Why Bearings Fail on rotating machine and
- 1. CHESTERTON CAUSES OF BEARING FAILURE Improper Lubrication - 43% – How Much, How Often, What Type, What Thickness, – What Properties are Important Improper Mounting - 27% – Alignment, Work Area, General Practices, Inventory Control and Storage of Bearings Other Lubrication Causes - 21% – Separation in Storage – Temperature Limit Exceeded – Moisture Contamination – Other Contamination Fatigue - 9% Ultimate L10 Life Expectancy 64% of Bearing Failures are Lubrication Related IS Not The Whole Story In the Industry We Serve, Most Bearings Fail Due To Some Form of CORROSION
- 4. CHESTERTON EFFECT OF MOISTURE ON BEARING LIFE MOBIL OIL REPRINT Base Oil Description Water Content of Wet Oil, % Fatigue Life Reduction, Percent Test Equipment Author Reference Mineral Oil -Dried 0.002 48 0.014 54 4-Ball Scott, 1960 3.00 78 6.00 83 Squalene Oil 1.000 32-43 4-Ball Schatzberg & Felsen, 1969 Mineral Oil-Dried Not Stated, Moist environment 80 4-Ball Ciruna & Szieleit, 1972 Esters 0.050 29-73 #204 Bearings Fein, 1969 Mineral Oil-Based Hydraulic Oil 1.00 45 Angular Contact Bearings Felsen,1972
- 5. CHESTERTON WATER WASHOUT RESISTANCE ASTM D1264 (DIN 51807) % Weight Loss of Grease Measured Typical Grease (Lithium) - 5% Water Resistant Grease <2% Exceptional < 0.5% Water, 80o C (175o F) Grease Packed Bearings
- 6. 90 80 70 60 50 40 30 20 10 0.002 3.0 6.0 % WATER IN OIL % REDUCTION IN FATIGUE LIFE 48 78 83 Mobil Oil evaluation on bearing fatigue life – 0.002% water reduces fatigue life 48% – 6.0% water reduces fatigue life 83% – 0.002% water is 1 drop of water in a quart of oil WATER CONTAMINATION REDUCES BEARING LIFE SIGNIFICANTLY
- 7. CHESTERTON ^30K^ Contacts Here FRETTED SHAFTS & SLEEVES When shaft scoring occurs. A newly installed Lip Seal riding in same location on shaft will leak. Water penetrates the bearing immediately…in all cases corrosion is RAPID and Bearing Life is reduced
- 8. CHESTERTON ^30K^ Contacts Here Fretted Shafts & Sleeves When shaft scoring occurs. A newly installed Lip Seal riding in same location on shaft will leak. A SpediSleve Seal is often used. While an improvement, the seal eventually fails, water penetrates the bearing immediately…in all cases corrosion is RAPID and Bearing Life is reduced
- 9. CHESTERTON ^30K^ Contacts Here Numerous Self-Fretting Bearing Seals Available Some are just metallic shields as OEM
- 10. CHESTERTON CIC 7810-192 Exhibit III % FAILURE 10 0 80 60 40 20 1000 2000 3000 4000 TIME HOURS TO FAILURE NATIONAL CR CR (Mean Life 1844 hours) NATIONAL (Mean Life 645 hours) CIC 7810-192 Exhibit IV NATIONAL Hours to Failure MEDIAN RANK ( % Failure) CR WAVESEAL Hours to Failure ®. 182 188 275 300 556 648 772 902 1264 1366 6.7 16.32 25.94 35.57 45.19 54.81 64.43 74.06 83.68 93.30 144 576 1343 1736 1763 1973 1979 2946 2982 3003 REPRINT FROM A CR INDUSTRIES REPORT Percent Failure vs. Hours to Leakage Conventional Bearing Lip Seals Testing Data (57 Days) (125 Days)
- 11. CHESTERTON CORROSION PROTECTION Salt Fog Performance - ASTM B117 0 200 400 600 800 1000 1200 # 615 HTG Aluminum Complex Lithium Complex Hours to Failure 12 microns 37 microns Film Thickness
