IE B002PLANT REFERENCE AND TECHNICAL REPORT · 2013–2015
PLATINO 2040: turbine bearing overheating eliminated without part replacement
Turbine bearing heating disappeared, emergency shutdowns stopped, the machine ran without parts replacement. 23 months — normal-mode operation with no bearing replacement (2013–2015).
and KhGAPP technical reportsignatures of authorised officers, company stamp
Key result
| OBJECT AND DOCUMENT | HOURS AT START | WHAT WAS RECORDED |
|---|---|---|
| PLATINO 2040 machine, blanking and stamping shop — Chief Mechanical Engineer's reference, 13.02.2013 | over 5000 h, three years in service | 23 days of normal operation after the treatment of 21.01.2013, overheating emergency stops did not recur |
| Same machine — technical report, approved by the Chief Engineer, 23.01.2015 | same, treatment 21.01.2013 | about 23 months of operation (January 2013 — December 2014), bearings never replaced, one preventive inspection with grease top-up |
Turbine bearing units: before and after treatment
| PARAMETER | BEFORE TREATMENT (December 2012 — January 2013) | AFTER TREATMENT (2013–2015) |
|---|---|---|
| Bearing unit temperature | On reaching critical values the machine's automatic emergency shutdown was triggered | Does not exceed the values permitted by the operating manual; emergency stops ceased |
| Reaching operating modes | The unit was never switched from the 14 000 rpm test mode to the operating mode | The machine runs in normal mode, turbine operating speed up to 40 000 rpm |
| Bearing condition | Extraneous noise; one bearing worn more than the others — found during disassembly on 21.01.2013 | Bearings not replaced throughout the period; over two years — one preventive inspection with a top-up of the same grease |
| Cost per unit | Set of new SR sleeves with bearings — about 93 000 UAH (2013), over 90 000 UAH (2015) | Flush and XADO “Protective 60K” grease — under 300 UAH in 2013, under 500 UAH including the top-up |
Temperature was monitored by the machine's built-in system with emergency shutdown on overheating; bearing noise and wear were assessed during unit disassembly.
Timeline: what preceded the treatment
| STAGE | WHAT WAS DONE | RESULT |
|---|---|---|
| About 4000 h of service | 10–15 g of the standard grease added to each bearing unit | Extraneous noise disappeared, later intense heating of the units developed |
| December 2012 — January 2013 | Standard grease replaced with high-speed Shell GADUS S5V42P, selected on the recommendation of its manufacturer | Heating did not stop; on severe heating the machine's emergency shutdown system was triggered |
| 21.01.2013 | Units disassembled, old grease removed, working cavities flushed, 25–30 g of XADO “Protective 60K” grease with revitalizant packed into each unit | After removing excess grease and 18–25 h of running-in, the temperature fell smoothly and stabilised — the machine was switched to the operating mode |
The unit, the fault and the maintenance personnel were the same in all three episodes — only the product changed.
Conclusions of the plant
Current equivalent
Revitalizant gel for compressors and bearings →
Piston, screw and centrifugal compressors; rolling and sliding bearings running in an oil bath; machine-tool spindle units and slideways.
How such units are treated:
About this result:
Limits of this report: The results relate to the generator turbine bearing units of the PRIMA POWER PLATINO 2040 laser cutting machine and to its operating conditions at KhGAPP; on other equipment and under other duty cycles the figures may differ.