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

Charlotte, North Carolina, USA

technology for 80 years.

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What Is Oil Mist Lubrication?

A i li d An automatic, centralized system that continuously delivers fresh, clean oil to multiple, and often widespread machine elements.

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From Liquid Oil To Mist

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Different Mist Forms for Different Mist Forms for Different Elements

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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”

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For High Speed Ball Bearings

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For Plain Bearings Slides For Plain Bearings, Slides and Other Sliding Motion Parts g

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For Gears Chains and For Gears, Chains and Large Rolling Element Bearings g g g

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Thin & Even Film Application

The way to save oil, energy & reduce bearing temperature!!!

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Advantages

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Success Story y

Paper Mill

Rewinder is Rewinder is lubricated by oil mist by oil mist.

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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

• il out of the bearings, resulting in excessive consumption
• f 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.

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Success Story Success Story

Paper Mill p

Oil mist has greatly reduced fire hazards.

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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 O il c o n s u m p tio n r e d u c e d F a n s w e r e m a n u a lly lu b r ic a te d e v e r y h o u r th a t c o n s u m e d 3 g a llo n s o f o il d a ily . O il c o n s u m p tio n r e d u c e d

• n e g a llo n p e r d a y ; h o u r ly

la b o r w a s s a v e d . y A v e r a g e 2 s e ts o f b e a r in g w e r e lo s t w ith in a w e e k . B e a r in g lif e w a s g r e a tly 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 T h e c o n s ta n t d e liv e r y o f E x c e s s iv e h e a t a n d s u c tio n f r o m th e f a n s d r e w th e lu b r ic a n t o u t o f th e b e a r in g s in to th e h o t a ir d u c t th a t T h e c o n s ta n t d e liv e r y o f f in e s p r a y o il b y o il m is t r e d u c e d th e f ir e h a z a r d s o 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 -

• 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 i l ti i id th d k

• n e f ir e a y e a r .

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in s u la tio n in s id e th e d u c k .

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.

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Success Story Success Story

Steel Mill

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Success Story Success Story

Chemical Plant

Mississippi Chemical Corporation Mississippi Chemical Corporation

Fertilizer plants are entirely open

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and exposed to the elements.

S St Success Story

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.

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S St Success Story

Chemical Plant Chemical Plant

The benefits to Mississippi Chemical are:

L b i i d i (a) Lubricating and purging equipment in operation. q p p (b) Protecting equipment in storage.

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Success Story Success Story

Chemical Plant

BEFORE AFTER

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

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S St Success Story

Pharmaceutical Laboratory Pharmaceutical Laboratory

Miles Laboratories

Bottle cappers, operating

Miles Laboratories

pp , p g 8 - 16 hours a day, producing up to 15 million tablets during two shifts, are lubricated with

• il mist. Primarily on spindle

shafts and bearings This unit shafts and bearings. This unit lubricates 20 separate points

• n the four machines in operation.

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p

S St Success Story

Pharmaceutical Laboratory Pharmaceutical Laboratory

ADVANTAGE NO. 1: SAVING 2/3 LUBRICATION COST The secret to the benefits lies in the positive, controllable d di bl i h hi h h Al i and predictable manner with which the Alemite systems put

• il 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.

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S St Success Story

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 d ld t t bl bl and would create an untenable problem. The positive control of oil mist systems protects products The positive control of oil mist systems protects products against lubricant contamination.

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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 h i All h i d b i l b i d b h d

• chains. All chains and bearings were lubricated by hand
• 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.

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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 i h lif f h i d b i f l increases the life of chains and bearings for at least 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

• il mist.

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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.

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Success Story Success Story Mining Industry/Shaker Screens

Solutions & Results

I J 1996 th il d i d d Al it In January 1996 the oil sumps were drained and an Alemite

• il 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

• il to the bearings, and a positive pressure inside the bearing

housings, which eliminates contamination.

