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EM - InterviewRamesh Suri President of ACMA & Chairman, Global Autotech (p.30)

Strategic importance of plant reliability

VOL 06 | NOV 2014

EF F IC I ENT MA NUFA CTUR ING

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PRODUCTION MANAGEMENT

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COVER STO RY MA NA GEM E N T

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PRODUCTION MANAGEMENTStrategic importance of plant reliability

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EM | O c t 2014

COVER STO RY MA NA GEME N T

Even though there is an intuitive understanding of the benefits of Plant Reliability, there is still lack of clarity on its direct contribution to profitability at an operational level and competitive advantage at a strategic level. This feature aims to establish and uncover the significant importance of plant reliability to a manufacturing organisation as a whole and not just to the plant maintenance department, while discussing the need for an agile, real-time infrastructure between the shop floor and the enterprise levels to achieve and sustain improvements in plant reliability.

Robert Gates Global Marketing Director ManufacturingGE Intelligent Platforms

20 EM | O c t 2014EM | No v 2014

Coverstory_Nov_2014.indd 20 11/8/2014 1:40:43 PM

56 EM | No v 2014

TECHNOLOGY | I NDU S TR IA L BEA R IN G S

smoothly. Depending on the clearances, there are several grades of bearings available, but this is of no concern to the user, in general. The engineering staff from the pump or motors manufacturer will choose the correct grade to ensure long life of the pump.

Types of grease lubricated bearings

Open bearings (single shielded, open shielded): These bearings are essentially open to the environment around them and will require some lubrication. The bearing in Figure 1 is an open bearing. If a cover was put on one side, the bearing would be called a single shielded or open shielded bearing. Double shielded bearings: In this type of bearing, a cover is placed on both sides, essentially isolating the bearings from the surrounding environment to a large extent. The shields do not actually touch the balls. These bearings are commonly known as simply shielded, but the term can be misleading given the single shielded bearing discussed above. They are also known as greased for life because the shields retain the grease and re-greasing is not required. Sealed bearings: A sealed bearing has a soft, contacting cover on both sides (usually rubber or another soft material). These bearings do not require re-lubrication.

Grease and lubrication basics

Bearing greases are usually a mixture of a thickener base

emulsified with lubricating oil. The base merely acts to keep the oil in suspension, but the type of base is very relevant. The two most common types of base are: lithium and polyurea.

Lithium-based grease is brown in colour; polyurea typically blue or blue-green. Lithium grease is often called axle grease and has high availability. Polyurea-based greases have a better resistance to water and condensation. When moving parts of the bearing come in sheer contact with the grease, a small quantity of the oil will adhere to the bearing surfaces. The oil that is picked up by the bearing (and thus removed from the grease) is gradually broken down by oxidation or lost by evaporation, centrifugal force, etc. The bearing cannot function properly unless the supply of oil keeps up with the demand as the oil in the grease is depleted or oxidised. Grease life cannot be accurately measured or predicted as all factors such as speed, load, humidity, type of service, frequency of lubrication, contaminants, etc. need to be considered.

In applications where elevated temperatures, high speed, severe dirt, high humidity, or other extreme conditions are encountered (particularly in open bearings), accelerated deterioration of the grease may occur. Such duties are normally spelled out in the IOM, and lubrication periods adjusted.

Lubricating the bearings

Prior to any lubrication, the owners manual should be consulted and only one of the recommended greases should be used. Depending on the manufacturer, the types of greases

A generalised ball bearing

Page _Technology industrial bearing GRUNDFOS.indd 56 11/8/2014 1:43:24 PM

58 EM | No v 2014

TECHNOLOGY | I NDU S TR IA L BEA R IN G S

> MORE@CLICK EM01391 | www.efficientmanufacturing.in

may vary. Motors typically use polyurea-based grease, which most pump manufacturers now use as standard. However, some manufacturers still use a lithium-based greased bearing.

Do not mix the greases: Mixing the greases, or lubricating a bearing full of one grease with the other grease, will cause the greases to come out of suspension and liquify or turn to wax; complete loss of all lubricity is also common. Failure of the machine is likely. All grease should be clean and free from dirt, abrasive matter, moisture, acid, or alkali. If grease appears dirty, it should not be used. Lubricate the bearings in accordance with the manufacturers recommendations of course, but generally t Old grease should be replaced with new grease during an

overhaul. t For equipment that is furnished with a grease fitting and

drain, the recommendation is to force out the old grease by injecting the new grease.

t Always lubricate the equipment while it is in operation, so temperatures are normalised (be careful of rotating parts).

t Leave the drain plug out for a short period of time after flushing to allow excess pressure build-up to purge itself.

t If there is no drain, follow the manufacturers recommendations on how to add grease and how much.

t Equipment which is idle must be set in motion periodically, even by hand, to spread the lubricant over all bearing surfaces as no grease resists the effect of time, even if left on a shelf. Manufacturers will usually recommend intervals of one to

three months for lubrication.

Conclusion

Ball bearings are precision machines within themselves and may require maintenance in accordance with manufacturers recommendations. They must be given proper care to promote reasonable life. Lack of knowledge and failure to follow the manufacturers recommendations may result in either premature, slow failure and symptomatic noise and vibration, or in complete catastrophic failure.

FUNCTIONS OF LUBRICATION

Lubrication of a bearing has four main functions:t5PMVCSJDBUFUIFTMJEJOHDPOUBDUFYJTUJOHCFUXFFOUIFSFUBJOFSBOEUIFPUIFSQBSUTPGUIFCFBSJOHt5PMVCSJDBUFUIBUQBSUPGDPOUBDUCFUXFFOUIFSBDFTBOEUIFSPMMJOHFMFNFOUUIBUJTOPUUSVMZSPMMJOH

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Those like HEIDENHAIN who manufacture micrometer-precise measurement technology know: its the details that make the vital difference. This applies to our productsand to our company. HEIDENHAIN has been engaged in metrology since 1889. We find this unparalleled performance to be worth investment: more than 10 percent of our revenue is allocated to research and development. The human side is also an important distinguishing feature. Mutual respect, fairness and trust are important to usparticularly when dealing with our customers. These inherited traits make our products that decisive tad better, and make HEIDENHAIN the worlds preferred partner in measurement technology.

HEIDENHAIN OPTICS & ELECTRONICS INDIA PRIVATE LIMITED, Citilights Corporate Centre, #1, Vivekananda Road, Off Spurtank Road, Chetpet, Chennai 600031, IndiaPhone: +91 44 3023 4000, Web: www.heidenhain.in, Email: sales@heidenhain.in; service@heidenhain.in

How large is a critical difference?

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