Challenge for Schaeffler

Fan bearing failure in chemical processing system. The plant operator was forced to quickly replace the rolling bearing due to the presence of toxic gases and the resulting explosive atmosphere, which was created in the chemical production process. Access to the standard spherical roller bearing in the fan bearing was very difficult. The operator's experience has shown that in such cases the bearing replacement time is approximately 14 hours.

Solution for Schaeffler
To optimize downtime and service costs, Schaeffler suggested using a FAG split spherical roller bearing.

FAG split spherical roller bearings can be mounted as a direct replacement for conventional spherical roller bearings and the corresponding adapter sleeve (outer diameter, outer ring width and shaft seat diameter are the same).
Scheaffler also provided the customer with support during the service work. All activities during the assembly were coordinated in cooperation with teams of engineers and specialists from Germany and Australia. An experienced Scheaffler service specialist coordinated the assembly in the production hall.

Diagram of a FAG split spherical roller bearing

The challenge in numbers

• Type of fan: radial industrial fan
• Drive: direct clutch drive
• Speed: 1180 RPM
• Power: 315 KW
• Throughput: 15.94 & nbsp; m & sup3; / s at 0.12 bar
• Working temperature 60-70 & deg; C

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Benefits of the proposed and implemented Schaeffler solution:

Minimize the likelihood of downtime risks from bearing failure. The factory has optimized the time and costs associated with bearing replacement servicing by using FAG split spherical roller bearings in a cast iron housing.

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Savings in numbers:

• Downtime: 14 hours has been limited to 3 hours of service
• Downtime costs: EUR 280,000 minimized to EUR 60,000
• The cost of service work of EUR 2632 was capped at EUR 564
• Costs of additional system alignment: additional costs removed
• Cost of using additional tools (eg crane): additional costs removed
• Use of additional drive bearings: no additional costs
• The total cost of repairing a fan bearing failure was reduced from EUR 284,202 to EUR 61,414.

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The production company saved EUR 222,788 by taking advantage of the Schaeffler offer and using split spherical roller bearings in a FAG cast iron housing.

Additionally:

In addition to the direct savings resulting from the use of FAG split spherical roller bearings in a cast iron housing, the manufacturing company has gained the opportunity for long-term savings related to faster replacement of bearing components in the future. The cost and time benefits mentioned above (savings in numbers) can be achieved in advance by considering the use of Schaeffler solutions in the design of new production equipment and machinery.

Split spherical roller bearing with cast iron housing

Split cast iron housing