ROLLING BEARING MOUNTINGS FOR CONVERTERS

ROLLING BEARING MOUNTINGS FOR CONVERTERSFAG OEM und Handel AG

CONTENTSPreface1 Requirements on the Trunnion Bearingsfor Converters2 Rolling Bearings and Housings forConverters2.1 Spherical Roller Bearings2.2 Split Spherical Roller Bearings2.3 KPG49 Housings2.4 KPGZ49 Housings3 Bearing DimensioningP. 4P. 6P. 7P. 8P. 2P. 3P. 4P. 94 Design of Adjacent Parts4.1 Fits4.2 SealsP. 10P. 10P. 105 Mounting, Lubrication and Maintenance5.1 Preparations for Mounting5.2 Mounting Unsplit Bearings5.3 Mounting Split Bearings5.4 Measures to be taken afterMounting5.5 Lubrication5.6 Maintenance5.7 Dismounting5.8 Maintenance FormsP. 11P. 11P. 13P. 17P. 19P. 19P. 20P. 20P. 116 Dimensional Tables for ConverterBearings and Housings6.1 Spherical Roller Bearings6.2 Split Spherical Roller Bearings6.3 KPG49 Housings6.4 KPGZ49 Housings7 References8 Selection of Special FAG Publications9 SpecificationP. 28P. 32P. 36P. 40P. 27P. 44P. 44P. 45FAG · 1

PREFACEThe OEM/Distribution BusinessUnit of FAG Kugelfischer GeorgSchäfer AG supplies rolling bearings,housings, accessories andservices to original equipmentmanufacturers in the sectors ofmachinery and plant constructionand to customers in the sectors distributionand replacement. Withtheir extensive know-how, competentadvice and comprehensivecustomer services, FAG are a mostimportant partner of their customers.Development and furtherdevelopment of our products areguided by the requirements ofpractical operation. In the idealcase, the spectrum of requirementsis defined jointly by our researchers,application engineers,the machine producers and users.This is the basis for technologicallyand economically convincing solutions.The Business Unit produces at locationsin Germany, Italy, Portugal,India, Korea (Rep.) and the USA.The market is supplied throughsubsidiaries and trading partners innearly all countries of the world.FAG · 2

1 REQUIREMENTS ON THE TRUNNION BEARINGS FORCONVERTERS1 Requirements on the TrunnionBearings for ConvertersWhen filled, large converter vesselsweigh several hundred tons. Theresulting loads must be accommodatedby the trunnion bearings.Since only slow swinging motionsoccur the bearings must primarilyfeature a high static load carryingcapacity. In addition, shock-typeloads must be accommodated dailyin converters.The bearings must also be able tocompensate for housing misalignmentsand deflections of the construction.Moreover, considerablelength variations caused by thetemperature changes during converterheat-up and cool-down aswell as changes of the trunnionring form must be compensatedfor.Today, converters are usually fittedwith spherical roller bearings.Apart from their great radial andaxial load carrying capacity andtheir insusceptibility to impactsthey can also compensate for significantmisalignments.Usually, the locating bearing at thedrive end provides axial guidancefor the converter. A sleeve inwhich the bearing outer ring canshift axially, fig. 1, is inserted inthe housing at the floating bearingend.Spherical roller bearings featuringthe main dimensions of series 249meet the requirements on converterbearings. These bearings haveproved to be particularly suitablein regard to axial displaceability.At the floating bearing end unsplitbearings are used whereas at thelocating bearing end the preferredchoice for replacement bearingsare split spherical roller bearingswhose dimensions are adapted tothose of series 249. The split bearingsfacilitate bearing replacementwithout dismounting the driveunit, cp. section 2.2.Locating bearingFloating bearing1: Trunnion bearing arrangement for a converter with two spherical roller bearingsFAG · 3

2 ROLLING BEARINGS AND HOUSINGS FOR CONVERTERSSpherical Roller Bearings2 Rolling Bearings and Housingsfor ConvertersThe technical data of the FAGspherical roller bearings and plummerblock housings for convertersare indicated in chapter 6.2.1 Spherical Roller BearingsFAG spherical roller bearings arerolling bearings designed for heavyduty applications. They containtwo rows of symmetrical barrelrollers which align smoothly in thespherical raceway of the outerring. In this way shaft deflectionsand misalignments of the bearingseats are compensated for.FAG spherical roller bearings forconverters usually feature the maindimensions of the standardized series249.Depending on design, bearingcomponents are bonderizedand/or Molykoted. The bearingsare available either with a cylindricalbore or with a tapered bore(taper 1:30).Spherical roller bearings with acylindrical bore are mounted directlyon the converter trunnion,fig. 1 on page 3. Bearings with atapered bore are mounted on taperedsleeves, fig. 2.2.1.1 Compensation of MisalignmentStatic misalignmentVertical or lateral housing offsetmay lead to misalignment, fig. 3.This so-called static misalignmentmay be due, for instance, to foundationsettling. Static misalignmentis harmless as long as the rollershave full length contact with theouter ring raceway. The misalignmentangle specified for static misalignmentis 1.5° for all FAG sphericalroller bearings.Experience has shown that, whenmounting the housing, static misalignmentshould be limited to 10angular minutes. This value mayseem small compared with the permissiblemisalignment but itshould be borne in mind that agradual subsidence of the foundationsor thermal influences may resultin major positional changes ofthe housing.αα232: Spherical roller bearing as a locating bearing on a sleeve 3: Static misalignment αFAG · 4

Spherical Roller BearingsDynamic misalignmentThe bearing centre distances oflarge converters are between 7 and12 meters. When the vessel is beingswung deflections may occurwhich vary in magnitude with themomentary vessel position. Howeverthe alignment motion thebearing has to take up during rotationis relatively slight.ββThe influence of the temperaturedifferential in the trunnion ring isgreater. It produces a misalignmentwhich causes distortion of varyingmagnitude. As a result the trunnionsbecome offset to each other.The wobbling of the trunnionswhen the vessel swings is calleddynamic misalignment, fig. 4.This means that each swinging motionof the vessel imposes on therolling elements in the bearings anaxial displacement in addition tocircumferential rolling. This is associatedwith sliding friction. In orderto avoid extra strain on thecontact points in the bearing thedistortion of the trunnion ringshould be minimized.4: Dynamic misalignment β55: Spherical roller bearing for converters with machined brasscage6: Spherical roller bearing for converters with pin-type cage6Data from the field have shown thedynamic misalignment of converterbearings to be in the order of 20 to50 angular minutes after severalyears of operation. In spite ofthese deviations from the geometricalaxis the extra loads can be accommodatedsince they were takeninto account in the internal designof the FAG bearings. The outerring raceways or the rollers featurea special coating which reducesfriction.2.1.2 CagesDepending on the strain to beaccommodated, FAG sphericalroller bearings for converters arefitted with machined brass cages(fig. 5) or with pin-type cagesand through-bored rollers(fig. 6).Pin-type cages consist of lateralcage washers to which the boltsare attached that pass through therollers. With this pin-type cage alarger number of rollers can be accommodatedand thus a higherload rating be achieved. Thesecages are also particularly strong.FAG · 5

2 ROLLING BEARINGS AND HOUSINGS FOR CONVERTERSSpherical Roller Bearings · Split Spherical Roller Bearings2.1.3 Tolerances, BearingClearanceFAG spherical roller bearings forconverters have the normal tolerancesof radial bearings (toleranceclass PN), see also FAG catalogueWL 41 520. Deviations for splitbearings, see section 2.2.The radial clearance of the sphericalroller bearings is selected accordingto the operating temperatureand the mounting fits.The main dimensions of splitspherical roller bearings are adaptedto those of unsplit bearingswith a tapered bore and a wedgesleeve (fig. 7a) or with a cylindricalbore (fig. 7b). Rings and cages ofsplit bearings are split horizontally.Due to the split clamping rings thesplit inner rings are considerablywider than the inner rings of unsplitbearings.The bore tolerance is such that atight fit is obtained with trunniontolerances of h7 to m6.In split bearings not only the outerring raceways are bonderized andMolykoted, but the rollers are bonderizedas well.2.1.4 Lubricating Groove,Lubricating HolesTo simplify lubrication, the FAGspherical roller bearings for convertersfeature a circumferential lubricatinggroove and three lubricatingholes in the outer ring, see figs.5 and 6.2.1.5 Heat TreatmentaFAG spherical roller bearings forconverters are heat-treated in sucha way that they are dimensionallystable up to an operating temperatureof 200 °C.2.2 Split Spherical RollerBearingsSteel works often demand that thebearing at the drive end (locatingbearing) of a converter can be replacedwithout dismounting thedrive unit. This is possible with splitspherical roller bearings, fig. 7. Forprice reasons split bearings are usuallyused as replacement bearings.b7: Split spherical roller bearingsa: Replacement for an unsplit bearing with a tapered bore andwedge sleeveb: Replacement for an unsplit bearing with a cylindrical boreFAG · 6

