The Situation
An asphalt plant in Leeds had an existing relationship with the team at the nearby HAYLEY DEXIS branch, and asked a member of the team to visit site to review the bearings within a hot stone vibrating screen application. An engineer from long-standing supply partners, NSK, were invited along to assess the situation as part of their Asset Improvement Programme (AIP).
The Solution
A comprehensive review was conducted, with an Application Report produced to inform the customer of the findings and recommendations. During the review, temperature sensors were mounted to the bearings to monitor temperatures either side of the units during operation. One of the significant recommendations made in the report was for the customer to substantially reduce the amount of grease being used during relubrication. Previously, grease was applied manually, but 10 months prior to the review, an automated system was installed, and it was determined that too high a quantity was being used.
IT IS ESTIMATED THE CUSTOMER COULD REDUCE THEIR GREASE CONSUMPTION BY UP TO 90%."
The Result
By following the recommendations, it is estimated that the customer could reduce the grease consumption of their vibrating screen bearings by up to 90%, saving considerable money as a result.
The over-lubrication of the bearings was causing their temperatures to sky-rocket, increasing the risk of catastrophic failure. In such a piece of critical equipment, the costs relating to a breakdown would be considerable. With a significantly lower volume of grease being used, the high temperatures recorded during the review would be far less of an issue.
Not only will the service life of the bearings be improved, but also the lifecycle of the automated greasing system, which currently only worked as intended for a few days after start-up. Wastage of unspent grease was also a problem for the customer, with less lubricant product being purchased following the outcome of the review, less product will have to be destroyed. This will help to reduce the environmental impact of the customers’ operation, at a time where sustainability has begun to come under intense scrutiny for this industry.