Quickly assist overseas customers and accurately overcome the problem of converter bearing equipment failure

Last week, we received urgent feedback from overseas cooperative customers that the converter core equipment on their production line suddenly had abnormal working conditions. The split bearings carried by the equipment continued to produce irregular noises, and the stability of the equipment operation was greatly reduced. The production line is facing the risk of shutdown.

Expected losses caused by malfunction: Our company attaches great importance to this sudden equipment problem and is well aware that the converter, as the core and key equipment for customer metallurgical production, once the malfunction continues to worsen, it will not only cause damage to equipment components, but also directly lead to the shutdown of the entire production line of the customer, causing huge production losses and economic losses.

Solution: Upon receiving customer information, our technical team immediately activated the overseas equipment emergency repair plan. After remotely inquiring about key information such as the operating conditions of the equipment, the time of occurrence of abnormal noise, the recent start stop status of the equipment, daily operation and maintenance, and the duration of bearing use, and preliminarily sorting out the direction of fault diagnosis. The technical team arrived at the fault site as quickly as possible and carried out on-site repair work.

After arriving at the customer's production plant, the team members immediately went deep into the production workshop to conduct comprehensive and detailed inspection and troubleshooting of the converter split bearing equipment that had abnormal noise.

The working conditions of the converter equipment are complex, the operating load is high, and it is in a continuous production environment, making fault diagnosis difficult. The team strictly follows the equipment maintenance standard process and thoroughly inspects key aspects such as equipment transmission structure, fixed components, operating parameters, bearing assembly accuracy, lubrication system, etc.

In the initial investigation, it was found that the source of the abnormal noise was concentrated in the core operating area of the split bearing, but no obvious problems such as bearing jamming, assembly misalignment, or loose parts were found.

Problem 1: In order to accurately locate the root cause of the fault, the team has decided to clean the residual grease inside the bearing, removing impurities, aging grease, and other attachments accumulated in the bearing raceway and rolling elements. After completing the comprehensive grease cleaning operation, the technicians restarted the equipment for trial operation, and the previously persistent abnormal noise disappeared completely. The equipment temporarily resumed stable operation.

Problem 2: Although the issue of abnormal equipment noise has been quickly eliminated, based on the principle of being responsible to customers and completely eliminating equipment hazards, in order to ensure the long-term stable operation of the equipment, the team has conducted a detailed disassembly and re inspection of the split bearings, and thoroughly checked the wear status of the core components of the bearings. After careful visual inspection, contact surface testing, and accuracy verification, it was found that there were large irregular pits on the surface of the shaft and housing, with a wide range of damage and uneven depth, which are irreversible damages.

Conclusion: After professional analysis by the technical team, such surface pit damage will directly damage the operating accuracy and force balance of the bearing. Under the high load and continuous production conditions of the converter, the damaged parts will quickly intensify wear, and in the short term, abnormal noise, vibration, jamming and other faults will inevitably occur again. In severe cases, it can also cause major equipment accidents such as bearing locking, equipment shutdown, and transmission component damage. Therefore, the shaft and shell with extensive pit damage no longer meet the equipment operating standards and do not have the conditions for continued use. It is necessary to replace them with new parts in a timely manner to fully ensure the safe and stable operation of the converter equipment.

After determining the final cause and solution of the malfunction, the technical team promptly provided detailed feedback to the customer on the entire process of troubleshooting, the root cause of the malfunction, the damage to components, and professional recommendations for subsequent equipment operation and replacement of parts. At the same time, they explained the triggering factors of such malfunctions and daily maintenance precautions to help customers improve their equipment operation and maintenance system.

The customer highly recognizes and affirms our company's efficient response speed, professional troubleshooting techniques, and rigorous and responsible service attitude.