KPG49 Housings2.3 KPG49 HousingsThe split plummer block housingsof series KPG49 are made of caststeel and feature a tensile strengthof more than 400 N/mm 2 . This providesgood support for the bearingouter ring, which is of great importancefor achieving a good distributionof pressure within the bearing.Three housing designs areavailable.In housings of design KPG49...F(fig. 8a) the locating bearing functionis achieved by arranging locatingrings on both sides of the bearing’souter ring. These housingsare used for spherical roller bearingswith a tapered bore which aremounted on the shaft with wedgesleeves.Housings of design KPG49...FG(fig. 8b) are locating bearinghousings. They accommodatesplit spherical roller bearingswhich replace unsplit bearingswith a tapered bore and wedgesleeve.In housings of design KPG49…L(fig. 8c) the outer ring of the floatingbearing can shift axially withina sleeve. Spherical roller bearingswith a tapered bore and wedgesleeve are mounted into thesehousings.abc8: Split plummer block housings KPG49 for convertersLocating bearing housing KPG49…F (a) and KPG49…FG (b)Floating bearing housing KPG49…L (c)FAG · 7

2 ROLLING BEARINGS AND HOUSINGS FOR CONVERTERSKPGZ49 Housings2.4 KPGZ49 HousingsSplit plummer block housings ofseries KPGZ49, unlike KPG49housings, are designed for bearingswith a cylindrical bore that aremounted directly on the shaft.These housings are also availableas designs F and L for unsplitspherical roller bearings (locatingbearing housings fig. 9a, floatingbearing housings fig. 9c). Housingsof design FG (fig. 9b) are locatingbearing housings for split sphericalroller bearings.abc9: Split plummer block housings KPGZ49 for convertersLocating bearing housing KPGZ49…F (a) and KPGZ49…FG (b)Floating bearing housing KPGZ49…L (c)FAG · 8

3 BEARING DIMENSIONING3 Bearing DimensioningConverter bearings perform swingingmotions and are rotated up to360° only occasionally. When theconverter swings, bearing speedsrange from 0.1 to 1 min -1 .During decarburization the converteris at rest, the blowingprocess causes vibrations.These conditions require bearingdimensions that are based on staticcriteria.The bearings’ service life is determinedby wear. Wear is caused by:• deflectiondue to the large bearing centredistance or due to deformationof the trunnion ring• axial displacementdue to temperature changes inthe converter.Index of static stressing, f sUsually, the index of static stressingrequired for converter bearingsisf s ≥ 2f s = C 0 /P 0C 0 static load rating [kN] as indicatedin bearing tablesP 0 equivalent static load [kN]Locating bearingP 0F = F rF + Y 0 · (F a + F a1 ) [kN]Floating bearingP 0L = F rL + Y 0 · F a1 [kN]F rF = maximum radial load onlocating bearing [kN] *F rL = maximum radial load onfloating bearing [kN] *Y 0 = thrust factor (bearing tables)F a = maximum external thrust[kN] *F a1 = µ · F rL reaction force fromfloating bearing displacement[kN]µ = 0.15 coefficient of friction ofsleeve* with possible shock loadsThe calculated results are enteredin the calculation sheet (sheet B insection 5.8).Wear can be reduced by phosphatizingand/or Molykoting the bearingcomponents.FAG · 9

4 DESIGN OF ADJACENT PARTSFits · Seals4 Design of Adjacent Parts4.1 Fits4.1.1 TrunnionsRecommended machining tolerances:h7m6if a tapered sleeveis usedif the bearing ismounted directlyon the trunnionHeavy converter bearings are bestmounted on a tapered sleeve. Itmakes mounting easier and reducesthe requirements on the seatquality. The out-of-roundness andtaper should not exceed 40 % oftolerance field h7.bearing O.D.; roughness depth< 6 µm.The unsplit sleeve is roughly asthick as the outer ring.The O.D. of FAG spherical rollerbearings is phosphatized andMolykoted so that the frictional resistanceduring displacement is reduced.4.2 SealsTwo types of seals have proved tobe suitable for this application. InEurope high-pressure packings aremainly used whereas in Americarubber-profile seals are preferred.4.2.1 High-Pressure PackingsOrder example:PRFL.1799-30x30x3850/Hecker orequivalent4.2.2 Rubber-Profile SealsOrder example (for d = 1135 mm):PRFL.GSH1003/1135.155330For a cylindrical bearing bore thetrunnion must be machined to m6(tight fit). Prior to mounting, largebearings must be heated in an oilbath; we recommend to dismountthem hydraulically. A sliding fitmay also be chosen if the trunnionsurface can withstand the resultingstrain.4.1.2 Housing BoreRecommended machining tolerances:H7 for floating bearings and locatingbearingsFor floating bearings the bore ofthe displacement sleeve, dependingon the diameter, is 0.120 to0.400 mm larger than the nominalØØ10 1110: High-pressure packing 11: Rubber-profile sealFAG · 10

5 MOUNTING, LUBRICATION AND MAINTENANCEPreparations for Mounting · Mounting Unsplit Bearings5 Mounting, Lubrication andMaintenanceThe bearings’ service life is determinedto a great degree by correctmounting and maintenance.Large bearings should be mountedby skilled personnel only.A specialized bearing fitter shouldalways be available to supervisethe mounting work and ensure thefitting work is carried out in accordancewith the mounting instructions.5.1 Preparations for MountingSmooth mounting of converterbearings requires some preparation.• Prepare tools• Check hoisting equipment andposition it correctly (some bearingsweigh several tons)• Have a sufficient amount of thespecified grease ready (see section5.5)• Check adjacent parts (form anddimensional accuracy, surfacefinish, cleanliness)• Enter measured values (trunniondiameter, housing bore) in datasheets E or F (section 5.8)Bearing mounting requires that• the converter vessel and trunnionring are already suspendedabove the foundation• the housing bases of locatingand floating bearings are alignedon the foundations• the bearings can be premountedin a workshop if necessaryFor bearings with a cylindricalbore that are heated in an oil bath• an oil container suitable for thebearing size and a ring burnermust be provided at the mountingsite• a device must be providedwhich axially presses the warmbearing against the shaft shoulderuntil it has cooled downFor bearings with a tapered borethat are mounted on sleeves• hydraulic tools are required (seesection 5.2.2)Unpack bearings only afterthese preparatory steps havebeen accomplished.Then check the bearings fortransport damage.Measure radial clearance over bothroller rows by means of a feelergauge and enter the values in datasheet E or F (section 5.8).5.2 Mounting Unsplit Bearings5.2.1 Bearings with a CylindricalBore (fig. 1)The tight fit (m6) on the cylindricaltrunnion requires previous heatingof the bearings in an oil bath. At atemperature of 80 to 90 °C the innerring expands sufficiently topermit the bearing to be pushedonto the trunnion unimpeded. Atemperature limit of 120 °C mustnot be exceeded because otherwisethe material structure maychange.The bearings shall be supported inthe oil container on a grid. Thisprevents contaminants in the oilwhich have deposited on the bottomfrom penetrating into thebearings. It also ensures an evenheating of the bearings.When a bearing has a temperatureof 80 to 90 °C lift it out of the oilcontainer. Let the oil drip off andwipe the bearing bore until it isnearly dry. Then push the bearingonto the trunnion. Adjust it axiallyagainst the shaft shoulder until ithas cooled down (adjust it againduring this period). Fill the bearingcavities with grease. Before mountingthe bearing at the oppositeend, wrap the already mountedbearing in oiled paper to protect itfrom contamination.More measures are described insection 5.4.FAG · 11

5 MOUNTING, LUBRICATION AND MAINTENANCEMounting Unsplit Bearings5.2.2 Bearings with a TaperedBore and Sleeve (fig. 2)The bearing seat on the trunnion ismachined to h7. A tight fit of bearing,sleeve and trunnion is obtainedby axially pressing the taperedsleeve a specified distanceinto the bearing bore. To preventaxial displacement, the bearing islocated on both sides of the innerring.The tapered sleeves are alwayssuitable for hydraulic mounting,which requires only one fifth ofthe force that would be necessaryfor dry mounting.12a: Oil supply via oil ductsPrior to mounting, measure the radialclearance over both rollerrows by means of a feeler gaugeand enter the measured values indata sheet E or F (section 5.8).Then place the bearing on thetrunnion and insert the sleeve untilthe bearing is centered and the innerring abuts the shaft shoulder orthe intermediate sleeve. Press oilinto the fitting joints by means of apump, fig. 12a. At the same timethe sleeve is pressed into the bearingbore, by means of severalscrews provided in the sleeve face,fig. 12b, until the specified radialclearance reduction has beenachieved (see project sheet A insection 5.8). The remaining radialclearance is entered in data sheet Eor F.12b: Arrangement of the pressure screws for sleeve positioningAbout 20 minutes after pressingthe sleeve into the bore the mountingaids may be removed. Fill thebearing cavities with grease. Priorto mounting the second bearing,wrap the already mounted bearingin oiled paper to protect it fromcontamination.FAG · 12

