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Case study on impact of high temperatures and loads on lubrication and therefore life of plummer block bearings in the drying range of a textile spinning mill.
The drying range or VDR (Vertical Drying Range) in the woven dyeing and printing segment of a textile mill enables rapid drying of fabric under high steam pressures and temperatures. The pillow or plummer block bearings play an important role in functioning of these vertical drying ranges by supporting movement of rotating shafts or rolls.
These vertically oriented plummer block bearings face unique operating conditions of high temperatures and loads, exposure to process chemicals, steam, dust and other contaminants. In the absence of effective lubrication, environmental factors can cause undue stress on the plummer block bearings, leading to premature failure and unexpected downtime in the drying section.
Selection of lubricant to endure such aggressive conditions determines the performance and life of functional elements in bearings like rollers, raceways, balls, and cages. BECHEM’s range of speciality greases for bearings operating in such harsh conditions ensure effective lubrication and also extend bearing service life.
Customer: A leading textile producer in India with a value chain extending from yarns to garments. With a production capacity of over 75,000 meters of fabric per day, the integrated textile unit has multiple facilities for the processes of bleaching, mercerizing, dyeing, printing of yarn, garment washing and finishing in the same vicinity.
The drying range is equipped with 16 vertically mounted cylinders in two rows. The customer was using a synthetic grease based on OE recommendation (brand Y) to lubricate a total of 32 bearings in each row.
Issues reported by the Maintenance Dept.
- Excessive oil bleeding and evaporation loss due to exposure to high temperatures
- When exposed to hot steam, grease oxidised rapidly losing its inherent properties
- Frequent re-lubrication
- In order to avoid plummer blocks going dry, re-lubrication frequency was increased. However, the process was tedious as bearings are located at different heights and in difficult-to-reach locations
- Nevertheless, frequent bearing failures were reported leading to downtime and productivity loss.
Operating conditions of ‘vertical drying range (VDR) cylinder
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- 1st row and 2nd row with 16 cylinders vertically mounted in each row
- Bearing number: UC 215 bearing
- Temperature: 150 to 180 ˚C
- Load: 1- 1.5 Ton
- RPM: very low
- Re-lubrication frequency: once in 15 days
- Bearing life: 1 year
Closely monitoring the operational parameters, BECHEM’s application team recommended the high temperature grease, Berutemp M 2 KN. A high-performance, polyurea grease developed for bearings that are exposed to high temperatures and loads, steam and water ingress.
Why Berutemp M 2 KN?
- Based on polyurea thickener and fortified with additives, Berutemp M 2 KN offers exceptional oxidation stability ensuring long term lubrication.
- Extended service life of the grease avoids repetitive lubrication breaks and production loss
- Berutemp M 2 KN forms a consistent lubrication film between rolling contact and sliding surfaces even at high temperatures
- Berutemp M 2 KN offers excellent resistance to water and steam, thereby protects rolling elements from corrosion
- Formulated with ultra-refined base oil, Berutemp M 2 KN exhibits excellent temperature resistance behavior with controlled oil bleed characteristics
- Developed on comparatively higher base oil viscosity (490 Cst at 40 ˚C), Berutemp M2 KN prevents metal-to-metal contact under high load conditions
- Based on the BECHEM team’s recommendation, a trial was initiated with Berutemp M2 KN to observe any change in lubrication life.
Trial Observations:
- No issue of grease oxidation when exposed to steam was reported
- Re- lubrication interval extended from 15 to 30 days
- No bearing failure reported in the drier section of the plant for a span of 1 year
Having observed performance of the product in optimizing production process efficiency, the customer switched over to ‘Berutemp M 2 KN’. Usage of grease was also extended to other bearings which were exposed to high operating temperatures and similar work environments.
For more details on Berutemp M 2 KN or for sample of the product, write to us at [email protected].
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