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TECHNICAL REPORT|METALLURGY · COKE CHEMISTRY|GEARBOX · SCREW-NUT PAIR

IE S035GREASE TEST REPORT · COKE-CHEMICAL PLANT, OJSC SEVERSTAL

Coke pusher No. 2: screw-nut pair outlasts the standard interval, no top-ups

The nut outlasted its rated service life without replacement, weekly lubricant top-ups stopped. 1.5× — nut service life: 3–4 months on the standard grease → 5 months 26 days with no replacement, no failure occurred; 6.3× — grease consumption over 177 days: 12.6 kg of weekly top-ups (calculated at 0.5 kg per week) → 2 kg charged once (2005).

OJSC Severstal, coke-chemical plant  ·  approved by V. E. Germanov, deputy head of the coke-chemical plant for maintenance  ·  signed by specialists of the plant service unit, the coke equipment repair shop (TsRKO) and the shop of coke batteries 5–6

Russia  ·  report dated 31 Mar 2005 · in-service observation 5 Oct 2004 — 31 Mar 2005

PRODUCTXADO Repair Greasesingle 2 kg charge into the gearbox housing
TEST OBJECTWorm-screw gearbox of the door-removal drivescrew-nut pair · coke pusher No. 2, shop of coke batteries 5–6
DOCUMENT TYPEReport of the coke-chemical plant,
OJSC Severstalsigned and stamped · four plant signatories

Key results

↑1.5×
nut service life:3–4 months on the standard grease → 5 months 26 days with no replacement, no failure occurred
↓6.3×
grease consumption over 177 days:12.6 kg of weekly top-ups (calculated at 0.5 kg per week) → 2 kg charged once
EQUIPMENTMODE BEFORE THE TESTWHAT WAS OBSERVED
Coke pusher No. 2, worm-screw gearbox of the door-removal driveIP-1 grease: 0.5 kg topped up weekly, nut replaced every 3–4 monthsNut service life, condition of the screw-nut pair, grease consumption

Screw-nut pair of the door-removal gearbox — standard mode and XADO Repair Grease

PARAMETERIP-1 GREASE, STANDARD MODEXADO REPAIR GREASE
Nut service lifereplacement every 3–4 months5 months 26 days with no replacement, unit still running
Grease replenishment0.5 kg topped up weekly2 kg charged once, no top-ups
Condition of the screw-nut pairnut life used up within 3–4 monthsgood — per inspection by plant specialists

Observation in the live unit of coke pusher No. 2 from 5 Oct 2004; as of the report date the screw-nut pair was still in operation.

Costs per plant records

COST ITEMIP-1 GREASE, STANDARD MODEXADO REPAIR GREASE
Grease over the observation period232.5 RUB including weekly top-ups4112 RUB — single 2 kg charge
Nut of the screw-nut pair10 800 RUB every 3–4 monthsno replacements

2005 prices per the internal cost records of the coke-chemical plant; the report gives no final savings calculation.

Conclusion of the plant commission

The commission of the coke-chemical plant of OJSC Severstal recorded in the report: the screw-nut pair of the worm-screw gearbox of the door-removal drive of coke pusher No. 2 has been running on XADO Repair Grease from 5 October 2004 to the report date — 5 months 26 days — and the condition of the pair is good. On the standard IP-1 grease, a nut costing 10 800 RUB was replaced every 3–4 months, and the grease itself was topped up by 0.5 kg every week; XADO Repair Grease was charged into the gearbox housing once, in the amount of 2 kg, and was never added again. As of the signing date the test was continuing and the unit remained in service. Conclusion of the commission: “Given the above, it is desirable to extend the use of XADO greases to various equipment of the coke-chemical plant.”

Current equivalent

How such units are treated: Reduction gearbox

Limits of this report: The results apply to the screw-nut pair of the worm-screw gearbox of the door-removal drive of a coke battery pusher; with a different unit, load or lubrication mode the figures may differ.

Request a pilot for this unit

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Pilot treatment on the enterprise's equipment

  • any oil- or grease-lubricated assemblies: gearboxes, engines, compressors, bearings and others;
  • treatment within the regular operating cycle, without halting production;
  • instrumental measurements before and after: vibration, temperature, power consumption or current;
  • procedure for the specific assembly, dose calculation and support from a XADO engineer.

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