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Success Story Success Story Food Industry/Sugar Beet Defuser

Problem Areas

S k l S C i C lif i ff d f Spreckels Sugar Company in California suffered from the problems existing in chains and sprockets on their sugar beet defuser equipment: oil reservoirs (for lubricating chains beet defuser equipment: oil reservoirs (for lubricating chains and sprockets) were contaminated with product, housekeeping was impeded due to oil reservoirs overflow, large sprockets and 11 of 150 ft long chains were replaced every year, oil consumption was 240 gallons in two years.

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Success Story Success Story Food Industry/Sugar Beet Defuser

Solutions & Results

A single Alemite oil mist unit was installed for lubricating A single Alemite oil mist unit was installed for lubricating all the 28 chains and sprockets in 1995. In two year time frame little or no wear of chain or sprocket was recorded, p ,

• il consumption rate dropped to 12 gallon, housekeeping

problems had been reduced by 90%.

Secrets

Oil application is well controlled that minimizes oil consumption, eliminates housekeeping problems. Fresh and clean oil is continuously supplied to chains and sprockets that prevents contamination

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sprockets that prevents contamination.

Success Story Success Story Sawmill/Edger Arbor Bearings

Problem Areas

H d L b Mill i C lif i h f d E h Harwood Lumber Mill in California has four edgers. Each edger has two arbor bearings with 100 mm I.D. Three edgers use double row bearings running at 1750 RPM the fourth use double row bearings running at 1750 RPM, the fourth edger has two Cooper bearings on the arbor running at 1,435

• RPM. All of them operate in areas that expose them to high

amounts of contamination from saw dust and water. The grease lubricated edgers’ failure rate was total 16 per year.

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Success Story Success Story Sawmill/Edger Arbor Bearings

Solutions & Results

In 1990 Harwood Lumber installed an Alemite oil mist

• system. 50 degree bearing temperature drop was

noticed immediately, no failure had been seen in four years In one occasion when air supply was turned off in error in In one occasion when air supply was turned off in error in the 5th year, only two bearings failed. The other six were still running in good conditions in 1997. g g

Secrets

Oil mist eliminates “wet friction” that reduces temperature by p y 50 degree, constantly purges bearing housings keeping housing clean.

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Textile Mill Applications

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Cold Rolling Mill Application

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When the oil mist When the oil mist carrier, AIR, is ti l h t d continuously exhausted into the workplace area and may be carrying some oil in it, potential , p users are concerned with this stray mist with this stray mist.

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What is the acceptable What is the acceptable level of oil content?

OSHA in the USA and the Ministry of Labor in Canada have established exposure limits for oil mist in a plant: p p

Both standards allow a workplace exposure limit of 5 mg oil/m3 air time-weighted average exposure value (TWAEV).

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Research Results

An independent laboratory, Guelph Chemical Laboratories used strict NOSH methods for measuring oil in stray mist. A cross section of industry including an aluminum mill A cross-section of industry including an aluminum mill, steel rolling mill, pulp & paper industry and automotive parts manufacturing were selected and tests made to parts manufacturing were selected and tests made to measure stray mist in the workplace area surrounding the equipment using oil mist systems, over an 8 hour period sometimes extending into the night. The results show:

i 0 675

3

f d maximum 0.675 mg/m3 was found at mist cloudy area in a steel mill.

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RESULTS

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RESULTS

* ALUMINUM MILL 0.35mg - 0.45mg by commercial gear lubricant b i bl l b i 0.20mg - 0.40 mg by mistable lubricant * COLD ROLLING MILL 0 40mg 0 67mg in 5 days 0.40mg - 0.67mg in 5 days. * PAPER MILL 0.22mg - 0.29mg in 5 days g g y * AUTO PARTS MANUFACTURING 0.04mg - 0.13mg in 4 days OPEN GEARS & CHAINS BEARING MFG * OPEN GEARS & CHAINS (BEARING MFG.) 0.8mg - 1.0mg in 4 days

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CONTROL

(A) Make sure that application fittings are used on the equipment. (B) Use correct size application fittings for the bearing. [Oversizing can create stray mist.] (C) Apply proper air temperature. i bl il i d h d (D) Use mistable oil instead that cuts down

• il in the stray mist

l f [example: from 0.6 mg to 0.32 mg] (E) Properly ventilate workplace.

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