Comprehensive online monitoring concept for trunnion bearings in converters

2015-06-16 | 000-005-896 DE-EN

SCHAEFFLER AG, D SSELDORF/SCHWEINFURT

Schaeffler at the 2015 METEC in Hall 3, Booth C16

Comprehensive online monitoring concept for trunnion bearings in converters

One of the main demands of the steel processing industry is the highest possible availability of the main manufacturing systems. In the case of bottleneck systems such as converters in oxygen steelworks in particular, downtimes can involve costs of up to several millions for the plant operator. Schaeffler offers a solution for issue with its new comprehensive online monitoring concept for the trunnion bearings and gears of converters. We have integrated several monitoring concepts such as acoustic emission measurements, our proven oil particle analysis with the FAG Wear Debris Check, and checking the condition of grease with the FAG GreaseCheck into a unique condition monitoring system. This enables maintenance work to be planned and prevents costly unplanned downtimes caused by damage to bearings. Certified experts provide support with data evaluation and give their recommendations to customers.

With its range of bearings, housings and mounting services, Schaeffler has an integrated approach in addition to condition monitoring that offers operators optimum total cost of ownership (TCO).

Acoustic emission measurements

For the first time, Schaeffler is offering a condition monitoring system that uses the principle of acoustic emission measurement. This method is ideal for use with slowly-rotating trunnion bearings such as those used in converters. The otherwise usual method of measuring vibrations cannot be used reliably here, since the speeds are not high enough to generate sufficient energy to measure the structure-borne noise during overrolling of damaged areas of the bearing. Excessively short processes can also shorten the measuring time so that the resolution is too low.

Acoustic emission measurements, on the other hand, utilize the effect that plastic deformation or breakages occur in materials that are subject to loads beyond the elastic limit. This defect leads to a concentration of stresses followed by the formation of cracks and, ultimately, to a sudden release of the tension in the material. This short process generates an acoustic emission event that moves away from the source in the form of an ultrasonic wave and that can be measured.

Oil particle analysis - FAG Wear Debris Check

Wear in bearings or gearings manifests itself well before impending failure in the form of metal abraded particles. Damage to gearboxes lubricated with oil circulation and plain bearings can be detected at an early stage if this abrasion is measured and monitored. The FAG Wear Debris Check device measures the number of particles in the oil and transmits key values to the upstream monitoring system and records and evaluates the particle concentration according to size and material.

Due to slow speeds in the bull gear of converters, monitoring by means of vibration analysis is not possible. This means permanent oil particle analysis using FAG Wear Debris Check is required.

Grease quality measurement - FAG GreaseCheck

More than half of all rolling bearing failures are directly attributable to lubrication. Lubrication conditions, physical grease aging, or the proportion of solid and liquid contamination such as water in the lubricant have a decisive influence on bearing life.

By using the FAG GreaseCheck grease sensor and the corresponding analysis unit, it is possible to detect any changes in the condition of the grease during operation, long before any damage to the rolling bearing occurs. This means the time the grease is changed can be precisely planned and the operating life of the bearing can be extended. It also enables a switch from scheduled relubrication to relubrication according to requirements. In addition to measurement points for the acoustic emission sensors, FAG spheroidal graphite cast iron housings for converter bearings already include bores to install the FAG GreaseCheck.

Consolidating and evaluating measurement data - FAG ProCheck

Besides the total of over 60 ascertainable key values, the process parameters also need to be recorded as part of the monitoring strategy. The FAG ProCheck monitors representative key values and prepares them for display on the plant visualization system. The alarm function on FAG ProCheck reports any faults and errors that may have occurred. Schaeffler service engineers can then evaluate and analyze these faults via remote access and give detailed recommendations regarding what action needs to be taken.

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