Morgan SiemensVAI Lubrication

Contamination control for rod and bar mill lubrication systems
MS R Long Rolling Services
Copyright Siemens AG 2009. All rights reserved
Lubrication Training Presentation agenda : Lubrication requirements Oil contamination and measurements Morgan mill operating parameters and details by mill location
Types of oils and applications
Filtration hardware Filter element information

Design details and operating information
Some effects of poor filtration in Morgan mills Case study of a Morgan lubrication system upgrade
Page 2
May-2010
Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved
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.
Page 3
May-2010
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
Page 4
May-2010
Lubrication System Classification Two Main Types:

Dry Systems Wet Systems
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
Page 5
May-2010
Lubrication Systems
Dry Systems:
Are NOT subject to water ingress and/or humidity contamination.
Gearbox Systems (Low-speed equipment) Wet Systems:

Are subject to water ingress and water and humidity contamination.
High-Speed Rod Mills High-Speed Bar Mills Morgoil Systems
Page 6
May-2010
Oils for Morgan Equipment

Mineral oils highly refined with two main Additive package chemistries: EP Gear Oil for Low-Speed gear boxes No-Twist Mill Oil for High-Speed Equipment Oil Viscosity Varies Based on Speed and Load Typical Range: ISO VG-100 to ISO VG-460
Oil chemistry must be fully compatible with equipment mechanical components and materials
Page 7
May-2010
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
Page 8
May-2010
Lubrication systems for Morgan (Continued)
Furnace
Roller Std A Table
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)
Page 9
May-2010
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)
Page 10
May-2010
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
0.74 2261 2.39
2.39
0.81 1832 2.95
2.95
0.76 1392 3.89
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)
Page 11
May-2010
Water Box
Side looper
PFM Stds 15-16
Side looper
PFM Stds 17-18
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
0.625 870 6.22 6.22
6.22
0.639 556 9.73
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
Page 12
May-2010
Water Box
Side looper
Shear
No-Twist Mill Water NTM Box
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 9.73
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
Page 13
May-2010
Rod TEKISUNTM Reducing/ Sizing Mill RSM
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
Page 14
May-2010
Oil characteristics Contamination in the oil affects several parameters. All of them are related to each other.
Viscosity Oil Color
Acid Number
Oil Cleanliness
Particle Count
Oil Properties
Oil Analysis Smell
H2 O Content
Page 15
May-2010
Morgan Lubrication Systems
Lubrication system General Overview

Page 16 May-2010
Morgan SiemensVAI_lubrication
Lubrication system - Temperature Control
Copyright Siemens AG 2009. All rights reserved
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)
Page 17 May-2010
Oil cleanliness and ISO codes
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
Page 18
May-2010
Oil cleanliness and ISO codes
ISO Code: 17/15/13

Particle Count Summary
Particle Size Number of particles / ml Range Code
4 um 6 um 14 um
850 220 60
17 15 13
Page 19
May-2010

NUMBER OF NOZZLE REQUIRED : 1
Temperature (Typical Values)

Distance
6 '' 152.4 mm
Breakup 4.57'' 116.1 mm
Image
145.1 mm 5.71 ''
68.60
Gear Width 180 mm 7.09 ''
Width @ breakup 6.47'' 164.4 mm
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
Width @ 6" 8.39'' 213.2 mm
Pressure (Typical Values)

Supply Pressure at Pumps: 6 to 10 bar (87 to 145 PSI) Supply Pressure at Equipment: 0.7 to 3.5 bar (10 to 51 PSI)
Note: Pressure depends on operating equipment and design parameters
Flow
Varies depending on Bearing Size, Speed, and Loads
Page 20 May-2010
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
Dynamic clearance Dynamic Clearance (um) 0.5 - 5 Image 5 - 10 15
Component Roller Bearings Clevite Bearings Ball Bearings Table 1 Bearing clearances
Page 21
May-2010
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
Page 22 May-2010
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
Lubrication systems for Morgan Maximum Allowable Water Content

In the tank: 0.2% (2000 ppm) * At Equipment: 0.2% (2000 ppm)
* Actual operating quantities at the mill may be higher, but not recommended
Cleanliness Levels
Low-Speed Equipment: ISO 21/19/16 or better High-Speed Equipment: ISO 18/16/13 or better
Page 23
May-2010
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
Page 24
May-2010

Effect of Water on Bearing Life
300
250
Bearing Life, (%)
200
150
100
50
25
100
200 400 500 750 1000 Amount of Water in Oil, (ppm)
5000
10000
Page 25
May-2010
Forms Of Water In Oil
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.
Page 26
May-2010
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.
Page 27 May-2010
MORGAN Vacuum Dehydrator Operation
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.
Page 28
May-2010
MORGAN Vacuum Dehydrator Description
Oil Return
Oil Tank 49C (Optimum Temperature)

Water settlement direction
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
Clean Water Outlet
Page 29
May-2010
Morgan/Morgoil Vacuum Dehydrators

