Morgan SiemensVAI Lubrication
Morgan SiemensVAI Lubrication
Morgan SiemensVAI Lubrication
Lubrication Training Presentation agenda : Lubrication requirements Oil contamination and measurements Morgan mill operating parameters and details by mill location
Types of oils and applications
Some effects of poor filtration in Morgan mills Case study of a Morgan lubrication system upgrade
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May-2010
Rolling mills and lubrication Everyone has heard the analogy that the oil is the blood of the rolling mill so This presentation is intended to provide knowledge to customers and end users to increase the reliability of the Morgan rolling mill equipment.
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Lubrication requirements Bearings are the critical components requiring oil in the rolling mill
Tapered Roller Bearings Found throughout the drive train and designed for heavy radial loads
Angular contact ball bearings Critical application for most high-speed drive shafts in the finishing train
Clevite Bearings Clevites are found in the PFM, NTM and RSM roll housings supporting high loads and speeds approaching 15000 rpm
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Other Classifications:
Pressure
Low Pressure (Maximum 10 bar) High Pressure (Hydrostatic, higher than 10 bar)
Oil Type Oil Viscosity (Equipment Speed) Operating Conditions
Temperature Flow
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Lubrication Systems
Dry Systems:
Are NOT subject to water ingress and/or humidity contamination.
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Lubrication systems for Morgan The higher the equipment speed the lower the oil viscosity Typical Oil Viscosities
Mill Equipment Breakdown Mill Roughing & Intermediate Mill Pre-Finishing Mills (PFM) No-Twist Mill (NTM) Reducing/Sizing Mill (RSM) Stands Reducing/Sizing Mill (RSM) Gearbox(es) High-Speed Pinch Roll and Laying Head * New standard: ISO VG-150 Viscosity ISO grade VG-320 to 460 VG-320 VG-220 to 320 VG-90 to 100 VG-90 to 100 VG-100 to 220 * VG-90 to 100
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Furnace
Std B
Std C
Shear
FURNACE Steel Density (kg/m3) Rolling Rate (MTPH) Reduction Average Billet Area (mm2) Mill Speed (m/s) 7700 150 0.885 16900 0.32
BREAKDOWN MILL
0.32
14957 0.36
13236.5025 0.41
11714.30471 0.46
0.46
FLUIDS REQUIREMENTS OIL LUBRICATION Oil type (Options) Oil Viscosity (Options) Oil Cleanliness Oil type (Options) Oil Viscosity (Options) Oil Cleanliness None Gear Oil (EP) Synthetic Oils (EP) ISO VG-320 ISO VG-460, ISO VG-680 (Old mills) ISO 21/19/16 (NAS 10)
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Roller Table
Std 1
Std 2
Std 3
Std 4
Std 5
Shear
ROUGHING MILL Steel Density (kg/m3) Rolling Rate (MTPH) Reduction Average Billet Area (mm2) Mill Speed (m/s)
0.46
10367.15967 0.52
9174.936308 0.59
8119.818633 0.67
7186.03949 0.75
6359.644949 0.85
0.85
FLUIDS REQUIREMENTS OIL LUBRICATION Oil type (Options) Oil Viscosity (Options) Oil Cleanliness Oil type (Options) Oil Viscosity (Options) Oil Cleanliness Gear Oil (EP) Synthetic Oils (EP) ISO VG-320 ISO VG-460, ISO VG-680 (Old mills) ISO 21/19/16 (NAS 10)
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Std 6
Std 7
Std 8
Std 9
Shear
Up looper
Std 10
Up looper
Std 11
Up looper
Std 12
Up looper
Std 13
Up looper
Std 14
INTERMEDIATE MILL Steel Density (kg/m3) Rolling Rate (MTPH) Reduction Average Billet Area (mm2) Mill Speed (m/s)
5628 0.96
4981.032915 1.09
4408.21413 1.23
3901.269505 1.39
1.39
1.39
3453 1.57
1.57
3056 1.77
1.77
2.39
2.95
FLUIDS REQUIREMENTS OIL LUBRICATION Oil type (Options) Oil Viscosity (Options) Oil Cleanliness Oil type (Options) Oil Viscosity (Options) Oil Cleanliness Gear Oil (EP) Synthetic Oils (EP) ISO VG-320 ISO VG-460, ISO VG-680 (Old mills) ISO 21/19/16 (NAS 10)
