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Motor Reliability
Solution ased Life
Extension Program
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2011 Global Sales Meeting The contents of this presentation may contain confidential and/or proprietary information or images, and is
intended for the sole purposes of training and educating. Any dissemination, distribution or copying of this
communication is strictly prohibited
USE DOCUMENTED REFERENCES
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2011 Global Sales Meeting The contents of this presentation may contain confidential and/or proprietary information or images, and is
intended for the sole purposes of training and educating. Any dissemination, distribution or copying of this
communication is strictly prohibited
Lubricating
Film
Piece of paper
Ef = 0,0005 mm
Otherwise:
200 times thinner than a piece of
paper.
0,1 mm
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intended for the sole purposes of training and educating. Any dissemination, distribution or copying of this
communication is strictly prohibited
Selection is Viscosity, Speed,
Diameter Dependent
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intended for the sole purposes of training and educating. Any dissemination, distribution or copying of this
communication is strictly prohibited
MOTOR BEARING FAILURES
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communication is strictly prohibited
EPRI, 1983 STUDY
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communication is strictly prohibited
WHEN DIS FAILURE OCCUR
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2011 Global Sales Meeting The contents of this presentation may contain confidential and/or proprietary information or images, and is
intended for the sole purposes of training and educating. Any dissemination, distribution or copying of this
communication is strictly prohibited
Re-GREASING and PLUG
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2011 Global Sales Meeting The contents of this presentation may contain confidential and/or proprietary information or images, and is
intended for the sole purposes of training and educating. Any dissemination, distribution or copying of this
communication is strictly prohibited
REASONS for FAILURE
LUBRICANT STARVATION
GREASE INCOMPATIBILITY
WRONG GREASE OVER PRESSURIZATION
GREASE INSIDE CAVITY
OVER HEATING DUE TO EXCESS GREASE
GREASE DEGREDATION/HARDENING
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intended for the sole purposes of training and educating. Any dissemination, distribution or copying of this
communication is strictly prohibited
SIMPLIFIED MOTOR BEARING
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intended for the sole purposes of training and educating. Any dissemination, distribution or copying of this
communication is strictly prohibited
SINGLE SHIELD BEARING
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communication is strictly prohibited
SHIELDED BEARING
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intended for the sole purposes of training and educating. Any dissemination, distribution or copying of this
communication is strictly prohibited
Grease Flow in a Bearing
22
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intended for the sole purposes of training and educating. Any dissemination, distribution or copying of this
communication is strictly prohibited
Over Greasing Does Happens
