Alemite Corporation The leader in lubrication and oil mist - PowerPoint PPT Presentation

Alemite Corporation The leader in lubrication and oil mist technology for 80 years . technology for 80 years Charlotte, North Carolina, USA 22/04/51 Rev. 04/99 1

What Is Oil Mist Lubrication? A An automatic, centralized system i li d that continuously delivers fresh, clean oil to multiple, and often widespread machine elements . 22/04/51 Rev. 04/99 2

3 From Liquid Oil To Mist Rev. 04/99 22/04/51

Different Mist Forms for Different Mist Forms for Different Elements 22/04/51 Rev. 04/99 4

Different Mist Fittings Different Mist Fittings Create Different Mist Forms * Mist fittings for metering input of oil * Mist fittings for metering input of oil in “mist form” * Condensing Fittings for metering input of oil in “droplet form” in droplet form * Spray fittings for metering input of oil spray * Spray fittings for metering input of oil spray in “combination of mist and larger oil particles” 22/04/51 Rev. 04/99 5

For High Speed Ball Bearings 22/04/51 Rev. 04/99 6

For Plain Bearings Slides For Plain Bearings, Slides and Other Sliding Motion Parts g 22/04/51 Rev. 04/99 7

For Gears Chains and For Gears, Chains and Large Rolling Element Bearings g g g 22/04/51 Rev. 04/99 8

Thin & Even Film Application The way to save oil, energy & reduce bearing temperature !!! 22/04/51 Rev. 04/99 9

10 Advantages Rev. 04/99 22/04/51

Success Story y Paper Mill Rewinder is Rewinder is lubricated by oil mist . by oil mist 22/04/51 Rev. 04/99 11

Success Story Paper Mill manufacture double - coated printing paper manufacture double coated printing paper Problem Areas before Oil Mist Application Elements of extreme heat and forced suction which drew oil out of the bearings, resulting in excessive consumption of oil, as well as materially shortened bearing life . Six , y g fans served the #3 coater, four feeding hot air into it, while two exhaust units pulled hot air out . Circulating fans were subjected to the highest temperatures These fans force subjected to the highest temperatures . These fans force 600F air to the coater . Temperature at the roller bearing of these fans was estimated at about 220F . 22/04/51 Rev. 04/99 12

Success Story Success Story Paper Mill p Oil mist has greatly reduced fire hazards . 22/04/51 Rev. 04/99 13

Paper Mill p BEFORE & AFTER B E F O R E A F T E R F a n s w e r e m a n u a lly F a n s w e r e m a n u a lly O il c o n s u m p tio n r e d u c e d O il c o n s u m p tio n r e d u c e d lu b r ic a te d e v e r y h o u r th a t o n e g a llo n p e r d a y ; h o u r ly c o n s u m e d 3 g a llo n s o f o il la b o r w a s s a v e d . d a ily . y A v e r a g e 2 s e ts o f b e a r in g B e a r in g lif e w a s g r e a tly w e r e lo s t w ith in a w e e k . e x te n d e d . E x c e s s iv e h e a t a n d s u c tio n E x c e s s iv e h e a t a n d s u c tio n T h e c o n s ta n t d e liv e r y o f T h e c o n s ta n t d e liv e r y o f f r o m th e f a n s d r e w th e f in e s p r a y o il b y o il m is t lu b r ic a n t o u t o f th e b e a r in g s r e d u c e d th e f ir e h a z a r d s o in to th e h o t a ir d u c t th a t m u c h th a t r e s u lte d in o n ly c r e a te d a s e r io u s p r o b le m - o n e f ir e a y e a r . o n e f ir e e v e r y d a y w h ic h b u r n e d o u t th e e x p e n s iv e in s u la tio n in s id e th e d u c k . i l ti i id th d k 22/04/51 Rev. 04/99 14

Success Story Success Story Steel Mill Problem Areas : Grease oozed out of bearings and onto the steel being rolled - finished and ready to go to the g y g customer, and the spotted condition was not tolerated . Solution : 8 lubrication points on the single - stand temper mill were served with oil mist . Problem of spotting was gone . was gone Additional Advantages : only 0.0003” wear on the 12” g y diameter tapered roller bearing, after 800,000 tons of steel rolled; substantial savings in lubricant cost . 22/04/51 Rev. 04/99 15

Success Story Success Story Steel Mill 22/04/51 Rev. 04/99 16

Success Story Success Story Chemical Plant Mississippi Chemical Corporation Mississippi Chemical Corporation Fertilizer plants are entirely open and exposed to the elements . 22/04/51 Rev. 04/99 17

