Maintenance and Reliability Improvement of Roller Bearings Operating at High Temperature: Thermal Stress Analysis Approach

D. K. Nahum, Gopinath Chattopadhyay
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Abstract

In this paper the authors present the outcome of an experimental maintenance and reliability investigation conducted to prevent operation failure of pinion bearings caused by excessive temperature with a case study of a 1360kW ball mill driveline system in mineral processing application. Aiming to improve the overall plant performance, the lubrication regime of pinion bearings as key component within the ball mill driveline system was studied to determine possible causes of temperature increase at 80 to over 100°C with a 25 - 30°C gap over the maximum operating temperature. An analytical review of maintenance data is conducted to mitigate future operational risks by implementing a new lubrication regime and shutdown frequency for overall statutory inspection. Accelerated life test based inverse power law has been applied to identify the root causes of excessive bearings temperature to establish immediate short-term solution paths towards a guaranteed less required maintenance asset improvement practice, less operational cost, and plant availability enhancement. Furthermore, long-term solutions have been proposed based on modelling by thermal network approach of pinion bearings for thermomechanical stress prevention. A single parameter based accelerated test on pinion bearings was applied to establish operational fault tolerant factors to be considered for asset capability improvement, which remains an open question for future studies. These actions have shown significant improvement with temperature decrease between 15 and 25°C below the maximum required temperature.
高温下工作的滚子轴承的维护和可靠性改进:热应力分析方法
在本文中,作者以矿物加工应用中的 1360 千瓦球磨机传动系统为例,介绍了为防止小齿轮轴承因温度过高而出现运行故障而进行的维护和可靠性实验研究的结果。为了提高设备的整体性能,对作为球磨机传动系统关键部件的小齿轮轴承的润滑机制进行了研究,以确定温度从 80°C 升至 100°C 以上的可能原因,与最高工作温度之间的差距为 25 - 30°C。对维护数据进行了分析审查,以通过实施新的润滑制度和停机频率进行全面法定检查来降低未来的运行风险。基于反幂律的加速寿命测试已被用于确定轴承温度过高的根本原因,以建立直接的短期解决方案路径,从而保证减少所需的维护资产改进实践、降低运营成本并提高设备可用性。此外,还提出了基于小齿轮轴承热网络方法建模的长期解决方案,以防止热机械应力。对小齿轮轴承进行了基于单一参数的加速测试,以确定为提高资产能力而需考虑的运行容错因素,这仍是未来研究的一个开放性问题。这些行动表明,随着温度降低到低于所需的最高温度 15 至 25°C 之间,情况会得到明显改善。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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