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communication is strictly prohibited
WHERE DOES THE GREASE GO?
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communication is strictly prohibited
Grease Relief Plugs
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intended for the sole purposes of training and educating. Any dissemination, distribution or copying of this
communication is strictly prohibited
Solution is Management of Lubrication
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intended for the sole purposes of training and educating. Any dissemination, distribution or copying of this
communication is strictly prohibited
MOTOR with GREASE RELIEF
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communication is strictly prohibited
MOTOR with GREASE RELIEF
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intended for the sole purposes of training and educating. Any dissemination, distribution or copying of this
communication is strictly prohibited
MOTOR with GREASE RELIEF
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CHESTERTON
© Copyright 2003 A.W. Chesterton, All rights Reserved31
Greasing BearingsCritical for Reliable Operations
How Much , How Often
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CHESTERTON
© Copyright 2003 A.W. Chesterton, All rights Reserved33
33
Rulman hızı– DN Numarası
Dm
DN = Dm x rpm
Dm = çap, mm
İlk yağ dolumuna Rulman Hızı yüzdesi
G l Y ğl A l ğ t
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CHESTERTON
© Copyright 2003 A.W. Chesterton, All rights Reserved3434
Yüksek Yağlama Aralığı
Düşük Yağlama Aralığı
Gresle Yağlama Aralığı, tfİdeal şartlar , %10 Rulman Bozukluğu F 10
FAG’ın izni ile
kf x DN (103 x mm/dk)(Değiştirilmiş DN Hız Numarası)
Y e n i d e n Y a ğ l a m a k
i ç i n
K a l a n S a a t
10
100
1,000
10,000
100,000
10 100 1000 10000
70OC, Lityumlu Gres
tf
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CHESTERTON
© Copyright 2003 A.W. Chesterton, All rights Reserved35
35
kf – Rulman Tasarım Faktörü
Rulman tipi Rulman tipi
Silindir makaralı rulman tek sıra 3....3.5
çift sıra 2tam donanım 25
Silindir makaralı eksenel rulman 90
İğne makaralı rulman 3,5
Konik makaralı rulman 4
Kovan biçimli makaralı rulman 10
Dudak tipi elemanları olmadan küresel makaralı rulman (E tasarımı) 7...9
Dudak tipi merkez elemanı ile küresel makaralı rulman 9...12
Derin yivli bilyeli rulman tek sıra 0.9....1.1
çift sıra 1.5
Açısal temaslı bilyeli rulman tek sıra 1.6 çift sıra 2
İğ rulman
Dört nokta rulman 1.6
Sarkaçlı bilyeli rulman 1.3....1.6
Bilyeli eksenel rulman 5....6
Açısal temaslı Bilyeli eksenel rulman çift sıra 1.4
Gresle Yağlama Aralığı t
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CHESTERTON
© Copyright 2003 A.W. Chesterton, All rights Reserved3636
Lub Interval High
Lub Interval Low
Gresle Yağlama Aralığı, tf
İdeal şartlar , %10 Rulman Bozukluğu F 10
Örnek:kf = rulman tipi, çiftaçısal temas için 2D = 3.4 inch (86mm)N = 1750 rpm
FAG’ın izni ile
kf x DN (103 x mm/min)
H o u r s t o R e - G r e a
s e
10
100
1,000
10,000
100,000
10 100 1000 10000
5,000 saat
300,000
70OC, Lityumlu Gres
tf
Yüksek Yağlama Aralığı
Düşük Yağlama Aralığı
Yetersiz Yağlama ve Çevresel Faktörler
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CHESTERTON
© Copyright 2003 A.W. Chesterton, All rights Reserved37
37
tfg = tf x q , Ayarlı yağlama aralığı
Şu durumda q = f 1 x f 2 x f 3 x f 4 x f 5 x f 6Örnek
1. Toz ve Nem orta derece f1=0.9 – 0.7yüksek f1=0.7 – 0.4 0.5
çok yüksek f1=0.4 – 0.12. Azami Yük ve Titreşim orta derece f2=0.9 – 0.7