Mounting Split BearingsThe inner ring halves are mountedfirst (mounting sketch, figs. a – d).Mount the clamping rings in thesame manner (fig. e). The gaps betweenthe two separating joints ofthe inner ring must be horizontal(fig. d) and identically sized. Theseparating joints of the clampingrings (fig. e) shall be offset by onlysuch a distance that the connectionbolts of the clamping rings can betightened comfortably from above(tightening torque, see projectsheet A in section 5.8).5.3 Mounting Split BearingsSplit bearings are preferably usedas replacement bearings at thedrive end. Since the drive unit isnot dismounted there is only limitedspace to work in. So the bearinglocation is accessible only fromabove.When the bearings are mountedcare must be taken that at eachend the right bearing componentsare installed. Apart from the bearingcode (six-digit number) on thestamped side, the components aremarked with a manufacturing number,e.g. 501. The components forthe stamped side bear this numberat the separating joints. The componentson the opposite side areadditionally marked by an A, forexample 501A.The bearing components featuretapped holes for easier handling.The inner ring is mounted onthe shaft with an interferencefit, resulting in a gap at theseparating joints of the innerring halves.Before the replacement bearingcan be mounted the unsplit bearingmust be removed (recommendations,see 5.7.1). Then check thebearing seat on the trunnion andmeasure the trunnion diameter.Enter the measured values in thedata sheet.Local irregularities in the trunnionsurface (fretting corrosion, coldweldings) must be reworked. Atany rate the diameter of the seatfor the split bearing must ensurean interference fit.Mount the other bearing componentsas shown in figs. f – i. Makesure that the bore provided in theouter ring faces for the anti-rotationdevice is exactly vertical. Asshown in fig. h, the halves of theroller-cage assembly shall bebraced against the inner ring racewaysby means of strong wire beforethe converter is lowered intothe housing bases.Before lowering the converter,• the bearing at the opposite endmust be mounted,• the housing bases must be positionedcorrectly relative to thetrunnions.Then• insert the two other roller-cageassembly halves (remove wireand eye bolts of the other halvesfirst),• fill in lubricant• mount the second outer ringhalf.Additional measures are describedin section 5.4.FAG · 13

5 MOUNTING, LUBRICATION AND MAINTENANCEMounting Split BearingsMounting sketch for split replacementbearingsaba-c Insert inner ring half underthe trunnion and adjust itagainst the trunnion frombelow by means of woodenwedges. Make sure that thewooden wedges do not coverthe seats for the clampingrings.cFAG · 14

Mounting Split Bearingsd Position second inner ringhalf.dee Insert clamping rings in thesame manner as the innerring halves. Then wedge andbolt them together. The separatingjoints of the clampingrings shall be slightly offsetagainst the separating jointsof the inner ring.f Insert outer ring half andlower it into the housingbase.fFAG · 15

5 MOUNTING, LUBRICATION AND MAINTENANCEMounting Split Bearingsg Suspend roller-cage assemblyhalves and roll them over theouter ring.ghh – i Brace the roller-cage assemblyhalves against theinner ring raceway.Now the converter can belowered.All other components aremounted later.iFAG · 16

Measures to be taken after Mounting5.4 Measures to be taken afterMountingAfter both bearings are mountedthe following measures must betaken:• Check position of the housingbases in relation to the trunnionand correct it if necessary (staticmisalignment, cp. 5.4.1)• Check position of floating bearinghousing relative to the trunnionand correct it if necessary(displacement possible?)• Lower converter• Measure bearing clearance ofunsplit bearings• Position housing cap• Fill in lubricant (fill ca. 60 % ofthe cavities at the left and rightof the bearing)• Bolt lateral cover to housing• Correct dynamic misalignment asstated in 5.4.2 (vertical errorcompensated for and housingin correct position relative tothe trunnion, cp. 5.4.1) andenter values in data sheet (section5.8)• Determine axial elongation inoperation (1st campaign) andenter value in the data sheet(section 5.8); displacement forfloating bearing, see 5.4.3)5.4.1 Checking the Static Misalignment(vessel at rest)Measure the maximum and theminimum distance between the innerring face and a machined faceof the housing cover. The staticmisalignment is calculated fromthe difference between these distancesand the diameter on whichthe values were measured:tan α = (a max - a min )/d 1Required: α ≤10 min, i.e.tan α ≤0.003 and consequently(a max - a min )/d 1 ≤ 0.003a maxa mind 1αHousing in incorrect positionrelative to the trunnionMeasuring the static misalignmentVertical errorFAG · 17

5 MOUNTING, LUBRICATION AND MAINTENANCEMeasures to betaken after Mountingl5.4.2 Checking the DynamicMisalignment (vesselswinging)Attach a dial gauge to the housingas shown in the sketch, and placethe stylus on the trunnion at a distancel from the bearing center.Then rotate the converter through360° and take the maximum readingb on the dial gauge. The dynamicmisalignment is:tan β = b/(2 · l)The measured values include theout-of-roundness of the trunnion.However, the permissible out-ofroundnessof the trunnion is muchless than the deviation from thegeometrical axis of rotation.Measuring the dynamic misalignmentThe measured values shall be enteredin the data sheet.The present state of manufacturingaccuracy makes misalignment ofmore than 10 angular minutes veryunlikely for new plants. By repeatingthe measurements it is possibleto determine any variation in trunnionposition at later stages. In viewof the slightness of the deviationsengineers often refrain from makinga measurement when erecting newconverters.5.4.3 Checking the Displacementof the Floating BearingMarkingDuring the first campaign of theconverter the floating bearing displacementshall be measured.Based on the position of the floatingbearing when the converter iscold, the displacement resulting afterseveral days of operation ismeasured. With an open end covertrunnion (upper picture) the displacementis determined from thedistance between the trunnion endand the housing cover face.xTrunnion endEnd coverMeasuring the axial displacement of the floating bearingIf the housing features a closedend a mark is made on that portionof the trunnion which points to theconverter (picture below).Enter the measured values in datasheet E (cp. 5.8) for future reference.FAG · 18

Lubrication · Maintenance5.5 LubricationFAG spherical roller bearings forconverters feature a lubricatinggroove and lubricating holes in themiddle of the outer ring. With eachrelubrication, the lubricant is fedfrom there directly into the bearings.The bearings shall be lubricatedwith lithium soap base greasescontaining effective EP and anticorrosionadditives, if possible alsoan MoS 2 additive.A high base oil viscosity in conjunctionwith a not-too-soft consistency(NLGI class 2) ensures agood lubricating condition.If possible, the bearings shall berelubricated with the same greaseblend that was used for initialgreasing (see project sheet A insection 5.8).The lubricant for the bearings shallalways be used to relubricate theseals as well if grease chambersare provided.Amount of grease for initial lubrication,replenishment quantity andrelubrication intervals, see projectsheet A in section 5.8).5.6. MaintenanceMaintenance of the converter bearingsshall be effected as follows:a ... a b a ... a c a ... a b a etc.a Activities after commissioningand during operation, see 5.6.1b Intermediate inspection after 1 to1 1 / 2 yearsc Main inspection after 2 to 3 years5.6.1 After Commissioning/BetweenInspections:1 After first “campaign” measurefloating bearing displacement2 After every “campaign” relubricateseal (depending on plant)3 After every “campaign” lubricatedisplacement sleeve (floatingbearing end)4 Lubricate bearings every 2 to 3months5.6.2 Intermediate Inspectionafter 1 to 1 1 / 2 Years:1 Remove lateral covers and removespent grease2 Check lubricant for contaminantson the spot3 Check seals and replace them ifnecessary4 Replenish lubricant5.6.3 Main Inspection after 2 to3 Years1 Remove lateral covers and housingcap and remove spent grease2 Take lubricant samples at differentdistances from the bearingand examine them3 Remove remaining lubricant4 Determine possible axial displacementof the floating bearing(inward and outward), comparewith the values recorded duringoriginal mounting and enter it indata sheet5 Measure radial clearance and entervalue in data sheet (old bearingposition)6 Lift converter until all bearingouter rings are exposed7 Check surfaces of raceways androlling elements (record conditionin data sheet)8 Mark four 90° arcs on the outerrings of unsplit bearings9 Rotate outer ring and roller-cageassemblies 90° and enter old andnew position of the outer ring indata sheet10 Rotate outer ring halves androller-cage assembly halves ofsplit bearings 180°11 Lower converter in this position12 Measure radial clearance andenter the value beside “Newbearing position”13 Fill in fresh lubricant14 Renew seals15 Check angular misalignment,compare it with previousrecords and enter it in datasheetFAG · 19

