly required t manuay re-lubricate the bearings. In fur years, bearing failure has been reduced 90%, with bearing life s far exceeding fur years. Bearings ften fail prematurely, causing excessive replacement csts and prductin lsses. Simple gals t imprve bearing life can be summarised as: l Keep cntaminants such as dirt and water ut. l Re-lubricate with the apprpriate grease. l Re-lubricate with the crrect amunt and frequency. Ntes 1. L 10, as defined by ISO 281:2007 'Rer bearings - Dynamic lad ratings and rating life', is the life expectancy f 90% f a large grup f apparently identical bearings.

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