Visakhapatnam Steel Plant - Success Story
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Success Stories at Visakhapatnam Steel Plant India
Equipments Lubricated with Molykote at Vizag Steel • • • • • • • • • •
Hammer Crushers Blender Reclaimers ID/FD Fans Motors Pumps Vibratory Screens Chains Hydraulic Cylinders Conveyor Bearings And, many many more
A Bird Eye View of Visakhapatnam Steel Plant with the Thermal Power Plant in the Foreground
Why the customer chose to go for Molykote Products •
Increasing demands on enhancing production without capacity expansion
•
Downtime had to be avoided
•
Unscheduled stoppages had to be avoided
•
Reliability had to be increased. Chances for human errors to be minimized.
•
Manpower costs as a %age of total lubrication costs had gone up due to wage increases.
•
Molykote products have a pedigree of proven performance and had shown excellent results in wherever they were used. Hence, more products were allowed in when new applications were found.
Hammer Crushers •
Conditions – Heavy Shock Loads, Dust, Vibrations and high loads
•
Concerns – Daily relubrication schedule increases chances of human errors
•
Desired – Weekly Lubrication Schedule.
•
Product Recommended – Molykote Long-term 2+.
•
Results – Relubrication period extended to weekly within 3 months of application.
•
Volume – 4 x 180 kg drums/ year
Blender Reclaimer •
Spherical Roller Bearings
•
Concern – Bearings go through a phase of abrasive wear followed by failure.
•
Relubrication Schedule – Daily
•
Product Used- Conventional EP Grease
•
Product Recommended – Molykote Longterm 2+
•
Current Relubrication Schedule – Once in 5 days without bearing failures. Extension to 7 days lead to bearing failures. So now schedule in once in 5 days.
•
Used since 2002. 2 x 180 kgs drums /year.
Vibratory Screens •
Conditions – Continuous operation, weekly shutdowns, vibrations, shock loads.
•
Concern – Failure can result in lot of downtime in the entire plant process
•
Desired – More reliable lubrication without extending relubrication schedule
•
Product Tried – Molykote Longterm 2+
•
Result – Schedule can be extended to 12 days.
•
Expected Volume - 720 kgs/year
Many screens have extended their schedule from one week to 45 days. This particular screen in the picture is the most critical in the plant’s Sintering Zone.
Continuous Caster •
Area – Secondary Cassette Cooling Zone
•
Component – Bush Rollers
•
Concerns – High temperature with cooling water washed out grease and bush sticking with corrosion
•
Molykote Product Recommended – P 40 Paste
•
Results – After 220 heats and six months of trials, product’s performance good. Formal orders awaited.
Bush Bearings were lubricated with Molykote P40. With steel mill environment of high temperatures and cooling water, P 40 Paste is an ideal product for many applications.
Torpedo Ladle (SMS - Demag) •
Torpedo Ladle Spherical Sheet (Ladle carries the hot metal from the BF to the Converter for Lancing)
•
Various products tried by customer with poor results
•
Product Suggested – Molykote Cu 7439 Paste
•
Results – Good. In use for last 5 years.
•
Volume: 20 kgs/year
Spherical sheets subjected to oscillation and high temperatures lubricated now with Molykote Cu 7439 for last 5 years, once during overhaul.
Other Molykote Products Supplied •
Molykote D Paste • – Roll Shop Roll Assembly – WRM Compactor Rails – Water Management for Valve Assembly
•
Molykote GN + Paste – Various assembly applications at Area Repair Shops
•
Molykote Z Powder – Various dry lubrication applications in utility plants, converters and coke ovens.
Molykote M 30 Chain Oil – Furnace Area Chains – Rolling Mill Conveyor Bed Chains
•
Molykote 1000 Paste – Anti-seize applications
•
Molykote 111 Compound – O ring assembly
•
DC 4 Compound – Electrical Repair Shop
Equipments Lubricated with Molykote at Vizag Steel • • • • • • • • • •
Hammer Crushers Blender Reclaimers ID/FD Fans Motors Pumps Vibratory Screens Chains Hydraulic Cylinders Conveyor Bearings And, many many more
A Bird Eye View of Visakhapatnam Steel Plant with the Thermal Power Plant in the Foreground
Why the customer chose to go for Molykote Products •
Increasing demands on enhancing production without capacity expansion
•
Downtime had to be avoided
•
Unscheduled stoppages had to be avoided
•
Reliability had to be increased. Chances for human errors to be minimized.
•
Manpower costs as a %age of total lubrication costs had gone up due to wage increases.
•
Molykote products have a pedigree of proven performance and had shown excellent results in wherever they were used. Hence, more products were allowed in when new applications were found.
Hammer Crushers •
Conditions – Heavy Shock Loads, Dust, Vibrations and high loads
•
Concerns – Daily relubrication schedule increases chances of human errors
•
Desired – Weekly Lubrication Schedule.
•
Product Recommended – Molykote Long-term 2+.
•
Results – Relubrication period extended to weekly within 3 months of application.
•
Volume – 4 x 180 kg drums/ year
Blender Reclaimer •
Spherical Roller Bearings
•
Concern – Bearings go through a phase of abrasive wear followed by failure.
•
Relubrication Schedule – Daily
•
Product Used- Conventional EP Grease
•
Product Recommended – Molykote Longterm 2+
•
Current Relubrication Schedule – Once in 5 days without bearing failures. Extension to 7 days lead to bearing failures. So now schedule in once in 5 days.
•
Used since 2002. 2 x 180 kgs drums /year.
Vibratory Screens •
Conditions – Continuous operation, weekly shutdowns, vibrations, shock loads.
•
Concern – Failure can result in lot of downtime in the entire plant process
•
Desired – More reliable lubrication without extending relubrication schedule
•
Product Tried – Molykote Longterm 2+
•
Result – Schedule can be extended to 12 days.
•
Expected Volume - 720 kgs/year
Many screens have extended their schedule from one week to 45 days. This particular screen in the picture is the most critical in the plant’s Sintering Zone.
Continuous Caster •
Area – Secondary Cassette Cooling Zone
•
Component – Bush Rollers
•
Concerns – High temperature with cooling water washed out grease and bush sticking with corrosion
•
Molykote Product Recommended – P 40 Paste
•
Results – After 220 heats and six months of trials, product’s performance good. Formal orders awaited.
Bush Bearings were lubricated with Molykote P40. With steel mill environment of high temperatures and cooling water, P 40 Paste is an ideal product for many applications.
Torpedo Ladle (SMS - Demag) •
Torpedo Ladle Spherical Sheet (Ladle carries the hot metal from the BF to the Converter for Lancing)
•
Various products tried by customer with poor results
•
Product Suggested – Molykote Cu 7439 Paste
•
Results – Good. In use for last 5 years.
•
Volume: 20 kgs/year
Spherical sheets subjected to oscillation and high temperatures lubricated now with Molykote Cu 7439 for last 5 years, once during overhaul.
Other Molykote Products Supplied •
Molykote D Paste • – Roll Shop Roll Assembly – WRM Compactor Rails – Water Management for Valve Assembly
•
Molykote GN + Paste – Various assembly applications at Area Repair Shops
•
Molykote Z Powder – Various dry lubrication applications in utility plants, converters and coke ovens.
Molykote M 30 Chain Oil – Furnace Area Chains – Rolling Mill Conveyor Bed Chains
•
Molykote 1000 Paste – Anti-seize applications
•
Molykote 111 Compound – O ring assembly
•
DC 4 Compound – Electrical Repair Shop
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