Howden Fan Bearing Upgrade
Replacing failing rolling element bearings with a custom hydrodynamic solution for a high-temperature process fan.
Overview
Oiltech developed a custom hydrodynamic bearing solution to replace repeatedly failing rolling element bearings on a high-temperature process fan.
The result was a significantly more robust and reliable bearing system designed for a demanding operating environment.
The Challenge
A Howden process fan operating above 200°C in a hydrogen environment within an explosion-rated area was experiencing frequent bearing failures.
The existing rolling element bearings had a typical service life of approximately 6 months, resulting in:
- Repeated maintenance interventions
- High operational downtime
- Increased maintenance costs
Previous attempts to resolve the issue through OEM and alternative suppliers had not delivered a viable solution.
The Approach
Oiltech carried out a full engineering assessment to determine whether an alternative bearing solution could operate within the existing system constraints.
Key considerations included:
- Load conditions and operating environment
- Lubrication limitations (no external oil system preferred)
- Installation constraints within the existing fan assembly
The Solution
A hydrodynamic bearing system was designed to replace the rolling element bearings.
Key features of the solution:
- Use of conventional bearing materials for reliability
- Inclined bearing split line to suit load direction
- Compatibility with oil ring lubrication (no external system required)
This design allowed the bearing to operate effectively within the mechanical and environmental constraints of the application.
Production & Delivery
Despite a challenging manufacturing scope, the complete bearing assembly was delivered within an 8-week lead time.
This was achieved through:
- Concurrent design and production
- Close coordination with foundry partners
- Alignment with the customer's scheduled overhaul
Testing & Validation
The new bearing assembly was installed on a test stand prior to full deployment.
During testing:
- Initial thermal issues were identified and resolved through design modification
- Subsequent testing showed improved temperature performance and stability
The results demonstrated that the hydrodynamic design provided:
- Improved reliability
- More stable operation
- A viable long-term replacement for the original bearing system
Ongoing Development
Further improvements are being considered to optimise heat dissipation, including:
- Enhanced cooling strategies
- Potential oil system integration
- Additional thermal management solutions
Key Outcomes
Bearing Replacement
Replacement of unreliable rolling element bearings with a hydrodynamic system
Improved Reliability
Significant improvement in system reliability and stability
Reduced Maintenance
Reduced maintenance frequency and associated downtime
Problem Solved
Engineered solution where others had not succeeded
Why This Matters
This project demonstrates Oiltech's ability to:
- Solve complex, high-temperature bearing challenges
- Deliver practical engineering solutions within real-world constraints
- Support both OEM upgrades and operator-driven improvements
Facing a Similar Reliability Issue?
Speak to our engineering team about custom bearing solutions.