Oil Mist Bearing Cartridge Solution. LSC Innovators of Reliability Solutions

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1 Oil Mist Bearing Cartridge Solution LSC Innovators of Reliability Solutions

2 Air Cooled Heat Exchanger Bearings Reliability Challenge: Excessive Air Cooled Heat Exchanger (ACHE) bearing failures Average Life for ACHE grease bearings years - University of Houston, Bauer College of Business, Dec 2008 Loss of cooling capability, leading to: Production Inefficiency and Loss Excessive Maintenance Cost 2

3 Air Cooled Heat Exchanger Bearings Root Cause #1: Bearing Failure due to Lubricant breakdown Inherent grease challenges, exacerbated by ACHE location & environment Improper amount of grease Maintaining grease systems Contamination from environment Degradation of grease due to elevated temperatures 3

4 Air Cooled Heat Exchanger Bearings Root Cause #2: Bearing Failure due to Bearing Overload SHAFT MISALIGNMENT - Failure mode #1 Axial and parallel misalignment during installation 4

5 Example: Air Cooled Heat Exchanger Bearings Root Cause #2: Bearing Failure due to Bearing Overload SHAFT THERMAL EXPANSION - Failure mode #2 Shaft rusts to inner race of ball bearing NO free movement of shaft during Thermal Expansion 2 15/16 diameter shaft Bearings spaced at 36 centers Temperature increase of only 200 F Will Grow Inches This Can Put Almost 200,000 lbf Through A Typical Bearing 5

6 Air Cooled Heat Exchanger Bearings LSC Solution: Lubricant (Grease) Breakdown: Oil Mist Clean, cool, continuous flow of oil delivered to bearings (patented closed loop system) Maintains positive pressure in bearing cartridge, preventing ingress of external contaminants Bearing Overload Patent pending, cartridge bearing Allows up to 20 axial and / or parallel misalignment Seal physically travels within the bearing cartridge, ensuring seal / shaft orientation Upper bearing supported on Wave Washers allowing axial growth of shaft 6

7 Cartridge Bearing Solution LSC MistLock Bearing Design Easy Installation Fits 6 or 7 inch bolt circle Ball Bearing Oil Mist - In Magnetic Bearing Seals or Lip Seals Oil Mist Out Bearing & Seal Alignment feature Sleeve Drive Collar & Locking device 7

8 Cartridge Bearing Solution Axial Misalignment Non-Parallel Surface 8

9 MistLock Bearing Solution Thermal Expansion Feature Shaft Locked to Bearing ID Rather Than This Being a Sliding Surface Sliding Surface Constantly Lubricated to Prevent Axial Seizure Upper Bearing Supported on Wave Washers to Allow Axial Growth of Shaft 9

10 MistLock Research Protocol LSC in partnership with parent company Colfax initiated an R&D program to improve the MTBF of ACHEs with an oil mist lubricated bearing and seal system Greatest challenge in using oil mist lubricated bearings in ACHE applications is the containment of the oil mist within the bearing housing Largely because of issues with the close run out tolerances required on rotary seals MistLock TM bearing cartridge engineered to address ACHE challenges through: Leveraging the superior lubrication properties of Oil Mist Maintaining seal, shaft and bearing alignment, regardless of shaft orientation Utilizing a shaft-locking device that centers the shaft in the bearing, to ensure the shaft runs true Allowing up to 20 degrees of misalignment between upper and lower bearings, eliminating any need to shim bearings during installation Accommodating axial thermal expansion of the shaft, to prevent bearing overloading The research protocol consisted of four distinct testing categories 10