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Water Box
Side looper
Side looper
PRE-FINISHING MILL AREA Steel Density (kg/m3) Rolling Rate (MTPH) Reduction Average Billet Area (mm2) Mill Speed (m/s)
3.89
3.89
3.89
3.89
6.22
FLUIDS REQUIREMENTS OIL LUBRICATION Oil type (Options) Oil Viscosity (Options) Oil Cleanliness Oil type (Options) Oil Viscosity (Options) Oil Cleanliness ISO VG-220 ISO VG-320 (Old mills) ISO 18/16/13 (NAS 7) No-Twist Mill Oil
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Water Box
Side looper
Shear
Water Box
Water Box
HS Shear
FINISHING MILL AREA (NO-TWIST MILL) Steel Density (kg/m3) Rolling Rate (MTPH) Reduction Average Billet Area (mm2) Mill Speed (m/s)
9.73
9.73
0.142 79 68.5
68.5
68.5
68.5
68.5
68.5
68.5
FLUIDS REQUIREMENTS OIL LUBRICATION Oil type (Options) Oil Viscosity (Options) Oil Cleanliness Oil type (Options) Oil Viscosity (Options) Oil Cleanliness ISO 18/16/13 (NAS 7) ISO VG-100 No-Twist Mill Oil
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Water Box
Water Box
PR LH
FINISHING REDUCING/SIZING MILL AREA Steel Density (kg/m3) Rolling Rate (MTPH) Reduction Average Billet Area (mm2) Mill Speed (m/s)
0.57 45 120.3
120.3
120.3
120.3
120.3
120.3
FLUIDS REQUIREMENTS OIL LUBRICATION Oil type (Options) Oil Viscosity (Options) Oil Cleanliness Oil type (Options) Oil Viscosity (Options) Oil Cleanliness ISO 18/16/13 (NAS 7) No-Twist Mill Oil (For RSM Gearbox) Gear Oil (Mild EP), Synthetic Mild EP (For RSM Gearbox) ISO VG-220 (For RSM Gearbox) ISO VG-100, ISO VG-150 (For RSM Gearbox) ISO 18/16/13 (NAS 7) (For RSM Gearbox) ISO VG-100 No-Twist Mill Oil
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Oil characteristics Contamination in the oil affects several parameters. All of them are related to each other.
Acid Number
Oil Cleanliness
Particle Count
Oil Properties
H2 O Content
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Oil and contaminants The micrometer (m) is the unit of measure when talking about contaminants Smallest resolution of the unaided eye = 40 m 10m = 0.0004 inch
As a comparison, a human hair @ 75 m with particles @ 10 m with As a comparison, a human hair @ 75 m with particles @ 10 m with 100x magnification (The scale is approximately 14 m/division) 100x magnification (The scale is approximately 14 m/division)
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Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved
Convenient format for reporting particle count data Graph of particle size vs. particle concentration Meant to be a simplified coding system Focuses on three particle size ranges: Total number of particles > 4m Total number of particles > 6m Total number of particles > 14m
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4 um 6 um 14 um
850 220 60
17 15 13
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6 '' 152.4 mm
Image
68.60
Tank Storage Temperature: 49 C Pump Outlet: 50 C Heat Exchanger Outlet: 40 C (*) Equipment: 40C (*) and 38 C (Highspeed equipment)
(*) Temperature may vary depending on oil used, operating equipment, and design parameters
Flow
Varies depending on Bearing Size, Speed, and Loads
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Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved
Bearing fatigue life Bar and rod mills are exposed to a range of contaminants that will compromise system performance if Morgan specifications are not maintained. Steel fines, scale and water enter the lubricating system during normal operation and maintenance of the equipment. Maintaining Morgan cleanliness specifications has a significant effect on bearing life, reliability and availability of the equipment.