5 MOUNTING, LUBRICATION AND MAINTENANCEDismounting · Maintenance Forms5.7 DismountingBasically, dismounting shall be effectedin the reverse order ofmounting.5.7.1 Bearings with a CylindricalBoreBearings with a cylindrical borewhich are mounted tightly on thetrunnion cannot be dismounted ina conventional manner.Instead, the bearings may, for example,be dismounted hydraulicallyusing additional auxiliary extractiontools. This, however, requiresholes and circular grooves in thetrunnions for pressing in the pressureoil. The design featuring acylindrical seat is intended for asplit replacement bearing (locatingbearing at the drive end). Since thegear is not dismounted the hydraulicmethod cannot be used todismount the locating bearing. Becauseof the considerable effort involved,it generally is not eligiblefor the floating bearing end either.As a rule, converter bearings witha cylindrical bore are destroyedduring dismounting because fatiguehas rendered them useless.Cut up outer rings and cages witha cutting torch. Try by all means toremove the inner ring by cracking.If this is not possible and the innerring has to be cut up by means ofa cutting torch, make tangentialcuts to ensure that the trunnion isnot damaged.After cutting up and removing theouter ring and the two cages, usea welding torch to heat the innerring well (ca. 300 °C) successivelyat two opposite points (over theentire width of the ring). Thenquench it with a jet of cold water.It is important to quickly produce,by means of the water jet, a greattemperature difference betweenthe surface and the core of thematerial because the resulting tensilestress causes the ring to crack.Because of the risk of accident,the cracking area must be covered.5.7.2 Bearings with a TaperedBore and HydraulicSleeveTo dismount bearings with a taperedbore and hydraulic sleevethe press fit between trunnion,sleeve and bearing must be slackened.First, loosen the parts whichaxially locate the bearing towardthe trunnion end and arrange themin such a way that the sleeve canshift 0.008 · d (with taper 1:12) or0.02 · d (with taper 1:30) (d = nominalbearing bore diameter). Thenconnect the pumps, via extremepressurehoses and adapters, to theconnections provided in the hydraulicsleeve. Loosen and removethe sleeve from the bearing boreby means of the pressure oil whichis then pressed into the fittingjoints and by means of the extractionbolts. The position of the extractionbolts is shown in the pictureopposite.5.8 Maintenance FormsPosition of the extraction bolts for the dismounting processABCDEFProject SheetCalculation SheetReplacementSequence of Mounting StepsData Sheet(Original Mounting)Data Sheet(Main Inspection)FAG · 20

Maintenance FormsA Project SheetManufacturer:Project:Code word:Installation site:Vessel capacity:Blowing process:Original equipment: Locating bearing endHousing FAGData see dwg. no.Bearing FAGData see dwg. no.Floating bearing endHousing FAGData see dwg. no.Bearing FAGData see dwg. no.Replacement: Locating bearing FAGSplit spherical roller bering Data see dwg. no.Floating bearingFAGSpherical roller bearing Data see dwg. no.Fit:Trunnion diameterHousing diameter (locating bearing)Housing diameter (floating bearing)Displacement in the housingLubrication:Arcanol rolling bearing grease (FAG)Relubricate with the same lubricant as used for initial greasingLubricating quantity: Initial chargeBearings 100 %Housings 60 %Floating bearing housing [kg]Locating bearing housing [kg]RelubricationBearingsca. 8 % of the initial grease fillkg every 3 monthsSliding area for ca. 0.8 % of the initial grease fill after every campaignaxial displacementSealafter every campaign until fresh grease is supplied(depending on specific plant)Equipment:FAG · 21

5 MOUNTING, LUBRICATION AND MAINTENANCEMaintenance FormsB Calculation SheetManufacturer:Project:Code word:Installation site:Design:Determination of the index of static stressing, f s , for trunnion bearingsInput parameters:Bearing designation:Dimensions:mmStatic load rating: C 0 = kNThrust factor: Y 0 =Radial load (floating bearing end, vertical): F rL1 = kNRadial load (floating bearing end, horizontal) F rL2 = kNRadial load (locating bearing end, vertical) F rF1 = kNRadial load (locating bearing end, horizontal) F rF2 = kNAxial load resulting from the blowing process F a = kNCoefficient of friction µ =Calculation resultSpherical roller bearing (floating bearing end): f s =P 0L = kNF a1 = kNCalculation resultSpherical roller bearing (locating bearing end): f s =P 0F = kNF a total = kNFAG · 22

Maintenance FormsC ReplacementReplacement (floating bearing)1 - FAG Spherical roller bearing, unsplit1 - RG. Displacement sleeveReplacement (locating bearing)1 - FAG Spherical roller bearing, splitReplacement (sealing/housing)4 - PRFL. Sealing2 - BTL.2 - BTL.8 - MTL.4 - BLZ.16 - MU.8 - BGSH.2 - FED.Parts for preloading bandFAG · 23

5 MOUNTING, LUBRICATION AND MAINTENANCEMaintenance FormsD Sequence of Mounting StepsLocatingbearingFloatingbearingMeasure the trunnion diameteror manufacturer’s acceptance reportMeasure the housing boresCheck the radii (bearing and shaft shoulder)Check ancillary partsDimensional and form accuracySurface finishCleanlinessMeasure the bearing’s radial clearance (enter values in data sheet)Mount bearings on trunnionsGrease bearingsMount housings and accessoriesCheck position of housings relative to trunnion and adjust it if necessary(take into account permissible misalignment; vertical error,housing not in correct position relative to trunnion)Height must be recorded appropriatelyCheck position of floating bearing housing relative to trunnion andadjust it if necessary (displacement possible?)Lower vessel until it is suspended ca. 2 mm above the platform, check againGrease bearing locationInsert sealClose bearing housingMeasure misalignment (static) and adjust it(trunnion diameter concentric with cover bore?)FAG · 24

Maintenance FormsE Data Sheet (Original Mounting)BearingsLocating bearingFloating bearingLocatingbearingFloatingbearingRadial clearance prior to mountingActual dimension (trunnion)Radial clearance after mounting *1Actual dimension (housing)[mm][mm][mm][mm]Misalignment resulting from housing being incorrectlypositioned relative to trunnionMisalignment resulting from vertical errorTotal static misalignmentPossible axial displacement of the floating bearinginwardoutward[mm][mm]Grease usedRemarks:*1calculated valueFAG · 25

5 MOUNTING, LUBRICATION AND MAINTENANCEMaintenance FormsF Data Sheet (Main Inspection)Total static misalignment (old position of the outer rings)Remove spent lubricant from housing and check forcontaminants on the spot.Result of grease inspectionPossible axial displacement of the floating bearinginwardoutward[mm][mm]Bearings Locating bearingFloating bearingRadial clearance (old position)[mm]Lift converter until bearing outer rings are exposedCheck surfaces (raceway and rolling elements)ConditionThe service life can be increased by rotating the outer rings and roller-cage assemblies 90°(split bearings: 180°). Enter old and new positions in the data sheet.Old position (outer ring)New position (outer ring)If necessary, radial clearance of new bearing position[mm]Lower converterReplenish lubricantInspect sealReplace if necessaryTotal static misalignment (new position of the outer rings)FAG · 26

FAG SPHERICAL ROLLER BEARINGS FOR CONVERTERSBearings of dimensional series 49 with machined brass cage (MB)with a cylindrical bore or with a tapered bore and wedge sleever sr sD 2 D 1dBD 1DCylindrical boreCodeDimensionsBearing Sleeve Bearing Sleeved d 1 D B r s l a R omin≈FAG FAG mm528739 460 620 160 4528739K30 H.528816 460 440 620 160 4 160 18 M 8528740 480 650 170 5528740K30 H.528817 480 460 650 170 5 170 20 M 8528741 500 670 170 5528741K30 H.524974 500 470 670 170 5 170 20 G 1 / 8528742 530 710 180 5528742K30 H.524976 530 500 710 180 5 180 20 G 1 / 8528743 560 750 190 5528743K30 H.524978 560 530 750 190 5 190 20 G 1 / 8528744 600 800 200 5528744K30 H.524980 600 570 800 200 5 200 20 G 1 / 4528745 630 850 218 6528745K30 H.524982 630 600 850 218 6 218 22 G 1 / 4528746 670 900 230 7.5528746K30 H.524984 670 630 900 230 7.5 230 22 G 1 / 4528747 710 950 243 6528747K30 H.524986 710 670 950 243 6 243 22 G 1 / 4528748 750 1000 250 6528748K30 H.524988 750 710 1000 250 6 250 22 G 1 / 4528749 800 1060 258 7.5528749K30 H.524990 800 750 1060 258 7.5 258 22 G 1 / 4528750 850 1120 272 6528750K30 H.524992 850 800 1120 272 6 272 22 G 1 / 4528751 900 1180 280 6528751K30 H.524994 900 850 1180 280 6 280 25 G 1 / 4528752 950 1250 300 7.5528752K30 H.524996 950 900 1250 300 7.5 300 25 G 1 / 4528753 1000 1320 315 7.5528753K30 H.524998 1000 950 1320 315 7.5 315 25 G 1 / 4FAG · 28

Br sRa0ldD 2 D 1d 1D 3D 1DK30, tapered bore (taper 1:30)Load rating Factor Abutment dimensions Grease quantity Massstat. ≈ ≈C 0 Y 0 D 1 D 2 D 3 Initial greasing Bearing SleevekN - mm kg kg6100 2.9 494 590 4 1406100 2.9 494 590 475 4 140 206800 2.9 517 615 4 1606800 2.9 517 615 495 4 160 227100 3 540 640 5 1707100 3 540 640 515 5 170 338000 3 570 675 5 2108000 3 570 675 545 5 210 389300 3 600 710 6 2409300 3 600 710 575 6 240 4410400 3.1 645 755 7 28010400 3.1 645 755 615 7 280 5011800 3 675 805 9 35511800 3 675 805 645 9 355 6013400 3 720 850 10 42013400 3 720 850 685 10 420 7815300 3 760 900 12 49015300 3 760 900 725 12 490 9516600 3.1 800 950 14 55016600 3.1 800 950 765 14 550 10518300 3.2 860 1010 15 62518300 3.2 860 1010 820 15 625 14020000 3.2 910 1070 18 72520000 3.2 910 1070 870 18 725 15522000 3.3 960 1120 20 82022000 3.3 960 1120 920 20 820 17525000 3.2 1015 1190 25 100025000 3.2 1015 1190 970 25 1000 20027000 3.3 1065 1250 30 118027000 3.3 1065 1250 1025 30 1180 225FAG · 29