11 MistLock Research Protocol - Testing Fan Simulation Test Rig 1. Accelerated Bearing Life Four sets of oil mist lubricated bearing assemblies and three sets of grease lubricated bearing assemblies were placed onto an accelerated test rig. Alignment between the top and bottom assemblies adjusted between 0 and 1½ degrees. Side load of 8,100 pounds applied to the shaft, just below the bottom bearing Simulate 4½ times baseline belt loading on the lower bearing and 2 times baseline radial load conditions on the upper bearing. Axial load of 5,200 pounds applied to the top of the shaft Simulate 3½ times baseline fan loading on the lower bearing. The bearings were arranged so that the lower bearing carried all thrust loads and a large portion of the radial load. Shaft rotated at 300 RPM. 11

12 MistLock Research Protocol - Testing Fan Simulation Test Rigs 2. Normal Belt Loading Test Three sets of oil mist lubricated bearing assemblies were placed onto a test rig, with the alignments between the top and bottom bearings set at 0. Side load of 2,700 pounds applied to the shaft, just below the bottom bearing Simulate 1½ times normal radial bottom-bearing belt loading. Loading decreased to verify that excessive belt loading can influence seal performance. Axial load applied to the top of the shaft remained at 5,200 pounds was still applied to the top of the shaft 12

13 MistLock Research Protocol - Testing 3. Field Testing A set of both oil mist and grease lubricated bearings was placed onto actual fans. Bearing loading: 646 pounds on lower bearing and 112 pounds on upper bearing (radial load). Axial force on lower bearing was 643 pounds Shafts rotated at 280 RPM for the duration of the testing Field Testing Colfax Facility in North Carolina 13

14 MistLock Research Protocol - Testing 4. Stand-Alone Seal Testing Three different seal types were placed onto a stand-alone seal-test stand that consisted of 10 vertically mounted shafts spinning at 300 rpm. One mechanical face seal Two lip-seal variations A single set of seals was mounted onto each shaft and individually lubricated with ISO 68 synthetic oil mist. The seals ran a minimum of 350 hours. Seal leakage was monitored daily. Seal Test Rig 14

15 MistLock Research Protocol - Results 1. MistLock TM Bearing Results Under Accelerated Testing Change in temperature and vibration levels was insignificant for all the oil mist lubricated bearings No MistLock bearings failed Some of the grease lubricated bearings showed signs of extreme vibration after only 24 hours. These bearings exhibited extreme pitting after 2,000 hour run time MTBR greatly increased with oil mist bearing even at 1 ½ degrees of shaft misalignment Grease Bearings after Accelerated Test 15

16 MistLock Research Protocol - Results 2. MistLock TM Under Normal Belt Loading The oil mist lubricated bearings appeared pristine after the normal-belt-loading testing. After 2,000 hours, the bearings were disassembled and showed no signs of wear. There were no seal leaks on any of the bearing assemblies. Bearings housings re-assembled and run for an additional 2,000 hours with no wear MistLock TM Bearings after testing 16

17 MistLock Research Protocol - Results 3. MistLock on Field Test Both grease and oil mist ran on fans side by side for 5,000 hours. The Oil Mist bearing assemblies did not show any sign of increased vibration Upon disassembly the Oil Mist bearing appeared pristine with no wear The overall vibration levels increased on both the lower grease bearing and the upper grease bearing during the test. The inner race on the top bearing and the rolling elements of the top bearing had significant pitting and fretting Grease Bearing MistLock TM Bearing 17

18 MistLock Research Protocol - Results 4. Stand-Alone Seal Testing All seals were run for a minimum of 350 hours at 300rpm Of the two types of multiple lips seals tested, none leaked under static or dynamic conditions 60% of mechanical seals tested leaked Bearing design with multiple lip seal (self aligning to shaft and bearing) proved capable to seal oil mist within closed loop system. No stray mist or coalesced oil was observed during testing Seal Test Rig 18

19 Conclusion Research demonstrates that LSC s MistLock TM solution overcomes the root causes to premature failure of ACHE bearings Oil Mist eliminates lubricant breakdown MistLock TM bearing cartridge design overcomes Bearing Overload Cartridge allows up to 20 axial and / or parallel misalignment Upper bearing supported on Wave Washers allowing axial growth of shaft 19

20 Thank You 20

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