ZA 2207, Rexnord housed roller bearings
Slow speed; ambient temperature; soapy water. Bearing life 2-3 weeks.
Currently getting 6 weeks life out of bearings.
Tapered roller bearings
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.
Bearings were filled with MPI-2000, high temperature MicroPoly. Bearings have been running for 9 months so far with no failures.
Roller thrust bearings, about 100 mm bore
Water, scale and heat contamination, combined with limited ability to lubricate and inability to contain grease. Temperature less than 120°F.
Bearing life was more than doubled.
Spherical and split roller bearings
Inconsistent bearing lubrication due to availability problems and safety considerations. This caused inconsistent bearing life.
Bearing life increased three to fourfold. Some plants totally eliminated manual lubrication.
Spherical roller bearing, 22226CK
Heat from furnace melted lubricant in bearing, causing melted lubricant to leak onto the steel strip. Temperature 300°F.
High temperature MicroPoly was installed in the bearings. The leakage problem has been solved, eliminating the need to scrap materials due to lubricant contamination.
Tapered roller bearing, 7" bore
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.
Bearings have been in use for 2 years.
Rexnord housed roller bearings
Bearings operate at 300°F. Bearing speed 80 RPM. Bearing life 2-3 weeks.
Bearings were filled with high temperature MicroPoly. Bearings have been running 3 months so far with no failures.
1" x 2" x 12" chain lube block
Some radiant heat, less than 200 degrees F. Previous chain guide material did not hold up and had to be replaced 3 or 4 times per year.
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.
Housed roller bearings
Conveyor removes scale from a water and scale pit. Bearing life 6 to 8 days.
MicroPoly filled bearings have lasted over 8 months.
Bronze liners plugged with MicroPoly
Normal mill environment, lube lines were damaged. Life unpredictable.
Achieved 4 to 10 years life with MicroPoly.
Bronze bushings plugged with MicroPoly
Steel shot contamination. Life unpredictable.
Life increased three to fourfold with MicroPoly.
Spherical roller bearings, 23124
MicroPoly filled bearings have increased life threefold.
Spherical roller bearings, 22211
Bearings were located deep within the equipment and could not be externally lubricated. Bearing life was 6 months.
MicroPoly filled bearings have been running 3 years with no failures. Cost savings have been substantial. Unscheduled down time to change out a failed bearing cost $250,000.
Spherical roller bearings, 23124 & 22224
Water, scale and heat contamination. Bearing life 3 months. Temperature less than 120°F. Speed 120 RPM.
With MicroPoly, bearing life was more than doubled.
Rexnord ZA 2203, 2-3/16" pillow block
MicroPoly filled bearings increased life twofold.
6204 single row ball bearing, shielded on one side
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.
Bearing life 60-70 days with MicroPoly.