Morgan Vacuum Dehydrators help maintain the integrity of the oil. They are intended for removal of water from the oil. Provided with a special heating system that raise the oil temperature in two steps to aid the water removal and there is no need to raise the temperature of the fluid in the reservoir. Oil is returned to tank at almost same temperature.
Page 30
May-2010
MORGAN Vacuum Dehydrator Efficiency and Performance
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
0.50% 99.63% 43.60% 47.57% 5332.3 1
1% 95.17% 23.21% 25.51% 13324.3 1
25 ltr slug 98.97% 44.00% 45.36% 6185.8 1
Page 31
May-2010
Filtration for Morgan Lubrication systems

Pall Ultipor III Coreless Technology Built and designed to CE & ASME standards Closure swing bolts for ease of service Hydraulic lifting jack for cover Welded filter posts Elements are self aligning inside the housing to prevent operator error Pressure equalization valve Visual and electrical differential pressure gauge Open center transfer valve Gear box for easy valve transfer
Page 32
May-2010
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
Page 33
May-2010
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.
Page 34 May-2010
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.
Page 35
May-2010
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
Page 36
May-2010
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)
Filter Beta number specifies the efficiency of a filter element

Based on absolute size of the particles tested and amounts of contaminants upstream and downstream the filter Higher the beta number for an absolute particle size, the higher the efficiency, and therefore the better the filter performance and cleaner the oil
Beta 2 10 50 75 100 200 1,000 Efficiency capture percent 50 90 98 98.67 99 99.5 99.9
Page 37
May-2010
Central lubrication filters Beta ratio Pall element (lower) vs typical elements (upper)
200 1000 Particles Particles > 12 m > 3 um

500 590 Pall __ b 3>200 Pall __ b 3>200
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
Pall __ b 3>200
Pall __ b 3>200 Pall __ b 3>200
1 1 = 1000 =200 Particle 3 = 200= 1000 Particle 1 > 3 um 1 > 12 m

12
Pall __ b 3>200
Page 38
May-2010
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
Page 39
May-2010
Morgan Field Services Mechanical Equipment Audits:

Inspect inside the equipment and look for contaminants Inspect failed components Inspect mechanical equipment during maintenance
Page 40
May-2010
Morgan Field Services (Continued) Lubrication Equipment Audits:

Inspect inside filter housings Inspect filter for possible by-pass in existing housings Inspect tank to look for potential problems
Page 41
May-2010
Morgan Field Services case study
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
Page 42
May-2010
Morgan Field Services case study (Continued)
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
Production: An average of 6 hours per month of unscheduled downtime
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%
Page 43
May-2010
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
Mission: Maximize mill utilization
Rebuilds
Training
Reconditioning
Services
Maintenance
Page 44
May-2010
Thank you for your attention!
Page 45
May-2010
Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. Alle Rechte vorbehalten. Copyright Siemens AG 2009. All rights reserved

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Contamination control for rod and bar mill lubrication systems

MS R Long Rolling Services

Copyright Siemens AG 2009. All rights reserved

Filtration hardware Filter element information

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Lubrication System Classification Two Main Types:

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Gearbox Systems (Low-speed equipment) Wet Systems:

High-Speed Rod Mills High-Speed Bar Mills Morgoil Systems

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Oils for Morgan Equipment

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Lubrication systems for Morgan (Continued)

Roller Std A Table

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Lubrication systems for Morgan (Continued)

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Lubrication systems for Morgan (Continued)

0.74 2261 2.39

0.81 1832 2.95

0.76 1392 3.89

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Lubrication systems for Morgan (Continued)

PFM Stds 15-16

PFM Stds 17-18

0.625 870 6.22 6.22

0.639 556 9.73

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Lubrication systems for Morgan (Continued)

No-Twist Mill Water NTM Box

9.73 9.73 9.73

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Lubrication systems for Morgan (Continued)

Rod TEKISUNTM Reducing/ Sizing Mill RSM

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Viscosity Oil Color

Oil Analysis Smell

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Morgan Lubrication Systems

Lubrication system General Overview

Lubrication system - Temperature Control

Copyright Siemens AG 2009. All rights reserved

Oil cleanliness and ISO codes

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Oil cleanliness and ISO codes

ISO Code: 17/15/13

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Lubrication systems for Morgan (Continued)

Temperature (Typical Values)

Breakup 4.57'' 116.1 mm

145.1 mm 5.71 ''

Gear Width 180 mm 7.09 ''

Width @ breakup 6.47'' 164.4 mm

Width @ 6" 8.39'' 213.2 mm

Pressure (Typical Values)

Dynamic clearance Dynamic Clearance (um) 0.5 - 5 Image 5 - 10 15

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Lubrication systems for Morgan Maximum Allowable Water Content

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Morgan SiemensVAI_lubrication Copyright Siemens AG 2009. All rights reserved

Pall b 3>200 Pall b 3>200

Pall b 3>200 Pall b 3>200