S Success Story St Chemical Plant Chemical Plant Spare reduction gear boxes in warehouse with oil mist continuously applied to protect them from rusting Oil mist keeps bearings running bearings running smoothly for this 500 HP electric motor in the rock grinding mill . 22/04/51 Rev. 04/99 18

S Success Story St Chemical Plant Chemical Plant The benefits to Mississippi Chemical are : ( a ) Lubricating and purging L b i i d i equipment in operation . q p p ( b ) Protecting equipment in storage . 22/04/51 Rev. 04/99 19

Success Story Success Story Chemical Plant AFTER BEFORE Bearings were not changed for six months . Dryer blowers were breaking down monthly due to bearing contamination . Have not had an elevator drive chain break Fertilizer plant has a potash elevator which down in four years . was frequently losing a drive chain . Oil consumption reduces to one drum every One plant used two - three 55 gallon drums 2-3 weeks . a week . After six months in storage with oil mist After six months in storage with oil mist Many gear boxes were rusting in storage b i i simply from exposure to the environment . applied, the gear boxes look like new, and have a thin coating of oil on all internal surfaces . 22/04/51 Rev. 04/99 20

S Success Story St Pharmaceutical Laboratory Pharmaceutical Laboratory Miles Laboratories Miles Laboratories Bottle cappers, operating pp , p g 8 - 16 hours a day, producing up to 15 million tablets during two shifts, are lubricated with oil mist . Primarily on spindle shafts and bearings This unit shafts and bearings . This unit lubricates 20 separate points on the four machines in operation . p 22/04/51 Rev. 04/99 21

S Success Story St Pharmaceutical Laboratory Pharmaceutical Laboratory ADVANTAGE NO . 1 : SAVING 2/3 LUBRICATION COST The secret to the benefits lies in the positive, controllable and predictable manner with which the Alemite systems put d di bl i h hi h h Al i oil right where it is needed at the precise time it is required . Not only is waste eliminated, but excess of lubricant is also controlled . Most bearings and shafts become “frozen” from g too much lubricant than are damaged by insufficient lubrication : LIQUID FRICTION . 22/04/51 Rev. 04/99 22

S Success Story St Pharmaceutical Laboratory Pharmaceutical Laboratory ADVANTAGE NO . 2 : NO LUBRICANT CONTAMINATION Since the products made are all intended for human consumption, they obviously must be free of all impurities . Indiscriminate or uncontrolled use of lubricants could and would create an untenable problem . d ld t t bl bl The positive control of oil mist systems protects products The positive control of oil mist systems protects products against lubricant contamination . 22/04/51 Rev. 04/99 23

Success Story Success Story Food Industry / Tomato Peelers Problem Areas CONTADINA FOODS in California has two peelers, each p , with its own peel eliminator . Each eliminator has 72 one inch Fafnir two hole flange bearings and 36 umber 50 drive chains . All chains and bearings were lubricated by hand h i All h i d b i l b i d b h d daily . Also during each day the units were washed down with a hot water & ammonia solution resulting in water with a hot water & ammonia solution, resulting in water getting into the bearings and oil being flushed from the chains . All 144 bearings and 72 chains required replacement every half season . 22/04/51 Rev. 04/99 24

Success Story Success Story Food Industry / Tomato Peelers Solutions & Results After using oil mist to lubricate bearings and chains, g g , CONTADINA FOODS did not replace any bearings or chains in 2 full season . In other words oil mist increases the life of chains and bearings for at least i h lif f h i d b i f l three times - maybe more . Secrets Secrets * Water residual ( during wash down ) is purged out of the bearings and chains . the bearings and chains * The flushed oil ( during wash down ) is filled in by fresh oil mist . 22/04/51 Rev. 04/99 25

Success Story Success Story Mining Industry / Shaker Screens Problem Areas Independence Mine in Nevada has three Allis Chalmers Independence Mine in Nevada has three Allis Chalmers shaker screens operating in a very dirty, dusty environment where winter temperature is as low as zero degree F . p g Each shaker screen has two FAG bearings with labyrinth seals operating at 900 RPM . The bearings were lubricated by rotating the bearings through an oil sump . Independence experienced 22 bearing failures in 1995 . 22/04/51 Rev. 04/99 26

Success Story Success Story Mining Industry / Shaker Screens Solutions & Results In January 1996 the oil sumps were drained and an Alemite I J 1996 th il d i d d Al it oil mist system was installed . No bearing was replaced in 1996 . No bearing was replaced in 1996 Oil consumption is reduced by 50% . Secrets Secrets Oil mist system provides a continuous supply of fresh, clean oil to the bearings, and a positive pressure inside the bearing housings, which eliminates contamination . 22/04/51 Rev. 04/99 27