Image
Machine clearance
Component Roller Bearings Clevite Bearings Ball Bearings Table 1 Bearing clearances
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Bearing fatigue life (Continued) Morgan field experience on some 75 rod and bar mills has shown an exponential increase in bearing fatigue life when Morgan specifications are maintained.
Bearing Life vs. Oil Cleanliness
20 18 Relative Bearing Life 16 14 12 10 8 6 4 2 0 Oil Cleanliness
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Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved
ISO 15/12/10
ISO 16/14/11
ISO 17/15/12 ISO 18/16/13 ISO 19/17/14 ISO 20/18/16 ISO 21/19/16 ISO 22/20/17
Cleanliness Levels
Low-Speed Equipment: ISO 21/19/16 or better High-Speed Equipment: ISO 18/16/13 or better
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Lubrication systems for Morgan (Continued) Even small amounts of water in the oil disrupts the lubrication process: Reduces the carrying load of oil Reduces the oil viscosity Generates corrosion Reduces the bearings life May interact with oil additive package Morgan uses vacuum dehydration on most systems to remove water
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250
200
150
100
50
25
100
5000
10000
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Free water: Plain water not mixed with the oil. Free water settles in the bottom of the lubrication tanks due to its higher density. Emulsified water: Small droplets of water in the oil; typically water is dispersed by high shear mixing. Can be considered as free water; however, it can be very stable and may not settle out from the oil. Dissolved water: Water absorbed in solution with the oil. The solubility of dissolved water in most hydrocarbons is less than 150 ppm at ambient temperature, but solubility increases slightly with temperature.
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Water Separation Processes Gravity Settling: Water and oil are separated by gravity force due to different densities. Eliminates free water at very low flow rates, but is ineffective removing emulsified and dissolved water. Centrifugation: Water and oil are separated by centrifugal force, which is generated by high speed spinning. They cannot remove all free water and particulate. Expensive to operate and maintain. Absorption: Water and oil are separated by absorbing water within the structure of hydrophilic media, such as starch and special absorbing polymers. Can take out all forms of water, but have limited life due to the saturation capacity of the media. Coalescence: Tiny water droplets adhere to fibers. Flow pushes the droplets to the fiber intersections where they are coalesced to form larger droplets. Water higher specific gravity helps them to settle to the bottom. High process rates and low energy cost, but not as effective in high viscosity oils. Vacuum Dehydration: Water and oil mixtures are separated due to different boiling points. Eliminates free, emulsified and dissolved water. Water vaporizes at a lower temperature when pressure is lowered in the vacuum chamber. Effectively remove water from oils up to 680 cSt and are generally not affected by surfactants. Vacuum dehydration and absorption are the only two techniques to remove free, emulsified, and dissolved water.
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Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved
Oil-water mix maintains its properties at low pressure, however water will evaporate at a lower temperature. If temperature is under the critical oil temperature, the oil and its additives will not suffer any changes. Once the water has been separated from the oil, it is condensed in the condenser unit by a reduction of temperature.
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Oil Return
Oil Supply
Oil Supply Water Removed From Oil Water Supply
Instr.Air
Water tank
Coalescer
Supply Pump
Heat Exchanger
Heat Exchanger
Filter
(Optional)
Filter
Vacuum Chamber
Oil Return
Thermal Oil
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ISO VG -100
Water Ingress directly into the Vac. Deh. inlet
0% Vacuum dehydrator water removal efficiency Vacuum dehydrator actual water removal efficiency Vacuum dehydrator actual water removal efficiency (average) ppm removed per hour (ppm/h) (*) Time measured (hours) 24.06% ----35.5 1
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Pall element performance and construction 1. Helical Wrap 2. Upstream Support 3. High Performance Filter Medium 4. Downstream support 5. Coreless Design
5 4 3 2 1
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Pall element performance and construction (Continued) 1. Helical wrap Elements are tightly wrapped with each pleat bonded to the helical wrap for stable pleat spacing. This allows complete medium utilization even under severe cold start and high viscosity applications. It further ensures uniform flow throughout the length of the filter, optimizing element pressure drop and service life. 2. Upstream support A unique combination of rugged proprietary synthetic mesh and open high strength support material optimizes flow distribution and strength. 3. High Performance Filter Medium Composed of proprietary inert, inorganic fibers bonded with resin into a tapered pore structure. The medium provides high efficiency particle removal and extended filter service life.
