PL

Testing of cement mill press bearing oil

facility: cement plant
machine: roller press
scope of work: circulation lubrication of bearings

problem description:

After the overhaul of the system, foaming of the oil in the main tank and a marked deterioration in its cleanliness were observed, with a significant reduction in the life of the filters. A sample of the lubricating oil was sent to the Ecol laboratory to check its parameters.

proposed solution:

Periodic refreshing and oil filtration, along with continuous diagnostics of oil parameters, were carried out to allow the machine to operate until the scheduled shutdown and overhaul. In order to maintain the proper viscosity of the oil, a certain amount of lubricant was periodically tempered and diluted with oil of the same type but with lower viscosity selecting the proportions based on laboratory analysis.

course of implementation:

The first analysis of the oil showed, among other things, contamination of the oil with grease and an accompanying marked increase in viscosity, above the acceptable limit for the proper functioning of the system. The bearings of the system, which were lubricated with the tested oil, in addition to the lip seal, were additionally sealed with grease from the outside – based on the information about the contamination of the oil in the system with the given grease, the conclusion was drawn that the seal during the overhaul was installed incorrectly and allowed grease to get inside the system. Faced with the impossibility of shutting down the machine and correcting the installation of the seals, the decision was made to use effective oil care based on cyclic laboratory analysis of the oil (every two weeks or so).

photo of cement plant
photo of cement plant

Faced with the impossibility of shutting down the machine and making adjustments to the seal assembly, the decision was made to use effective oil care based on cyclic laboratory analysis of the oil

result achieved:

By conducting cyclic oil refreshment and filtration, based on regular laboratory tests that determine the optimal time to take corrective action, it was possible to safely operate the press until the scheduled shutdown. A possible production stoppage due to an improper oil condition, where an overhaul time of several days at best would have been required, could have caused millions of dollars in losses, which were avoided through a combination of oil diagnostics and proper oil care.

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