CASE 1: Steel coil straightener
| BEARING TYPE: |
Spherical roller bearings, 22211 |
| CONDITIONS: |
Bearings were located deep within the equipment and could not be externally lubricated. An unscheduled down time to change out a failed bearing cost $250,000. Bearing life was 6 months. |
| RESULTS: |
MicroPoly filled bearings have been running 3 years with no failures. Cost savings have been substantial. |
CASE 2: Oven bearings, coating metal pipes
| BEARING TYPE: |
Rexnord housed roller bearings |
| CONDITIONS: |
Bearings operate at 300°F. Bearing speed 80 RPM. Bearing life 2-3 weeks. |
| RESULTS: |
Bearings were filled with high temperature MicroPoly. Bearings have been running 3 months so far with no failures. |
CASE 3: Billet turner bearings
| BEARING TYPE: |
Tapered roller bearings |
| CONDITIONS: |
Billet comes out of reheat furnace and dependent on size and shape, may need to be turned 90° prior to entering mill stand for rolling. Estimated ambient temperature is 300 – 400° F and bearing life was approximately 2 months. |
| RESULTS: |
Bearings were filled with MPI-2000, high temperature MicroPoly. Bearings have been running for 9 months so far with no failures. |
CASE 4: Crane wheel bearings
| BEARING TYPE: |
Spherical and split roller bearings
|
| CONDITIONS: |
Inconsistent bearing lubrication due to availability problems and safety considerations. This caused inconsistent bearing life. |
| RESULTS: |
Bearing life increased 3 to 4 fold. Some plants totally eliminated manual lubrication. |
CASE 5: Crane hook bearings
| BEARING TYPE: |
Roller thrust bearings, about 100 mm bore
|
| CONDITIONS: |
Water, scale and heat contamination, combined with limited ability to lubricate and inability to contain grease. Temperature less than 120°F. |
| RESULTS: |
Bearing life at least doubled. |
CASE 6: Table roll
| BEARING TYPE: |
Spherical roller bearings, 23124 & 22224
|
| CONDITIONS: |
Water, scale and heat contamination. Bearing life 3 months. Temperature less than 120°F. Speed 120 RPM. |
| RESULTS: |
With MicroPoly, bearing life at least doubled.
|
CASE 7: Wire cabling for tire cord (one to five strands)
| BEARING TYPE: |
6204 single row ball bearing, shielded on one side
|
| CONDITIONS: |
Eccentric forces pushed grease out of bearing. Bearing life 2 hours to 7 days with conventional lubrication. Speed 1200 RPM and 2500 RPM eccentric speed. |
| RESULTS: |
Bearing life 60-70 days with MicroPoly. |
CASE 8: Wet strip grinders – squeegee & brush rolls
| BEARING TYPE: |
Rexnord ZA 2203, 2-3/16” pillow block |
| CONDITIONS: |
Water spray. |
| RESULTS: |
MicroPoly filled bearings increased life 2 fold.
|
CASE 9: Acme strip grinder-polisher
| BEARING TYPE: |
ZA 2207, Rexnord housed roller bearings |
| CONDITIONS: |
Slow speed; ambient temperature; soapy water. |
| RESULTS: |
Currently getting 6 weeks life out of bearings: 2-3 times life. |
CASE 10: Hot strip mill runout table rolls
| BEARING TYPE: |
Tapered roller bearing, 7” bore |
| CONDITIONS: |
Water and heat. MicroPoly serves as a back up to an automatic lubrication system to reduce the unscheduled maintenance. Bearing life was unpredictable and inconsistent. |
| RESULTS: |
Bearings have been in use for two years.
|
CASE 11: Slab mill feeder table
| BEARING TYPE: |
Spherical roller bearings, 23124 |
| CONDITIONS: |
Water quench. |
| RESULTS: |
MicroPoly filled bearings have increased life 3 fold.
|
CASE 12:
Furnace bearing
| BEARING TYPE: |
Spherical roller bearing, 22226CK |
| CONDITIONS: |
Heat
from furnace melted lubricant in bearing, causing melted
lubricant to leak onto steel strip. Temperature 300°F. |
| RESULTS: |
High
temperature MicroPoly was installed in the bearings. The
leakage problem has been solved, eliminating the need to scrap
materials due to lubricant contamination.
|
CASE 13:
Scale conveyor
| BEARING TYPE: |
Housed roller bearings |
| CONDITIONS: |
Conveyor removes scale from a water and scale pit. Bearing
life 6 to 8 days. |
| RESULTS: |
MicroPoly filled bearings have
lasted over 8 months.
|
CASE 14: Re-bar and angle iron, open conveyor, return guide
| MICROPOLY TYPE: |
1” x 2” x 12” chain lube block |
| CONDITIONS: |
Some radiant heat, less than 200°F. Previous chain guide material did not hold up and had to be replaced 3 or 4 times per year. |
| RESULTS: |
MicroPoly chain lube blocks, placed at interval spacing, reduced replacement frequency of chain guide to once per year. This resulted in saving significant material replacement and labor costs. |
CASE 15: Shotblast car
| MICROPOLY TYPE: |
Bronze bushings plugged with MicroPoly |
| CONDITIONS: |
Steel shot contamination. Life unpredictable. |
| RESULTS: |
Life increased 3 to 4 fold with MicroPoly.
|
CASE 16: Shears
| MICROPOLY TYPE: |
Bronze liners plugged with MicroPoly |
| CONDITIONS: |
Normal mill environment, lube lines were damaged. Life unpredictable. |
| RESULTS: |
Achieved 4 to 10 years life with MicroPoly. |
CASE 17: Crane wheel flange lubrication
| MICROPOLY TYPE: |
Block type, spring loaded applicators for double flanged wheels. Various wheel sizes. |
| CONDITIONS: |
Generally, no lubrication utilized. Life varied, depending on crane usage and rail/crane condition. |
| RESULTS: |
Wheel life increased 3 to 4 fold with MicroPoly. |
|
