NSK Case Study

Application

Continuous Annealing
Process Line

Cost Savings: $399,296

The continuous annealing process line at a steelworks was experiencing unplanned stoppages. Downtime was averaging 17 hours annually at $23,488 per hour due to required heavy lifting machinery as well as additional maintenance personnel. NSK engineers performed analysis on the failed bearings and identified that both the bearing type and the sealing arrangement were inadequate for the application. The high load and low speed of the application were major factors impacting bearing performance. A multi-row sealed cylindrical roller bearing (for crane sheaves) was an ideal solution.

Key Facts

Steel strip manufacturing process – multiple locations
High load and slow speed application
Inadequate bearing specification in original equipment design
Bearing failure due to contamination and improper lubrication
Lost production of 17 hours annually

Continuous Annealing Process Line

Value Proposals

Failure analysis revealed significant fatigue on the existing ball bearing
Crane sheave bearing unit with integral sealing arrangement proposed
Machine design review resulted in a modified housing design to accommodate bearing
Bearing condition analysis performed mid-trial demonstrated no indications of wear
Post-trial review showed no significant bearing damage
Bearing life was extended to more than 3 years

Product Features

Accommodates extremely high radial and axial loads
Advanced contact seal prevents grease leakage and ingress of water and external contaminants
Corrosion resistant phosphate coating permits use in a wide range of environments, including exposure to external environments
Simple re-lubrication – even during operation – with inner and outer ring lubrication holes and grooves
Bearings filled with Lithium Complex grease
Can be fitted with snap rings on the outer ring
Full Complement
Cylindrical Roller
Bearings for Crane Sheaves

Cost-Savings Breakdown

  Before Cost NSK Solution Cost  
  Lost production: more than 119 hours over 7 years due to bearing failure. Annual downtime: 17 hours X $23,488 $399,296 No lost production: Bearings in full operational condition after 3 years in service.Expected lifetime of the new NSK design: 5 years $0  
  Total Costs $399,296 Total Costs $0  
Before Cost
Lost production: more than 119 hours over 7 years due to bearing failure. Annual downtime: 17 hours X $23,488 $399,296
Total Costs $399,296
NSK Solution Cost
No lost production: Bearings in full operational condition after 3 years in service. Expected lifetime of the new NSK design: 5 years
 
$0
Total Costs $0

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