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Pall element performance and construction (Continued) 1. Downstream support Integral medium substrate and rugged proprietary synthetic mesh provide additional filter medium support during cold starts and extended service. 2. Coreless Design The coreless design of Pall Ultipor III incorporates the benefits of high efficiency filtration in a lightweight package by removing metal components from replacement cartridges. This reduces filter element replacement costs while providing the same benefits of high efficiency particulate removal.
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Pall element and performance and construction Tapered pore vs. uniform pore media
High dirt capacity Low pressure drops 2 in 1 filter with coarse prefilter combined with final filter
Lower dirt capacity Higher pressure drops Only utilize 20 30% of the media because upper layer becomes blocked
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Central lubrication filters Multi-Pass test ISO 16889 measures filter performance
Gives a series of Beta ratios for the filter Beta
x micron:
Number of Particles Upstream (x micron and larger) Number of Particles downstream (x micron and larger)
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Central lubrication filters Beta ratio Pall element (lower) vs typical elements (upper)
100 500 = 1000 = Particles 3 = 200= 2 2 Particles 500 > 12 um 100 > 3 m
12
Pall __ b 3>200
Pall __ b 3>200
Pall __ b 3>200
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Filter comparison When comparing Pall filter elements with non-Pall elements:
At low b ratios (<200) for a specific particle size (6 m (c)) there is little difference between Elements A and B When the ratings at higher b ratios are considered the difference in performance are clearly seen. Element A gives a b>1000 rating at 7.5 m (c), but Element B cannot achieve this rating
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Background
A rod & wire mill producer was looking to improve the performance of their older vintage Morgan K-mill. The mills product range was from 5.5 mm to 15 mm with an outlet speed of 85 m/s. Frequent roll housing and bevel gear drives repairs were commonly affecting the monthly output of the mill.
A review of the lubricating equipment was conducted by the Morgan field service group and deemed to be inadequate in several key areas: a) removal efficiency, b) ease of use and c) capacity. The existing equipment was antiquated and unable to maintain current cleanliness standards leading to frequent bearing failures.
Problem
It was determined that the existing equipment would not meet Morgans new cleanliness specification and would need to be upgraded. The lubrication system details are as follows: Parameters:
Solution
Filtration Supplied : (2) Ultipor III Filter Elements Morgan Part Number: 10271484
Flow rate: 662 l/min per strand Available pressure: 2 bar Clean pressure drop: 0.14 bar Fluid Viscosity: 100 cSt Temperature: 38C
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May-2010
Prior to installation Oil cleanliness: ISO 22/19/17 or worse High iron content Post installation
Results
Repairs: 6 month average roll housing life 2 year bevel gear drive repair
Oil cleanliness: ISO 17/15/12 or better Iron and wear metals reduced
Repairs: No roll housing failures in 12 months No bevel gear repairs in 12 months Production An average of 4% increase in mill utilization has been achieved for 12 months
Return on Investment : The equipment has paid for itself in the first 4 months of operation Annual expense costs have been reduced by 500%
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Closing Utilizing Pall filtration with Morgan know-how has produced a total product offering that benefits our customers and improves equipment reliability
Upgrades
Spares
Guides
Audits
Rebuilds
Training
Reconditioning
Services
Maintenance
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Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. Alle Rechte vorbehalten. Copyright Siemens AG 2009. All rights reserved