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OPERATION & MAINTENANCE OF POWER PLANTS


and 20-33mm/s velocity. Indeed, a recent bearing failure on one unit broke the steel frame/mounting brackets, with excessive temperatures and vibration figures recorded. In the past, the plant had even tried balancing the fans using a third-party resource, but the bearing failures continued.” NSK’s application


review included a failed bearing examination from the drive and non-drive end bearings. A number of issues, including fretting corrosion, were noted to the external diameter of the outer ring. It was also clear that both bearings exhibited a raceway which had supported an axial load; evident from a wider and more pronounced running band. Tis is unusual as the fan configuration had a fixed and free-end arrangement – to allow for shaft expansion from


operating temperatures – thus the free end should only support a radial load. As the free end bearing at the energy plant exhibited axial loading, NSK was able to attribute the root cause of the ongoing failures to incorrect bearing arrangement. High-capacity spherical roller bearings within SNN plummer blocks were therefore recommended, along with correcting the fixing arrangement. NSK’s spherical roller bearings use advanced materials that make them suitable for high speeds and loads. Offering special ring tolerances to withstand vibration, shock loads and misalignment, the bearings are heat stabilised up to 200°C. Furthermore, they were the preferred choice as the internal design is more reliable for direct-coupled overhung industrial fan units, thanks largely to inner ring ribs that provide better roller guidance. “A trial was conducted with our engineering team overseeing the installation and implementation of our recommendations,” explains Briggs-Price. “Te result was zero bearing failures over a 12-month period. Furthermore, our


solution offered increased productivity with reduced maintenance and downtime costs, with four times greater bearing lifetime.”


As can be seen in this example, using the wrong bearings or fitting them incorrectly can reduce the output of machines or industrial units, and even cause a whole plant to grind to a halt. NSK’s AIP is designed to make operations and maintenance processes more efficient and more profitable by saving money at each value-added step. Experienced NSK specialists use a tried and tested method to develop the ideal solution for each specific application, working with the customer and taking every requirement detail into account. At the UK energy plant, the AIP process encompassed services from initial survey and product selection, through to customer training and final inspection. Te results speak for themselves. Due to the new solution, savings of €134,040 are being achieved annually based on reductions in bearing costs, fitting costs and downtime costs.


www.cwst.co.uk T: 01635 279621


Shot peening is a cost effective method to help prevent:


l Metal fatigue l Pitting/Fretting


Engineered coatings help with: l High lubricity/low friction l Anti-corrosion l High release/anti-stick l Low noise/anti-squeak


C.A.S.E.TM super finishing is used to:


l Increase gearbox efficiency l Reduce surface/contact fatigue l Decrease lubricant temperature l Reduce transmission noise


Engineered technologies Surface treatments for critical components


www.engineerlive.com 21


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