FAG SPHERICAL ROLLER BEARINGS FOR CONVERTERSBearings of dimensional series 49 with pin-type cagewith a cylindrical bore or with a tapered bore and wedge sleever sr sD 2 D 1dBD 1DCylindrical boreCodeDimensionsBearing Sleeve Bearing Sleeved d 1 D B r s l a R omin≈FAG FAG mm249/500.541821 500 670 170 5249/500K30.541821 H.524974 500 470 670 170 5 170 20 G 1 / 8249/530.541822 530 710 180 5249/530K30.541822 H.524976 530 500 710 180 5 180 20 G 1 / 8249/560.541823 560 750 190 5249/560K30.541823 H.524978 560 530 750 190 5 190 20 G 1 / 8249/600.541824 600 800 200 5249/600K30.541824 H.524980 600 570 800 200 5 200 20 G 1 / 4249/630.541825 630 850 218 6249/630K30.541825 H.524982 630 600 850 218 6 218 22 G 1 / 4249/670.541826 670 900 230 6249/670K30.541826 H.524984 670 630 900 230 6 230 22 G 1 / 4249/710.541827 710 950 243 6249/710K30.541827 H.524986 710 670 950 243 6 243 22 G 1 / 4249/750.541828 750 1000 250 6249/750K30.541828 H.524988 750 710 1000 250 6 250 22 G 1 / 4249/800.541829 800 1060 258 6249/800K30.541829 H.524990 800 750 1060 258 6 258 22 G 1 / 4249/850.541830 850 1120 272 6249/850K30.541830 H.524992 850 800 1120 272 6 272 22 G 1 / 4249/900.541831 900 1180 280 6249/900K30.541831 H.524994 900 850 1180 280 6 280 25 G 1 / 4249/950.541832 950 1250 300 7.5249/950K30.541832 H.524996 950 900 1250 300 7.5 300 25 G 1 / 4249/1000.541833 1000 1320 315 7.5249/1000K30.541833 H.524998 1000 950 1320 315 7.5 315 25 G 1 / 4249/1060.541834 1060 1400 335 7.5249/1060K30.541834 H.525000 1060 1000 1400 335 7.5 335 25 G 1 / 4249/1120.541835 1120 1460 335 7.5249/1120K30.541835 H.525001 1120 1060 1460 335 7.5 335 27 G 1 / 4249/1180.541836 1180 1540 355 7.5249/1180K30.541836 H.525003 1180 1120 1540 355 7.5 355 27 G 1 / 4249/1250.541837 1250 1630 375 7.5249/1250K30.541837 H.525005 1250 1180 1630 375 7.5 375 27 G 1 / 4249/1320.541838 1320 1720 400 7.5249/1320K30.541838 H.525007 1320 1250 1720 400 7.5 400 28 G 1 / 4FAG · 30

Br sRa0ldD 2 D 1d 1D 3D 1DK30, tapered bore (taper 1:30)Load rating Factor Abutment dimensions Grease quantity Massstat. ≈ ≈C 0 Y 0 D 1 D 2 D 3 Initial greasing Bearing SleevekN - mm kg kg9000 3 540 640 5 1759000 3 540 640 515 5 175 3310000 3 570 675 5 21010000 3 570 675 545 5 210 3811400 3 600 710 6 25011400 3 600 710 575 6 250 4412700 3 645 755 7 29012700 3 645 755 615 7 290 5015000 2.9 675 805 9 37015000 2.9 675 805 645 9 370 6016600 3 720 850 10 43516600 3 720 850 685 10 435 7818600 2.9 760 900 12 51018600 2.9 760 900 725 12 510 9520000 3 800 950 14 57520000 3 800 950 765 14 575 10522400 3.1 860 1010 15 65522400 3.1 860 1010 820 15 655 14024500 3.1 910 1070 18 76024500 3.1 910 1070 870 18 760 15527500 3.2 960 1120 20 85527500 3.2 960 1120 920 20 855 17531000 3.2 1015 1190 25 104031000 3.2 1015 1190 970 25 1040 20034500 3.2 1065 1250 30 122534500 3.2 1065 1250 1025 30 1225 22537500 3.2 1135 1325 35 147037500 3.2 1135 1325 1085 35 1470 29040500 3.3 1195 1385 37 154040500 3.3 1195 1385 1145 37 1540 30546500 3.3 1260 1460 43 182046500 3.3 1260 1460 1205 43 1820 34051000 3.3 1330 1550 50 215051000 3.3 1330 1550 1275 50 2150 39057000 3.3 1400 1640 60 250057000 3.3 1400 1640 1350 60 2500 485FAG · 31

FAG SPLIT SPHERICAL ROLLER BEARINGS FOR CONVERTERSMain dimensions adapted to those ofspherical roller bearings of series 249Br sb na nr sB iDD 2D idD b D 1Split spherical roller bearingCodeSplit bearingFAGDimensionsd D B r s B i D b D i a n b nminmm537276 500 670 170 5 250 534 608 13 14537277 530 710 180 5 260 566 644 15 15537278 560 750 190 5 270 600 678 15 15533761 600 800 200 5 290 636 724 15 15537279 630 850 218 6 310 678 768 18 18537280 670 900 230 7.5 325 720 810 18 18526073 710 950 243 6 350 756 860 18 20533414 750 1000 250 7.5 355 800 900 15 13532063 800 1060 258 7.5 370 856 960 17.5 16537281 850 1120 272 6 385 910 1020 20 20537282 900 1180 280 6 390 958 1068 22.5 20534826 950 1250 300 7.5 410 1016 1130 20 20533567 1000 1320 315 7.5 450 1070 1205 17.5 13537283 1060 1400 335 7.5 475 1134 1268 25 20537284 1120 1460 335 7.5 475 1194 1328 25 20536806 1180 1540 355 7.5 500 1256 1400 25 25537285 1250 1630 375 7.5 545 1336 1498 25 20FAG · 32

BB idD 1D 2Dreplaces unsplit spherical roller bearingwith lateral spacer ringsLoad rating Factor Abutment dimensions Grease quantity Massstat. ≈ ≈Initial greasing BearingC 0 Y 0 D 1 D 2kN - mm kg kg7650 3 540 620 5 2258650 3 570 660 5 27010200 3 600 695 6 30511200 3.1 645 745 7 36013200 3 675 785 9 46015000 3 720 830 10 54016000 3 760 880 12 64019000 3 800 930 14 74020400 3.2 860 980 15 81022000 3.2 910 1040 18 94023600 3.3 960 1100 20 105028500 3.2 1015 1160 25 125032000 3.2 1065 1230 30 156536000 3.2 1135 1300 35 182036500 3.4 1195 1360 37 192040500 3.3 1260 1440 43 224045000 3.4 1330 1530 50 2700FAG · 33

FAG SPLIT SPHERICAL ROLLER BEARINGS FOR CONVERTERSMain dimensions adapted to those of spherical roller bearings ofseries 249 with a tapered bore and wedge sleeveBr sb na nr sB iDD 2D idD bD 1Split spherical roller bearingCodeSplit bearingFAGDimensionsd D B r s B i D b D i a n b nminmm529173 470 670 170 5 250 515 595 15 15528441 500 710 180 5 260 545 630 15 15529223 530 750 190 5 270 580 665 15 15529224 570 800 200 5 290 625 710 15 15529225 600 850 218 6 310 660 752 18 20529226 630 900 230 6 330 690 790 20 20529227 670 950 243 6 350 740 842 20 20527943 710 1000 250 6 360 765 895 18 20529228 750 1060 258 6 370 825 940 20 20529229 800 1120 272 6 390 870 990 20 20529230 850 1180 280 6 400 925 1050 22 25527254 900 1250 300 7.5 420 980 1115 22 25529231 950 1320 315 7.5 460 1035 1180 25 25529232 1000 1400 335 7.5 490 1100 1255 25 25529233 1060 1460 335 7.5 490 1160 1315 25 25529234 1120 1540 355 7.5 520 1220 1385 25 25529128 1180 1630 375 7.5 550 1280 1465 25 25529215 1250 1720 400 7.5 580 1370 1545 25 25FAG · 34

BB idD 1D 2Dreplaces unsplit spherical roller bearingwith wedge sleeve and lateral spacerringsLoad rating Factor Abutment dimensions Grease quantity Massstat. ≈ ≈Initial greasing BearingC 0 Y 0 D 1 D 2kN - mm kg kg7350 3 540 620 5 2658650 2.9 570 660 5 3109300 2.9 600 695 6 35510400 2.9 645 745 7 41012200 2.9 675 780 9 52513200 2.9 720 830 10 63015600 2.9 760 880 12 74017300 3.1 800 930 14 85019000 3 860 980 15 95020400 3 910 1040 18 110023200 3.1 960 1100 20 125025500 3.1 1015 1160 25 149028500 3.1 1065 1230 30 180032500 3 1135 1300 35 218035500 3.3 1195 1360 37 230037500 3.3 1260 1440 43 265043000 3.3 1330 1520 50 315049000 3.3 1400 1610 60 3800FAG · 35

