Success Story
Industry: Steel & Metals
Application: Gas Turbine Blade Casting
Cost Savings: € 100 095
Introduction
A company was experiencing a short service lifetime from the bearings used in the casting of gas turbine blades. NSK undertook an Application Review of the existing design which included an inspection of the failed bearings. An extremely caustic solution combined with high loads and misalignment was causing lubrication and seizure problems. An alternative wheel design was proposed using a cylindrical roller bearing, with improvements in sealing and lubrication. This resulted in significantly improved performance and doubled lifetime.
- Gas turbine blade casting
- Sealed cylindrical roller bearing
Key Facts
- Gas Turbine casting
- Bearing replacement every 6 weeks
- Caustic solution: 50% Sodium hydroxide at 180°C
- NSK solution: Application design change of wheel used on carousel, with bearing substition to NSK sealed cylindrical roller bearing
- Reduced downtime and maintenance
- Doubled bearing life
- Significant reduction in bearing and maintenance costs
Value Proposals
- The customer was experiencing poor performance on bearings within a carousel application. A Failed Bearing Analysis erformed by NSK Engineers showed that this was caused by ingress of extremly agressive caustic solution, combined with high loads and misalignment
- An Application Review highlighted inadequate sealing as the cause and NSK Engineers designed an alternative wheel design, incorporating improved sealing, easier assembly and an NSK sealed cylindrical roller bearing
- A trial was conducted using the new design and the results were reviewed. The redesign was succesful with the remaining lines modified
Product Features
- High load rating
- Highly corrosion resistant phosphate coating
- Contact seals prevent ingress of foreign particles or water
- Increased radial and axial capability
- Bearings pre-greased with Lithium grease
- Re-lubrication holes for easy maintenance & grease replenishment
- Snap ring (DIN 471) can be applied to the outer ring
Cost Saving Breakdown
| Before | Cost p.a. | NSK Solution | Cost p.a. | |
|---|---|---|---|---|
| Bearing Costs: Cost of 1 set of assemblies = € 4.462 |
€ 133.860 | Bearing Costs: Cost of 1 set of assemblies = €7.089 Cost of 1 bearing / seal kit = €1.487 |
€ 39.111 | |
| Engineering Costs: Cost of labour to renew 1 set of assemblies = € 297 |
€ 8.910 | Engineering Costs: Cost of labour to renew 1 set of assemblies = € 297 | € 3.564 | |
| Costs of lost production: Bearing life 6 weeks | Costs of lost production: Bearing life 12 - 14 weeks | |||
| Engineering Costs: Total costs per year à 10 changes (x 3 rotators) = € 142.770 | Engineering Costs: Total cost per year for 1 change (x 3 rotators) = € 42.675 |
|||
| Total Costs | € 142 770 | € 42 675 | ||
Reference:SS-E-2011
Share