October 30, 2007 ©SKF Group Slide 0
Transcript of October 30, 2007 ©SKF Group Slide 0
October 30, 2007 © SKF Group Slide 2
Industry and application
The applictions:
• Hot gas or high speed process fans
Target industries (end users):• Steel
• Cement
• Mining
• Pulp and paper
• Power
• Food
• Chemicals
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Customer needs and trends
Commercial: • Complete packages
• Sub supply of complete fan
Technical: • Lower bearing operating temperature
• Lower maintenance costs
• Easy servicing
• Oil lubrication
• Reliability in operation
• Increased fan performance
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Problems and issues
Fans are a critical part of many industrial processes• process fan failures are costly and result in production stop
and/or environmental risks
Fan performing on the limit due to high temp. and speed• high operating temperatures and hot gases
• high operating temperatures- higher maintenance costs – higher breakdown risks
Higher performance demands
Lower Total Cost of Operation • maintenance cost, downtime and service life (bearing and lubrication)
• SKF hot line receives one phone call a day on hot running fans (USA)
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Technical impact
• How can SKF reduce the temperature from 105 C to 60 C?
current situation value for customer
bearing temp.105 °C 60°C
fan speed (rpm)
perform
ance
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The SKF fan upgrade services solution
• By combining multi-platform knowledge, SKF is now providing a completestandardized ‘system solution’ that addresses all the customer’s critical issues.
• The innovative design of new lubrication 'kits' (automatic grease and oil) based on the bearing lubrication needs.
• SKF aim to reduce the Total Cost of Ownership (TCO) by increasing reliability and lowering maintenance costs, while reducing operating temperature.
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What is the fan upgrade service solution?
Assessment
SKF Asset Mgt Services
SKF Engineering service
Bearing housings (optimised design) and low friction seals
Self-aligning solution
Circulating oil / automatic greaselubricationsystems
Installation and ongoing support e.g. CoMo
• Full value is achieved when the complete SKF fan upgrade is installed.
• SKF has combined knowledge from the key platform areas and created a complete ‘system solution’ for industrial fan applications
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Benefits to the customer
• A complete ‘fan upgrade service’ offer from one supplier
– Including a specific lubrication system (oil or grease) designed together with the
bearing / housing unit for optimal performance.
• Standardized fan upgrade alternative to a customer designed system
• Enhanced bearing and seal service life and higher fan speeds.
• Reduced operating temperature
• Increased reliability
• Reduced total cost of operation (including maintenance costs)
• Reduced environmental effects
• Uniqueness: SKF is the only supplier offering products and knowledge in bearings and lubrication; and providing optimum integration engineering capabilities
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Fan upgrade service – key technical areas
The automatic lubrication systems:• Essential for preventive maintenance
• Single most important component in the temperature-reducing solution
• Grease is a more temperature sensitive lubrication method than oil lubrication
SKF circulating oil lubrications systems• A few standard variants for very critical applications
• Capacity for one or two fans
• Controlled temperature and oil viscosity – cool, clean oil increasing oil life
• SKF software program and recommendations
• Frequency controlled pumps and cooling fan for lower energy consumption
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The bearing shaft solution
Traditional bearing systems
• Free bearing moving in the bearing housing creates axial loads in the system
• Load is higher on one side of the bearing
SKF Self-aligning bearing systems
• SKF solution overcomes friction, misalignment, vibrations and heat
• Keeps operating temperatures down, reduces vibration and noise, leading to extended bearing service life.
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The bearing shaft solution
SKF bearing housings
• Specific designs to address temperature issues and remove thermal energy
• Specially designed oil seals to avoid leakage.
• Combined with the self aligning system SKF can dramatically reduce bearing operating temperatures in high speed and hot gas fans.
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Fan upgrade service value: Total Cost of Ownership
• The results are obviously beneficial from a business perspective, but they are also important for sustainability!
Amount of
Production
Machine efficiency
Capacity
Increased production output can be achieved by reduction of unplanned stops or by increasing machine
capacity i.e. fan speed
“Reduce the total cost of ownership by increasing reliability and lowering maintenance costs, by a unique combination of bearing and housing units and
dedicated lubrication systems”
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Energy saving and sustainability
• Much reduced friction
• Lower bearing operating temperature
• Reduced lubrication consumption v fan life
• Reduced levels of excessive oil
• Reduced grease waste
• No oil leakage
• Reduced energy consumption
• Longer component life
Users stretch Fan performance to the limit: energy costs become the largest part of the total cost due to the high heat levels (up to 80% of total TCO).
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DSP on a critical fan at a large paper mill
SKF offered a step-by-step process to boost fan performance and cut operating costs• Assessment
• Recommendations
• Installation and ongoing support
SKF offered one source for a complete fan upgrade service:
Assessment
SKF Asset Mgt Services
SKF Engineering service
Bearing housings (optimised design) and low friction seals
Self-aligning solution
Circulating oillubricationsystems
Installation and ongoing support e.g. CoMo
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• From 3 months mean time between failures to 16 months
• From average 82 C to 65 C bearing operating temperature
Return On Investment (ROI) summary• Investment in new SKF solutions: $24 150
• Total maintenance, repair and downtime savings: $140 909
– Met EPA downtime requirement saving $25 000
• Total net savings: $116 759
� ROI (16 months): 483%
ROI calculations are from the SKF Documented Solutions Program.
Cost savings may vary between end users and industries.
DSP on a critical fan at a large paper mill
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Fan upgrade services: Communication material
2008-06-17 ©SKF Slide 17 [Code] SKF [Organisation]
Brochure 6597 EN