Lubrication of grinder bearings in a metallurgical workshop.

Context

In a metallurgical workshop's machining and rectification unit, large-diameter bearings are utilised in a 7-meter production line. Internal grinding of pipes precedes cementation, requiring precise execution.

To maintain smooth operation, bearings on the grinder are regularly lubricated manually using EP 2 multifunctional grease. With speeds ranging from 1,500 to 3,000 rpm, maintenance is conducted five days a week, totaling 2.5 hours weekly.

During maintenance, eight pumps of grease ensure optimal performance, preventing operational issues. This diligent lubrication regimen supports efficient production processes in the workshop.

Problem

Manual greasing procedures are both repetitive and excessive, leading to premature bearing failure within just 4 to 6 months.

Solution

We recommended a high-performance grease solution, equipped with MFt Pd technology, namely Castrol's Tribol Gr 100-2 Pd. This advanced grease formulation is meticulously engineered to meet the demanding requirements of industrial applications, particularly those involving high speeds, heavy loads, and vibrations.

This grease offers superior lubrication properties, ensuring smooth operation and minimizing wear even under extreme operating conditions. Its exceptional performance capabilities enhance the longevity of bearings, effectively addressing the challenge of premature failure experienced previously. By using Castrol's Tribol Gr 100-2 Pd, our solution provides not only reliable lubrication but also peace of mind, enabling the equipment to operate at peak efficiency while reducing maintenance frequency and associated costs.

RESULTS

We proposed a comprehensive solution aimed at optimizing the greasing process, introducing Castrol's advanced Tribol Gr 100-2 Pd grease. By dividing the greasing frequency by five, we streamlined maintenance to just one session per week, while maintaining the same quantity of grease applied with 8 pumps per refill.

This adjustment resulted in a remarkable increase in bearing longevity, extending beyond 12 months. Moreover, the implementation of Tribol Gr 100-2 Pd led to a substantial reduction in operational times, encompassing both greasing and bearing replacement procedures.

Most notably, our solution eliminated production downtime caused by bearing failures, ensuring uninterrupted workflow. Furthermore, the rationalization of Tribol Gr 100-2 Pd grease across other high-speed, shock, and vibration applications underscores its versatility and effectiveness in industrial settings.