Advertorial: A case study on reduced bearing failure and improved productivity with the use of Mobil Grease XHP 222

By Umesh Malik, Chief Engineer – Sub-Continent, ExxonMobil Lubricants Pvt. Ltd

A recent joint study commissioned by consulting firm McKinsey and the Confederation of Indian Industry (CII) highlights India as the most favoured country to capitalise on emerging trends that increasingly favour global delivery models in automotive technology development and manufacturing, owing to a skilled workforce coupled with low-cost technology design and manufacturing capabilities.

Here is a case study of how the right industrial lubricant can improve performance, increase productivity and thereby, contribute to the bottom-line.

Swastik Pipes Limited was facing issues such as grease washout by coolant, increased bearing temperature, high regreasing frequency.

Swastik Pipes Limited has been one of India’s leading manufactures and exporter of T.T. Swastik Band high quality Mild Steel/Carbon Steel ERW Black and Galvanized Pipes/Tubes since 1973. Swastik Pipes is also manufacturing LINE PIPES as per APL Spec.5L since December 2005. Its advancement state-of-the-art manufacturing facilities with ISO 9001: 2000 and APIQ1 approvals has achieved national and international recognition.

Swastik Pipes Ltd. is one of the leading manufacturers of ERW Pipes and Tubes, Steel Tubular Poles, Cold Rolled Sheets and Strips in North India. The facility is located in Bahdurgarh, Haryana and equipped with state-of-the-art equipment.

At its manufacturing facility in Bahadurgarh, Haryana, India, sophisticated machines produce CR Coils, galvanized coil, ERW tubes, steel galvanized coil, CRCA coils and sheets and galvanised products in desired specifications and nishes. Swastik Pipes Limited had started manufacturing CR coils and strips in year 2003 with annual capacity of 1 lac MT / annum in various sizes and thickness.

CR production plant consists of two 4 HI and one 6 HI cold rolling mills along with bell furnaces, skin pass, slitting, cut to length and testing facilities. In the CRM rollers bearing lubrication, SPL was using competitor lithium-thickener EP2 grease. SPL had to be regreased or topped up frequently to avoid bearing failures and maintain the running temperature of the bearings. SPL was also facing other issues like getting the grease to dry, dust entering into the bearings, grease bleeding etc. The main problem encountered by the SPL in CRMs was grease washout because of coolant used in process.

After discussing with Mobil FES team and NIS engineers Mobilgrease XHP 222 was suggested as a solution.

Switching to a Mobilgrease to reduce bearing failures and to reduce temperatures

The innovation of Mobil Grease XHP 222 was of greater convenience to Swastik Pipes Limited. The application of Mobil Grease XHP 222 overcame the problem of grease washout by coolant, increased bearing temperature, and high re-greasing frequency. There was substantial increase in bearing life which further resulted in considerable savings in Total Cost of Ownership for Swastik Pipes Ltd. And, has led the annual saving of Rs. 2,35,275.

Mobil Grease XHP 222 provides good sealing and intercepts dust from entering into bearings. It absorbed and continued to hold its consistency even after a long duration. It worked well at temperatures as high as 100 Deg C. There was considerable amount of improvement in Mill reliability, Decrease in bearing failure and grease consumption, along with this Mobilgrease XHP 222 enhanced Mill availability by 8 Man days/annum. All these combined resulted in an increased production and saved US$10,000 by reduction in bearing failure and grease consumption.

Switching to Mobilgrease XHP 222 resulted in considerable savings in Total Cost of Ownership for Swastik Pipes Ltd. Moreover, a considerable increase in the duration of regreasing intervals to approximately three times more than the competitor lithium thickener grease was observed. Previously SPL used to top up on daily basis which has now scheduled to after every third day with Mobilgrease XHP 222.

Though Swastik Pipes Limited had been using Lithium thickener EP2 grease for a long period but the notable results provided by Mobil Grease XHP 222 drove the company to take full advantage of the bene ts obtained from the same.

Benefits:

• Improves productivity
• Decreases bearing failure by 50%
• Decreases grease consumption by 33%
• Improved Mill reliability
• Increase in Mill overhauling schedule and hence enhanced Mill availability by 8 man days/annum

Impact:

• Cut down Mills stoppage by 8 days by increasing overhauling schedule.
• $10,000 savings achieved by reduction in bearing failure and grease consumption.
• About ExxonMobil Lubricants Private Limited

Customers have relied on ExxonMobil lubricants for more than 120 years. Marketed in nearly 200 countries and territories worldwide, ExxonMobil products stand for performance, innovation and expertise. As an industry leader in synthetic lubricants, a full range of ExxonMobil products is available in the automotive, commercial and industrial business sectors. ExxonMobil recognises that business success and social responsibility go hand in hand. To that end, ExxonMobil works closely to support the communities where they operate and pledges to maintain the highest ethical standards, comply with local laws and respect local and national cultures. The term "ExxonMobil" is used for convenience only, and may include Exxon Mobil Corporation or any of its affialiates.

©ExxonMobil, Mobil and Mobil 1 are trademarks of Exxon Mobil Corporation or one of its subsidiaries. ExxonMobil Lubricants Private Limited is a wholly-owned a liate of Exxon Mobil Corporation.

Mobil Industrial Lubricants is a business of Exxon Mobil Corporation. Today, Mobil Industrial Lubricants are used extensively in many industrial market sectors - including power generation, general manufacturing, metal working, food and beverage processing, pulp and paper, cement, construction, metals and mining. Every day, Mobil-branded lubricants help enable industrial companies to successfully boost productivity, enhance the performance and life of their equipment, increase pro tability and reduce downtime.
For more information on Mobil Industrial’s range of lubricants and services, visit mobilindustrial.com