US-based Dodge Industrial embark on a mission to save customers installation time, reduce waste, and minimise downtime, saving substantial annual costs.
Synopsis
Application: Rotating biological contactor (RBC)
Problem: SAF-style bearing failure with lengthy maintenance
Solution: Dodge Safety Mount™ mounted spherical roller bearings
The Problem
A large wastewater treatment plant in the north-eastern US uses 96 RBCs to remove organic material from the water, ensuring the water is safe to be released back into the environment.
RBCs are a biological wastewater treatment system in which multiple media discs are shaft mounted and partially submerged in influent water. As the shaft turns at approximately 1.5 revolutions per minute, microorganisms on the discs are alternately exposed to water and air. This provides them with the organic matter in the water as a food source and oxygen for proper digestion, resulting in the removal of unwanted material.
Running around-the-clock, RBCs carry heavy loads and are supported by a 25-foot shaft with a mounted bearing on each side. The bearings are located just inches from the water and exposed to constant splashing and corrosive elements. SAF-style bearings are commonly used in this application, but their ineffective sealing systems and grease path design fail to prevent contamination and clean grease from accessing the rolling elements, leading to premature failure.
Their replacement requires specialised maintenance procedures, a crane, and up to 26 hours of labour for the replacement of a single bearing — creating a significant pain point for operational maintenance.
The Test
Premature failures due to contamination and lengthy replacements of existing SAF-style bearings led plant management to seek a more reliable solution and make the switch to Dodge Safety Mount for their RBC applications
The Results
Upon first installation of Dodge Safety Mount, plant management realised the value of a significantly faster and easier installation — saving 16 hours of labour per bearing over the SAF-style bearings. Its enhanced reliability and reduced maintenance had an immediate positive impact on efficiency, leading them to standardise operations with Dodge®.
The Success
In addition to being a drop-in replacement for SAF-style bearings, Dodge Safety Mount’s easy installation and removal made it the ideal choice for plant management to streamline maintenance, resulting in an average annual saving of $156,863.
The Why
A drop-in replacement for SAF-style bearings, Dodge Safety Mount features an innovative design for the fastest installation and removal on the market.ts patented push-pull tapered adapter system is optimised with predetermined drive-up, eliminating the need for feeler gauges and manual calculations to reduce labour and improve reliability.
Dodge Safety Mount’s efficient design provides a direct path for grease to access the rolling elements, ensuring correct lubrication and facilitating the purging of old grease. Its mechanically retained triple-lip seal prevents contamination and seal blowout. Built to revolutionise mounted spherical roller bearing installations, Dodge Safety Mount is the premier solution for critical applications.
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