SPLIT FAG PLUMMER BLOCK HOUSINGS FOR CONVERTERSLocating bearing housings KPG49..F and KPG49..FG,floating bearing housings KPG49..Lfor spherical roller bearings with a tapered bore and wedge sleevefor split spherical roller bearingsmh 1nbshcaHousing Bearing Sleeve DimensionsMB cage Pin-type cage split d 1 D B B i D 1 d 3 d 5 d 6 w t s 2 s 2DIN931 NumberFAG FAG FAG FAG FAG mmKPG49/470F 528741K30 249/500K30.541821 H.524974 470 670 170 540 125KPG49/470L 528741K30 249/500K30.541821 H.524974 470 670 170 540 375 480 505 125 437.5 M20x70 8KPG49/470FG 529173 470 670 170 250 540 125KPG49/500F 528742K30 249/530K30.541822 H.524976 500 710 180 570 130KPG49/500L 528742K30 249/530K30.541822 H.524976 500 710 180 570 400 510 535 130 465 M20x70 8KPG49/500FG 528441 500 710 180 260 570 130KPG49/530F 528743K30 249/560K30.541823 H.524978 530 750 190 600 135KPG49/530L 528743K30 249/560K30.541823 H.524978 530 750 190 600 420 540 565 135 490 M20x70 8KPG49/530FG 529223 530 750 190 270 600 135KPG49/570F 528744K30 249/600K30.541824 H.524980 570 800 200 645 145KPG49/570L 528744K30 249/600K30.541824 H.524980 570 800 200 645 450 580 610 145 525 M20x80 8KPG49/570FG 529224 570 800 200 290 645 145KPG49/600F 528745K30 249/630K30.541825 H.524982 600 850 218 675 155KPG49/600L 528745K30 249/630K30.541825 H.524982 600 850 218 675 475 612 640 155 552.5 M20x80 8KPG49/600FG 529225 600 850 218 310 675 155KPG49/630F 528746K30 249/670K30.541826 H.524984 630 900 230 720 165KPG49/630L 528746K30 249/670K30.541826 H.524984 630 900 230 720 505 642 675 165 587.5 M24x90 8KPG49/630FG 529226 630 900 230 330 720 165KPG49/670F 528747K30 249/710K30.541827 H.524986 670 950 243 760 175KPG49/670L 528747K30 249/710K30.541827 H.524986 670 950 243 760 535 682 715 175 622.5 M24x90 8KPG49/670FG 529227 670 950 243 350 760 175KPG49/710F 528748K30 249/750K30.541828 H.524988 710 1000 250 800 180KPG49/710L 528748K30 249/750K30.541828 H.524988 710 1000 250 800 565 722 755 180 657.5 M30x100 8KPG49/710FG 527943 710 1000 250 360 800 180KPG49/750F 528749K30 249/800K30.541829 H.524990 750 1060 258 860 185KPG49/750L 528749K30 249/800K30.541829 H.524990 750 1060 258 860 600 762 805 185 700 M30x100 8KPG49/750FG 529228 750 1060 258 370 860 185FAG · 36

g 1 g 1k kg1L L LDDDDDDBBD 1 h11d 1h7D H7g 3w g 2D 1 h11 D H7B iw g 2g 3g 4d d D 1 h11w g 46 5D H7 d 1h7s 2FAG · 37d 3H8h8 t d 6 D 1 h11d 1h745°g 3BKPG49..F KPG49..L KPG49..FGL Bearing relubrication D Seal relubrication B Sleeve relubricationHousing dimensionsGrease quantity Mass≈≈a b c g 1 g 2 g 3 g 4 h h 1 k m n s Initial greasing Housing Bearing Sleevemm kg kg1170 375 130 400 210 40 425 820 975 230 M42 10 945 170 331170 375 130 400 40 230 425 820 40 975 230 M42 14 945 170 331170 375 130 400 210 425 820 975 230 M42 8 945 2651240 400 140 410 215 40 450 875 1050 240 M42 10 1050 210 381240 400 140 410 40 235 450 875 40 1050 240 M42 14 1050 210 381240 400 140 410 215 450 875 1050 240 M42 8 1050 3101320 420 145 420 220 40 475 930 1100 255 M48 13 1365 240 441320 420 145 420 40 240 475 930 40 1100 255 M48 15 1365 240 441320 420 145 420 220 475 930 1100 255 M48 10 1365 3551400 440 155 460 240 45 500 980 1150 270 M52 15 1575 280 501400 440 155 460 45 260 500 980 40 1150 270 M52 20 1575 280 501400 440 155 460 240 500 980 1150 270 M52 12 1575 4101500 480 165 480 250 46 535 1040 1225 295 M56 20 2205 355 601500 480 165 480 46 270 535 1040 40 1225 295 M56 24 2205 355 601500 480 165 480 250 535 1040 1225 295 M56 15 2205 5251570 500 175 500 260 50 570 1110 1300 310 M56 22 2625 420 781570 500 175 500 50 280 570 1110 40 1300 310 M56 25 2625 420 781570 500 175 500 260 570 1110 1300 310 M56 18 2625 6301660 535 185 560 290 53.5 600 1170 1375 325 M64 26 2835 490 951660 535 185 560 53.5 317.5 600 1170 50 1375 325 M64 30 2835 490 951660 535 185 560 290 600 1170 1375 325 M64 20 2835 7401750 550 195 590 305 55 630 1240 1450 335 M64 30 2940 550 1051750 550 195 590 55 332.5 630 1240 50 1450 335 M64 35 2940 550 1051750 550 195 590 305 630 1240 1450 335 M64 24 2940 8501850 570 205 600 310 56 670 1310 1550 345 M72 35 3465 625 1401850 570 205 600 56 337.5 670 1310 50 1550 345 M72 40 3465 625 1401850 570 205 600 310 670 1310 1550 345 M72 26 3465 950

SPLIT FAG PLUMMER BLOCK HOUSINGS FOR CONVERTERSLocating bearing housings KPG49..F and KPG49..FG,floating bearing housings KPG49..Lfor spherical roller bearings with a tapered bore and wedge sleevefor split spherical roller bearingsmh 1nbshcaHousing Bearing Sleeve DimensionsMB cage Pin-type cage split d 1 D B B i D 1 d 3 d 5 d 6 w t s 2 s 2DIN931 NumberFAG FAG FAG FAG FAG mmKPG49/800F 528750K30 249/850K30.541830 H.524992 800 1120 272 910 195KPG49/800L 528750K30 249/850K30.541830 H.524992 800 1120 272 910 640 812 855 195 745 M30x110 8KPG49/800FG 529229 800 1120 272 390 910 195KPG49/850F 528751K30 249/900K30.541831 H.524994 850 1180 280 960 200KPG49/850L 528751K30 249/900K30.541831 H.524994 850 1180 280 960 675 862 905 200 787.5 M30x110 8KPG49/850FG 529230 850 1180 280 400 960 200KPG49/900F 528752K30 249/950K30.541832 H.524996 900 1250 300 1015 210KPG49/900L 528752K30 249/950K30.541832 H.524996 900 1250 300 1015 715 915 960 210 832.5 M36x110 8KPG49/900FG 527254 900 1250 300 420 1015 210KPG49/950F 528753K30 249/1000K30.541833 H.524998 950 1320 315 1065 230KPG49/950L 528753K30 249/1000K30.541833 H.524998 950 1320 315 1065 750 965 1010 230 875 M36x130 8KPG49/950FG 529231 950 1320 315 460 1065 230KPG49/1000F 249/1060K30.541834 H.525000 1000 1400 335 1135 245KPG49/1000L 249/1060K30.541834 H.525000 1000 1400 335 1135 795 1015 1070 245 927.5 M36x130 8KPG49/1000FG 529232 1000 1400 335 490 1135 245KPG49/1060F 249/1120K30.541835 H.525001 1060 1460 335 1195 245KPG49/1060L 249/1120K30.541835 H.525001 1060 1460 335 1195 840 1075 1130 245 980 M42x140 8KPG49/1060FG 529233 1060 1460 335 490 1195 245KPG49/1120F 249/1180K30.541836 H.525003 1120 1540 355 1260 260KPG49/1120L 249/1180K30.541836 H.525003 1120 1540 355 1260 885 1135 1190 260 1032.5 M42x140 8KPG49/1120FG 529234 1120 1540 355 520 1260 260KPG49/1180F 249/1250K30.541837 H.525005 1180 1630 375 1330 275KPG49/1180L 249/1250K30.541837 H.525005 1180 1630 375 1330 940 1195 1255 275 1095 M42x150 8KPG49/1180FG 529128 1180 1630 375 550 1330 275KPG49/1250F 249/1320K30.541838 H.525007 1250 1720 400 1400 290KPG49/1250L 249/1320K30.541838 H.525007 1250 1720 400 1400 990 1265 1325 290 1155 M48x180 8KPG49/1250FG 529215 1250 1720 400 580 1400 290FAG · 38

