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Motor Reliability

Solution ased Life

Extension Program



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






Lubricating

Film

Piece of paper

Ef = 0,0005 mm

Otherwise:

200 times thinner than a piece of

paper.

0,1 mm






Selection is Viscosity, Speed,

Diameter Dependent












MOTOR BEARING FAILURES






EPRI, 1983 STUDY






WHEN DIS FAILURE OCCUR






Re-GREASING and PLUG






REASONS for FAILURE

LUBRICANT STARVATION

GREASE INCOMPATIBILITY

WRONG GREASE OVER PRESSURIZATION

GREASE INSIDE CAVITY

OVER HEATING DUE TO EXCESS GREASE

GREASE DEGREDATION/HARDENING








SIMPLIFIED MOTOR BEARING






SINGLE SHIELD BEARING








SHIELDED BEARING






Grease Flow in a Bearing

22








Over Greasing Does Happens






WHERE DOES THE GREASE GO?






Grease Relief Plugs






Solution is Management of Lubrication






MOTOR with GREASE RELIEF















CHESTERTON

© Copyright 2003 A.W. Chesterton, All rights Reserved31

Greasing BearingsCritical for Reliable Operations

How Much , How Often





CHESTERTON


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



CHESTERTON


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



CHESTERTON


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



CHESTERTON


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



Yetersiz Yağlama ve Çevresel Faktörler



CHESTERTON


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



CHESTERTON


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



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



CHESTERTON


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



CHESTERTON


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



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



CHESTERTON


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.



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.



CHESTERTON


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



CHESTERTON


THE LUBRI-CUP® SYSTEM

Manual versus Automatic



45

Courtesy SKF

Manual versus Automatic

Lubrication

Automatic : Apply correct amount, time and grease type

LubriCup EM or VG with QBT Lubricant



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



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



4848


LubriCup Applications Electric



4949

LubriCup Applications – Electric

Motors

Lubri up Applications Pumps Air



5050

Air Handling Units

Lubri up Applications –

Pumps AirHandling

Pumps

LubriCup Applications Cooling



5151

LubriCup Applications – Cooling

Towers



5252

Electric Motors




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







Solution in Place





Solution in Place





Solution in Place





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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Documents

2. Motor ProgramWEBcast (NXPowerLite)