Success Story
Industry: Quarrying, Mining & Construction
Application: Overland Conveyor Head Pulley
Cost Savings: € 4 538 304
Introduction
A quarrying company was experiencing bearing failures due to contamination on each side of the conveyor head pulley. This caused increased maintenance cost, reduced lifetime of the bearing and a downtime in production every 18 months. NSK analysed the bearing and recommended to use bearings in High Tough steel (HTF). After the bearings were put into service they lasted 6 years.
- Quarry Conveyor
- Bearings in High-Tough Quality (HTF)
Key Facts
- Conveyor Head Pulley
- Highly abrasive conditions including water and grit
- Failure of the bearing through contamination with consequental loss of production
- NSK Solution: bearings in High Tough Quality (HTF)
- Changing to bearings in HTF steel increased the life time circle to 6 years
- Cost savings generated based on reduced maintenance and downtime cost
Value Proposals
- NSK performed a bearing analysis showing route cause as ingress of water and grit
- Application assessment showed highly abrasive conditions
- Technical support provided for improved bearing performance
- NSK recommended to replace the bearings by products with HTF matieral
- HTF Bearings were put into service and lasted 6 years instead of 18 months
Product Features
- NSK High Tough Steel (HFT) bearings have been designed for outstanding toughness under harsh conditions
- Longer service life and superior resistance against wear, seizure and heat
- Resistance with contaminated lubrication
- Innovative heat treatment technology
- HTF material can be applied for cylindrical, tapered and spherical roller bearings
- Up to 7 times service life with contaminated lubrication compared to conventional bearings
- Up to 20 % improvement of seizure resistance
Cost Saving Breakdown
| Before | Cost p.a. | NSK Solution | Cost p.a. | |
|---|---|---|---|---|
| Engineering Costs: 6 People, working 12 hours @ 32 € per hour | € 2.304 | Engineering Costs: No mentainance necessary | € 0 | |
| Costs of lost production: 7,000 tons per hour x 12 hour stoppage x 4 times x 13.5 € per ton | € 4.536.000 | Costs of lost production: No lost production stoppages | € 0 | |
| Total Costs | € 4 538 304 | € 0 | ||
Reference:SS-E-0020
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