yüksek f2=0.7 – 0.4 0.5
çok yüksek f2=0.4 – 0.13. Yüksek sıcaklık <75C f3=0.9 - 0.6 0.8
75’den 85C’ye f3=0.6 – 0.385’den 120C’ye f3=0.3 – 0.1
4. Çok Yük, P/C 0.1’den 0.15’e f4 = 1.0 – 0.7
0.15’den 0.25’e f4 = 0.7 – 0.4 0.50.25’den 0.35’e f4 = 0.4 – 0.1
5. Rulmandan geçen Hava Akımı az f5 = 0.7 – 0.5 1.0
çok f5 = 0.5 – 0.16. Santrifüjlü Etki dikey rulman f6 = 0.7 – 0.5 1.0
Örnekq = 0.5 x 0.5 x 0.8 x 0.5 x 1.0 x 1.0 = 0.10
İdeal Sürenin 1/10’nunda Yeniden Yağlama,tf, tfq
= 5000 x 0.10 = 500 saat
Yetersiz Yağlama ve Çevresel FaktörlerHalen F10, 10%10 Rulman Bozukluğu
G l Y ğl A l ğ t
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CHESTERTON
© Copyright 2003 A.W. Chesterton, All rights Reserved38
38
500 - çevresel faktörler ile
10
100
1,000
10,000
100,000
10 100 1000 10000
kf x DN (x1000)
5,000 - %10 bozulma
300,000
Yüksek Yağlama Aralığı
Düşük Yağlama Aralığı
Çevre ile
Gresle Yağlama Aralığı, tfqGerçek Şartlar , %10 Rulman Bozukluğu F 10
tfq
Gerçek şartlar– F 10 , halen %10 Rulman Bozukluğu
70OC, Lityumlu Gres
Yetersiz Yağlama ve Çevresel Faktörler
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CHESTERTON
© Copyright 2003 A.W. Chesterton, All rights Reserved39
39
tfg = tf x q , Ayarlı yağlama aralığı
Şu durumda q = f 1 x f 2 x f 3 x f 4 x f 5 x f 6Örnek
1. Toz ve Nem orta derece f1=0.9 – 0.7yüksek f1=0.7 – 0.4 0.5 0.9
çok yüksek f1=0.4 – 0.12. Azami Yük ve Titreşim orta derece f2=0.9 – 0.7
yüksek f2=0.7 – 0.4 0.5 0.9
çok yüksek f2=0.4 – 0.13. Yüksek sıcaklık <75C f3=0.9 - 0.6 0.8 0.9
75’den 85C’ye f3=0.6 – 0.385’den 120C’ye f3=0.3 – 0.1
4. Çok Yük, P/C 0.1’den 0.15’e f4 = 1.0 – 0.7
0.15’den 0.25’e f4 = 0.7 – 0.4 0.5 0.90.25’den 0.35’e f4 = 0.4 – 0.1
5. Rulmandan geçen Hava Akımı az f5 = 0.7 – 0.5 1.0 1.0
çok f5 = 0.5 – 0.16. Santrifüjlü Etki dikey rulman f6 = 0.7 – 0.5 1.0 1.0
Örnekq = 0.5 x 0.5 x 0.8 x 0.5 x 1.0 x 1.0 = 0.10
İdeal Sürenin 1/10’nunda Yeniden Yağlama, tf,
tfq
= 5000 x 0.10 = 500 saat
AWC Adjusted tfq = 5000 x 0.656 = 3280 saat
Yetersiz Yağlama ve Çevresel FaktörlerHalen F10, 10%10 Rulman Bozukluğu
Gresle Yağlama Aralığı t
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CHESTERTON
© Copyright 2003 A.W. Chesterton, All rights Reserved40
40
500 - çevresel faktörler ile
10
100
1,000
10,000
100,000
10 100 1000 10000
kf x DN (x1000)
5,000 - %10 bozulma
300,000
Yüksek Yağlama Aralığı
Düşük Yağlama Aralığı
Çevre ile
Gresle Yağlama Aralığı, tfqGerçek Şartlar , %10 Rulman Bozukluğu F 10
tfq
Gerçek şartlar– F 10 , halen %10 Rulman Bozukluğu
70OC, Lityumlu GresVS AWC
ADJUSTED FOR TECHNOLOGY
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CHESTERTON
© Copyright 2003 A.W. Chesterton, All rights Reserved41
41
Rulmanlarınız aşağıdaki sert koşullar altındasağlam kalabiliyor mu?
Su/buhar
Yüksek sıcaklık / yüksek hız
Ağır yük / yüksek basınç
Başla/Duruş ve Bekleme anındakiHizmet
Aşındırıcı madde buharı
Sterilize edici maddeler
Yayınlanan Veri Yağ Performansını Değerlendirmek için kullanılabilir.
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CHESTERTON
© Copyright 2003 A.W. Chesterton, All rights Reserved4242 42
Chesterton QBT™ AdditivePlating Technology
QBT™ smoothes out surface roughness, reduces wear and vibration.
This molecular surface chemistry passivates the steel and extends bearing life
by reactively fusing a wear shield
onto the contact surfaces. Micro porosityis filled in and reactive Fe++ ions are inhibited.
QBT™ works even in the presence of up to 30% water contamination.
