Success Story
Industry: Steel & Metals
Application: Continuous Casting Machine
Cost Savings: € 14 850
Introduction
A Steel maker was experiencing problems with their continuous casting machine for steel sections. The lifetime of a Cylindrical Roller Bearing mounted on a continuous cast roller was about one to two months. The casting machine had a very complicated cooling and lubricating piping system. The main problem was the high maintenance costs 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 and time saving for maintenance works.
- Continuous Casting Machine
- Sealed Spherical Roller Bearing
Key Facts
- Continuous Casting Machine
- Long replacement time for Cylindrical Roller Bearing with oil lubrication because of complicated process to reconnect the piping system
- NSK Solution: Sealed Spherical Roller Bearings specifically designed for the application
- Significant increase of the operating lifetime
- Improved bearing protection
- Eco-friendly due to lack of contamination from the equipment
- Substantial cost savings made by reducing the maintenance time
Value Proposals
- NSK analysed 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 any more during the maintenance works
- Eco-friendly system reducing the oil consumption as bearings included high-temperature grease
- The time required for the replacement of the roller in the segments was reduced from 20 to 10 hours
- The operating lifetime 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 conserves grease offering longer running & improved efficiency
- Reduction in grease consumption & no grease leaks due to special seal & cleaner working environments
- Increased maintenance intervals
Cost Saving Breakdown
| Before | Cost p.a. | NSK Solution | Cost p.a. | |
|---|---|---|---|---|
| Bearing Costs: 6 Sets of bearings per segment per year | € 25.200 | Bearing Costs: 3 Sets of bearings per segment per year | € 28.350 | |
| Costs of lost production: 6 Replacements per year x 3 hours | € 18.000 | Costs of lost production: 3 Replacements per year x 3 hours | € 9.000 | |
| Engineering Costs: 6 Replacements x 20 hours | € 12.000 | Engineering Costs: 3 Replacements x 10 hours | € 3.000 | |
| Total Costs | € 55 200 | € 40 350 | ||
Reference:SS-E-7005
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