g 1 g 1k kg1L L LDDDDs 2DDBBD 1 h11d 1h7D H7D 1 h11g 3w g 2D 1 h11 D H7B iw g 2g 3g 4d 6 d 5w g 4D H7 d 1h7d 3H8h8 t d 6 D 1 h11d 1h745°g 3BKPG49..F KPG49..L KPG49..FGL Bearing relubrication D Seal relubrication B Sleeve relubricationHousing dimensionsGrease quantity Mass≈≈a b c g 1 g 2 g 3 g 4 h h 1 k m n s Initial greasing Housing Bearing Sleevemm kg kg1960 600 220 630 325 59 710 1390 1600 360 M72 40 3885 725 1551960 600 220 630 59 352.5 710 1390 50 1600 360 M72 50 3885 725 1551960 600 220 630 325 710 1390 1600 360 M72 30 3885 11002060 620 230 660 340 60 740 1450 1700 370 M80 45 4515 820 1752060 620 230 660 60 375 740 1450 60 1700 370 M80 55 4515 820 1752060 620 230 660 340 740 1450 1700 370 M80 35 4515 12502200 660 250 680 350 60 800 1550 1820 390 M90 55 5460 1000 2002200 660 250 680 60 385 800 1550 60 1820 390 M90 65 5460 1000 2002200 660 250 680 350 800 1550 1820 390 M90 45 5460 14902330 650 255 720 370 72.5 830 1620 1980 360 M90 65 5660 1180 2252330 650 255 720 72.5 412.5 830 1620 70 1980 360 M90 80 5660 1180 2252330 650 255 720 370 830 1620 1980 360 M90 50 5660 18002450 740 275 780 400 77.5 880 1710 2000 460 M100 75 7140 1420 2902450 740 275 780 77.5 435 880 1710 60 2000 460 M100 95 7140 1420 2902450 740 275 780 400 880 1710 2000 460 M100 60 7140 21902560 740 285 800 410 77.5 920 1780 2150 460 M100 80 8400 1500 2902560 740 285 800 77.5 452.5 920 1780 70 2150 460 M100 100 8400 1500 2902560 740 285 800 410 920 1780 2150 460 M100 65 8400 23002700 780 300 820 420 82.5 970 1880 2300 480 M110 95 9450 1750 3302700 780 300 820 82.5 462.5 970 1880 70 2300 480 M110 110 9450 1750 3302700 780 300 820 420 970 1880 2300 480 M110 75 9450 26502850 820 320 850 435 87.5 1010 1985 2400 510 M110 110 11550 2070 3902850 820 320 850 87.5 477.5 1010 1985 70 2400 510 M110 130 11550 2070 3902850 820 320 850 435 1010 1985 2400 510 M110 85 11550 31503000 850 340 900 460 90 1080 2100 2500 520 M125 125 13440 2460 4853000 850 340 900 90 502.5 1080 2100 70 2500 520 M125 170 13440 2460 4853000 850 340 900 460 1080 2100 2500 520 M125 100 13440 3800FAG · 39

SPLIT FAG PLUMMER BLOCK HOUSINGS FOR CONVERTERSLocating bearing housings KPGZ49..F and KPGZ49..FG,floating bearing housings KPGZ49..Lfor spherical roller bearings with a cylindrical borefor split spherical roller bearingsmh 1nbshcaHousing Bearing DimensionsMB cage Pin-type cage split d D B B i D 1 d 2 d 3 d 4 d 6 w w L t s 2 s 2DIN931 NumberFAG FAG FAG FAG mmKPGZ49/500F 528741 249/500.541821 500 670 170 540 495 510 125KPGZ49/500L 528741 249/500.541821 500 670 170 540 375 505 85 437.5 M20x70 8KPGZ49/500FG 537276 500 670 170 250 540 495 125KPGZ49/530F 528742 249/530.541822 530 710 180 570 525 540 130KPGZ49/530L 528742 249/530.541822 530 710 180 570 400 535 90 465 M20x70 8KPGZ49/530FG 537277 530 710 180 260 570 525 130KPGZ49/560F 528743 249/560.541823 560 750 190 600 555 570 135KPGZ49/560L 528743 249/560.541823 560 750 190 600 420 565 95 490 M20x70 8KPGZ49/560FG 537278 560 750 190 270 600 555 135KPGZ49/600F 528744 249/600.541824 600 800 200 645 595 610 145KPGZ49/600L 528744 249/600.541824 600 800 200 645 450 610 100 525 M20x80 8KPGZ49/600FG 533761 600 800 200 290 645 595 145KPGZ49/630F 528745 249/630.541825 630 850 218 675 625 642 155KPGZ49/630L 528745 249/630.541825 630 850 218 675 475 640 109 552.5 M20x80 8KPGZ49/630FG 537279 630 850 218 310 675 625 155KPGZ49/670F 528746 249/670.541826 670 900 230 720 665 682 162.5KPGZ49/670L 528746 249/670.541826 670 900 230 720 505 675 115 587.5 M24x90 8KPGZ49/670FG 537280 670 900 230 325 720 665 162.5KPGZ49/710F 528747 249/710.541827 710 950 243 760 695 722 175KPGZ49/710L 528747 249/710.541827 710 950 243 760 535 715 121.5 622.5 M24x90 8KPGZ49/710FG 526073 710 950 243 350 760 695 175KPGZ49/750F 528748 249/750.541828 750 1000 250 800 745 762 177.5KPGZ49/750L 528748 249/750.541828 750 1000 250 800 565 755 125 657.5 M30x100 8KPGZ49/750FG 533414 750 1000 250 355 800 745 177.5KPGZ49/800F 528749 249/800.541829 800 1060 258 860 795 812 185KPGZ49/800L 528749 249/800.541829 800 1060 258 860 600 805 129 700 M30x100 8KPGZ49/800FG 532063 800 1060 258 370 860 795 185FAG · 40

g 3d 4g 1g 1 g 1D 1 h11 d m6 D H7D H7d H7 D 1 h11 d H82 m63 h8 t d 6 D 1 h11 D 1 h11 d D H7d H7m62 m6d m6g 3k kL L LDDDDs 2DDBBB iw g 2w L g 4 w g 2g 345°BKPGZ49..F KPGZ49..L KPGZ49..FGL Bearing relubrication D Seal relubrication B Sleeve relubricationHousing dimensions Grease quantity Mass≈≈a b c g 1 g 2 g 3 g 4 h h 1 k m n s Initial greasing Housing Bearingmm kg kg1170 375 130 400 210 40 425 820 975 230 M42 10 900 1701170 375 130 400 40 230 425 820 40 975 230 M42 14 900 1751170 375 130 400 210 425 820 975 230 M42 8 900 2201240 400 140 410 215 40 450 875 1050 240 M42 10 1000 2101240 400 140 410 40 235 450 875 40 1050 240 M42 14 1000 2101240 400 140 410 215 450 875 1050 240 M42 8 1000 2601320 420 145 420 220 40 475 930 1100 255 M48 13 1300 2401320 420 145 420 40 240 475 930 40 1100 255 M48 15 1300 2501320 420 145 420 220 475 930 1100 255 M48 10 1300 3001400 440 155 460 240 45 500 980 1150 270 M52 15 1500 2801400 440 155 460 45 260 500 980 40 1150 270 M52 20 1500 2901400 440 155 460 240 500 980 1150 270 M52 12 1500 3601500 480 165 480 250 46 535 1040 1225 295 M56 20 2100 3551500 480 165 480 46 270 535 1040 40 1225 295 M56 24 2100 3701500 480 165 480 250 535 1040 1225 295 M56 15 2100 4501570 500 175 500 260 47.5 570 1110 1300 310 M56 22 2500 4201570 500 175 500 47.5 280 570 1110 40 1300 310 M56 25 2500 4351570 500 175 500 260 570 1110 1300 310 M56 18 2500 5401660 535 185 560 290 53.5 600 1170 1375 325 M64 26 2700 4901660 535 185 560 53.5 317.5 600 1170 50 1375 325 M64 30 2700 5101660 535 185 560 290 600 1170 1375 325 M64 20 2700 6401750 550 195 590 305 52.5 630 1240 1450 335 M64 30 2800 5501750 550 195 590 52.5 332.5 630 1240 50 1450 335 M64 35 2800 5751750 550 195 590 305 630 1240 1450 335 M64 24 2800 7401850 570 205 600 310 56 670 1310 1550 345 M72 35 3300 6351850 570 205 600 56 337.5 670 1310 50 1550 345 M72 40 3300 6551850 570 205 600 310 670 1310 1550 345 M72 26 3300 810FAG · 41