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CHESTERTON
© Copyright 2003 A.W. Chesterton, All rights Reserved43
Lubri-Cup™ Delivery System• Demand Feed System -
Patented Metering System, SlowlyFeeds Grease Only as Needed
• Prevents Over or Under Filling ofBearings
– Eliminates Cause of Over 40%of Bearing Failures
• Low Feed Pressure PreventsBearing Seal Failure
• Time Interval for RelubricationIncreased by 6x
• Reduces Labor Cost to Regrease byOver 80%
• Can Be Mounted at Any Angle
• Transparent Grease Reservoir -Easy to See Grease Level
• Easy to Refill in Place
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CHESTERTON
© Copyright 2003 A.W. Chesterton, All rights Reserved4444
THE LUBRI-CUP® SYSTEM
Manual versus Automatic
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45
Courtesy SKF
Manual versus Automatic
Lubrication
Automatic : Apply correct amount, time and grease type
LubriCup EM or VG with QBT Lubricant
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4646
LubriCup EM or VG with QBT LubricantAdjustment Guide
(Motor Bearing)
RPM
Shaft Dia. Under 1,000 1,000 ~ 2,000 2,000 ~ 3,000 Over 3,000
Under 2” 125cc-12Mon
125cc-12Mon
125cc-12 Mon 125cc-12 Mon
2”~2 1/2" 125cc-12Mon
125cc-12Mon
125cc-12 Mon 125cc-12 Mon
2 1/2"~3 1/8” 12 Mon 12 Mon 12 Mon 12 Mon
3 1/8”~3 1/2" 12 Mon 12 Mon 12 Mon 12 Mon
3 1/2"~4 1/8” 12 Mon 12 Mon 6 Mon 6 Mon
4 1/8”~4 3/4" 6 Mon 6Mon 6 Mon 3 Mon
Over 4 3/4" 3 Mon 3 Mon 3 Mon 3 Mon
Multipurpose Multipurpose Multipurpose Moderate Load/High Speed
Lubri up
StandardGrease
615
625FG
615
625FG
615
625FG
635
625FG
LubriCup EM or VG with QBT Lubricant
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4747
LubriCup EM or VG with QBT LubricantAdjustment Guide
(Anti-Friction Roller Bearing-non motor)
RPM
Shaft Dia.
Under 500 500 ~ 1,000 1,000 ~ 3,000 Over 3,000
1”~2” 12 Mon 12 Mon 12 Mon 12 Mon
2”~2 1/2” 6 Mon 6 Mon 6 Mon 6 Mon
2 1/2”~3 1/8” 3 Mon 6 Mon 6 Mon 3 Mon
3 1/8”~ 3 1/2” 3 Mon 3 Mon 3 Mon 3 Mon
3 1/2" ~ 4 1/8 2 Mon 3 Mon 3 Mon 2 Mon
4 1/8”~ 4 3/4” 1 Mon 2 Mon 2 Mon 1 Mon
Over 4 3/4" 1 Mon 1 Mon 1 Mon 1 Mon
Heavy
Load/ Low
Speed
Multipurpose Multipurpose ModerateLoad/
High Speed
LubriCup
Standard Grease615
625FG
615
625FG
615
625FG
635
630FG
THE LUBRI CUP® SYSTEM
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4848
THE LUBRI-CUP® SYSTEM
LubriCup Applications Electric
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4949
LubriCup Applications – Electric
Motors
Lubri up Applications Pumps Air
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5050
Air Handling Units
Lubri up Applications –
Pumps AirHandling
Pumps
LubriCup Applications Cooling
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5151
LubriCup Applications – Cooling
Towers
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5252
Electric Motors
THE LUBRI-CUP® SYSTEM
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2011 Global Sales Meeting The contents of this presentation may contain confidential and/or proprietary information or images, and isintended for the sole purposes of training and educating. Any dissemination, distribution or copying of this
communication is strictly prohibited
THE LUBRI-CUP® SYSTEM
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2011 Global Sales Meeting The contents of this presentation may contain confidential and/or proprietary information or images, and isintended for the sole purposes of training and educating. Any dissemination, distribution or copying of this
communication is strictly prohibited
Solution in Place
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communication is strictly prohibited
Solution in Place
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communication is strictly prohibited
Solution in Place
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2011 Global Sales Meeting The contents of this presentation may contain confidential and/or proprietary information or images, and isintended for the sole purposes of training and educating. Any dissemination, distribution or copying of this
communication is strictly prohibited
Results
Largest Underground Mine in Chile
24-30 Motors per Year @ 5,000 USD
each plus 5-6X related costs
In 2009 began AWC Solution.
Since 2009, 3-4 per Year, NONE DUE TOBEARINGS
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