SPLIT FAG PLUMMER BLOCK HOUSINGS FOR CONVERTERSLocating bearing housings KPGZ49..F and KPGZ49..FG,floating bearing housings KPGZ49..Lfor spherical roller bearings with a cylindrical borefor split spherical roller bearingsmh 1nbshcaHousing Bearing DimensionsMB cage Pin-type cage split d D B B i D 1 d 2 d 3 d 4 d 6 w w L t s 2 s 2DIN931 NumberFAG FAG FAG FAG mmKPGZ49/850F 528750 249/850.541830 850 1120 272 910 845 862 192.5KPGZ49/850L 528750 249/850.541830 850 1120 272 910 640 855 136 745 M30x110 8KPGZ49/850FG 537281 850 1120 272 385 910 845 192.5KPGZ49/900F 528751 249/900.541831 900 1180 280 960 895 912 195KPGZ49/900L 528751 249/900.541831 900 1180 280 960 675 905 140 787.5 M30x110 8KPGZ49/900FG 537282 900 1180 280 390 960 895 195KPGZ49/950F 528752 249/950.541832 950 1250 300 1015 945 965 205KPGZ49/950L 528752 249/950.541832 950 1250 300 1015 715 960 150 832.5 M36x110 8KPGZ49/950FG 534826 950 1250 300 410 1015 945 205KPGZ49/1000F 528753 249/1000.541833 1000 1320 315 1065 985 1015 225KPGZ49/1000L 528753 249/1000.541833 1000 1320 315 1065 750 1010 157.5 875 M36x130 8KPGZ49/1000FG 533567 1000 1320 315 450 1065 985 225KPGZ49/1060F 249/1060.541834 1060 1400 335 1135 1055 1075 237.5KPGZ49/1060L 249/1060.541834 1060 1400 335 1135 795 1070 167.5 927.5 M36x130 8KPGZ49/1060FG 537283 1060 1400 335 475 1135 1055 237.5KPGZ49/1120F 249/1120.541835 1120 1460 335 1195 1115 1135 237.5KPGZ49/1120L 249/1120.541835 1120 1460 335 1195 840 1130 167.5 980 M42x140 8KPGZ49/1120FG 537284 1120 1460 335 475 1195 1115 237.5KPGZ49/1180F 249/1180.541836 1180 1540 355 1260 1175 1195 250KPGZ49/1180L 249/1180.541836 1180 1540 355 1260 885 1190 177.5 1032.5 M42x140 8KPGZ49/1180FG 536806 1180 1540 355 500 1260 1175 250KPGZ49/1250F 249/1250.541837 1250 1630 375 1330 1245 1265 272.5KPGZ49/1250L 249/1250.541837 1250 1630 375 1330 940 1255 187.5 1095 M42x150 8KPGZ49/1250FG 537285 1250 1630 375 545 1330 1245 272.5KPGZ49/1320F 249/1320.541838 1320 1720 400 1400 1315 1335 290KPGZ49/1320L 249/1320.541838 1320 1720 400 1400 990 1325 200 1155 M48x180 8KPGZ49/1320FG 545161 1320 1720 400 580 1400 1315 290FAG · 42

g 3d 4g 1g 1 g 1D 1 h11 d m6 D H7D H7d H7 D 1 h11 d H82 m63 h8 t d 6 D 1 h11 D 1 h11 d D H7d H7m62 m6d m6g 3k kL L LDDDDs 2DDBBB iw g 2w L g 4 w g 2g 345°BKPGZ49..F KPGZ49..L KPGZ49..FGL Bearing relubrication D Seal relubrication B Sleeve relubricationHousing dimensions Grease quantity Mass≈≈a b c g 1 g 2 g 3 g 4 h h 1 k m n s Initial greasing Housing Bearingmm kg kg1960 600 220 630 325 56.5 710 1390 1600 360 M72 40 3700 7251960 600 220 630 56.5 352.5 710 1390 50 1600 360 M72 50 3700 7601960 600 220 630 325 710 1390 1600 360 M72 30 3700 9302060 620 230 660 340 55 740 1450 1700 370 M80 45 4300 8202060 620 230 660 55 375 740 1450 60 1700 370 M80 55 4300 8552060 620 230 660 340 740 1450 1700 370 M80 35 4300 10502200 660 250 680 350 55 800 1550 1820 390 M90 55 5200 10002200 660 250 680 55 385 800 1550 60 1820 390 M90 65 5200 10402200 660 250 680 350 800 1550 1820 390 M90 45 5200 12502330 650 255 720 370 67.5 830 1620 1980 360 M90 65 5770 12002330 650 255 720 67.5 412.5 830 1620 70 1980 360 M90 80 5390 12252330 650 255 720 370 830 1620 1980 360 M90 50 5680 15652450 740 275 780 400 70 880 1710 2000 460 M100 75 6800 14202450 740 275 780 70 435 880 1710 60 2000 460 M100 95 6800 14702450 740 275 780 400 880 1710 2000 460 M100 60 6800 17502560 740 285 800 410 70 920 1780 2150 460 M100 80 8000 15002560 740 285 800 70 452.5 920 1780 70 2150 460 M100 100 8000 15402560 740 285 800 410 920 1780 2150 460 M100 65 8000 19002700 780 300 820 420 72.5 970 1880 2300 480 M110 95 9000 17502700 780 300 820 72.5 462.5 970 1880 70 2300 480 M110 110 9000 18202700 780 300 820 420 970 1880 2300 480 M110 75 9000 22402850 820 320 850 435 85 1010 1985 2400 510 M110 110 11000 20702850 820 320 850 85 477.5 1010 1985 70 2400 510 M110 130 11000 21502850 820 320 850 435 1010 1985 2400 510 M110 85 11000 27503000 850 340 900 460 90 1080 2100 2500 520 M125 125 12800 24603000 850 340 900 90 502.5 1080 2100 70 2500 520 M125 170 12800 25003000 850 340 900 460 1080 2100 2500 520 M125 100 12800 3120FAG · 43

7 REFERENCES · 8 SELECTION OF SPECIAL FAG PUBLICATIONS7 References8 Selection of Special FAG PublicationsFAG works together with allbuilders of converter plants. Todate, more than 200 converters allover the world have been fittedwith FAG bearings and housings.Examples of new converters fittedwith FAG rolling bearings andhousings are presented in our “Examplesfrom Application Engineering”,copies of which we will sendyou on request.Moreover, FAG supplies replacementbearings for existing convertersall the time.Catalogue WL 41 520Publ. No. WL 00 106Publ. Nr. WL 17 107Publ. No. 80 100Publ. No. 80 102Publ. No. 80 111Publ. No. 80 123Publ. No. 80 134Publ. No. 80 135Publ. No. WL 81 115Publ. No. WL 81 116Publ. No. WL 82 102TI No. WL 00-11TI No. WL 80-14TI No. WL 80-46FAG Rolling BearingsW.L.S. Rolling Bearing Learning SystemModerne Lagerungen in Stahl- und Walzwerken(available in German only)Mounting and Dismounting of Rolling BearingsHow to Mount and Dismount Rolling BearingsHydraulicallyRolling Bearing Mounting Cabinet and MountingSets – a fundamental course for vocational trainingAll About the Rolling Bearings – FAG TrainingCourse on Rolling Bearings Theory and PracticeFAG Video: Mounting and Dismounting RollingBearingsFAG Video: Hydraulic Methods for Mounting andDismounting Rolling BearingsRolling Bearing LubricationArcanol · Rolling-Bearing Tested GreaseRolling Bearing DamageFAG Videos on Rolling BearingsMounting and Dismounting of Spherical RollerBearings with Tapered BoreFAG Hand Pump SetsFAG · 44

9 SPECIFICATION9 SpecificationOriginal equipment For which operatorReplacementBuilt by? Year of constructionCode wordConverter sizeDesign - Trunnion ring One-piece/multiple-piece/closed/horseshoe- Slag removal Slags are burnt/knocked off- Drive system Single-ended/double-endedSystems- Oxygen top blowing- Oxygen bottom blowing- Combined blowing process- Specially developed processesSub-assembly - Housing - With displacement sleeve KPG49/KPGZ49- With linear bearing- Other (double displacement sleeve, cylindrical roller bearing)- Bearing - Spherical roller bearing- Spherical roller bearing, splitCollective loads (Bearing loads F r and F a must be determined for every bearing location)- Maximum radial load (locating bearing) F rF =- Maximum radial load (floating bearing) F rL =- Maximum external thrust load F a =KinematicsSpeed; swinging angle; number of swingsAmbient influences Bearing ambient temperature, moisture, dust etc.Lubrication Grease lubrication - Grease type- Replenishment quantity- Relubrication intervalSealing- High-pressure packingMounting space- US rubber profile(if possible, enclose assembly drawing or sketch)- Location Locating bearing/floating bearing- Bearing seat Cylindrical/mounting on sleeve- Seat diameter Shaft/housing/fits- Bearing design Split/unsplitOther requirements - Design - Max. misalignment- Mounting requirements- Max. axial displaceability- Lubricant distribution- Wearing parts- Required housing material- Temperature of trunnion and housing- Technical specifications - Packing- Housing design- Preservation- Measuring report- Acceptance test reports- Plant test reports- Other - Warranty- Mounting instructions- LanguageFAG · 45

FAG · 46NOTES

NOTESFAG · 47

FAG · 48NOTES

FAG OEM und HandelAktiengesellschaftPostfach 1260D-97419 SchweinfurtGeorg-Schäfer-Straße 30D-97421 SchweinfurtTelefon ++49 9721 91 34 90Telefax ++49 9721 91 31 00E-mail: steel@fag.dewww.fag.deEvery care has been taken to ensure thecorrectness of the information contained inthis publication but no liability can beaccepted for any errors or omissions.We reserve the right to make changes inthe interest of technical progress.© by FAG 2000. This publication or partsthereof may not be reproduced withoutour permission.WL 17 104/2 EA/97/7/00