- 12. CHESTERTON BALL AND ROLLER BEARING LUBRICATION (OIL AND GREASES) Shaft Diameter <2.5cm 2.5cm- 5.1cm- 7.1 cm- 10.2cm 5.1cm 7.1cm 10.2cm <1” 1” to 2” 2” to 3” 3” to 4” Over 4” Operating Temperatures Lubricant Recommended Oil Viscosity Sec. @ 38o C Greases (100o F) NLGI No. Up to Up to Up to Up to Up to 1,000rpm 500rpm 300rpm 200rpm 100rpm 1,000 to 500 to 300 to 200 to 100 to 3,000rpm 1,500rpm 1,000rpm 750rpm 500rpm 3,000 to 1,500 to 1,000 to 750 to 500 to 10,000rpm 5,000rpm 3,000rpm 2,000rpm 1,000rpm Over Over Over Over Over 10,000rpm 5,000rpm 3,000rpm 2,000rpm 1,000rpm Below 0o C (32o F) 0o C (32o F) to 38o C (100o F) 38o C (100o F) to 93o C (200o F) Over 93o C (200o F) Below 0o C (32o F) 0o C (32o F) to 38o C (100o F) 38o C (100o F) to 93o C (200o F) Over 93o C (200o F) Below 0o C (32o F) 0o C (32o F) to 38o C (100o F) 38o C (100o F) to 93o C (200o F) Over 93o C (200o F) Below 0o C (32o F) 0o C (32o F) to 38o C (100o F) 38o C (100o F) to 93o C (200o F) Over 93o C (200o F) 150 to 185 0 to 1 250 to 350 1 400 to 1,000 2 1,500 to 2,500 2 to 3 150 to 185 0 to 1 250 to 350 1 400 to 600 2 700 to 1,000 2 90 to 120 0 to 1 150 to 185 0 to 1 250 to 350 1 500 to 1,000 2 33 to 85 0 to 1 50 to 110 0 to 1 75 to 250 1 350 to 550 2
- 13. CHESTERTON BALL AND ROLLER BEARING LUBRICATION (OIL AND GREASES) Shaft Diameter <2.5cm 2.5cm- 5.1cm- 7.1 cm- 10.2cm 5.1cm 7.1cm 10.2cm Operating Temperatures Lubricant Recommended Oil Viscosity Greases Sec. @ 38o C NLGI No. Up to Up to Up to Up to Up to 1,000rpm 500rpm 300rpm 200rpm 100rpm 1,000 to 500 to 300 to 200 to 100 to 3,000rpm 1,500rpm 1,000rpm 750rpm 500rpm 3,000 to 1,500 to 1,000 to 750 to 500 to 10,000rpm 5,000rpm 3,000rpm 2,000rpm 1,000rpm Over Over Over Over Over 10,000rpm 5,000rpm 3,000rpm 2,000rpm 1,000rpm Below 0o C 0o C to 38o C 38o C to 93o C Over 93o C Below 0o C 0o C to 38o C 38o C to 93o C Over 93o C Below 0o C 0o C to 38o C 38o C to 93o C Over 93o C Below 0o C 0o C to 38o C 38o C to 93o C Over 93o C 150 to 185 0 to 1 250 to 350 1 400 to 1,000 2 1,500 to 2,500 2 to 3 150 to 185 0 to 1 250 to 350 1 400 to 600 2 700 to 1,000 2 90 to 120 0 to 1 150 to 185 0 to 1 250 to 350 1 500 to 1,000 2 33 to 85 0 to 1 50 to 110 0 to 1 75 to 250 1 350 to 550 2
- 14. CHESTERTON 615 HIGH TEMPERATURE GREASE Very High Dropping Point, 300 o C ( 570 o F) Temperature Range - 40 o C to 204 o C (- 40 o F to 400 o F) Excellent Shear Resistance Excellent Shock Load and Wear Properties Very High Timken O.K. Load 29 kg (65 lbs.) Good Compatibility with Popular Greases Very High Water Washout Resistance, Below 1.6% Loss Extreme Water Tolerance (Add 30% Water and Still Get 20 kg (45 lbs.) Timken) Excellent Corrosion Resistance Highest Rating Possible for Automotive Bearing and Chassis Lubrication, NLGI GC-LB
- 15. CHESTERTON 615 HTG #1 “Best in Class” Extreme Pressure Properties and Antiwear Characteristics Exceptional Corrosion Protection Excellent Oxidation Resistance, Long Grease Life Excellent Resistance to Water Washout and Contamination Easily Pumpable, Good in Central Lubrication Systems Shear Stability and Grease Performance Maintained Over Wide Temperature Range Measurably Longer Bearing Life Temperature Range - 40 o C to 204 o C (- 40 o F to 400 o F)
- 16. CHESTERTON 615 HTG #1 General Rule of Thumb on Where to Use 615 # 1 Vs. the Standard 615: Where Operating Speeds are Higher Where Average Operating Temperatures are Lower When Customer Wants to Use in Automatic Lubrication System See Pocket Guide for Reference on Specific Operating Conditions
- 17. CHESTERTON TEMPERATURE EFFECT ON GREASE LIFETIME “ Most Mineral-Oil-Based Greases (of Adequate Dropping Point) Will Operate Successfully to About 121 o C (250 o F). A Smaller Number Can Handle 150 o C (300 o F). A Few Mineral-Oil- Based Greases Can Operate to About 177 o C (350 o F).” Relubrication Intervals - Rolling Element Bearings, 8 hours per Day 82 o C (180 o F) - 6 Months 104 o C (220 o F) - 3 Months 149 o C (300 o F) - 1 Month 193 o C (380 o F) - 1 Week 238 o C (460 o F) - 1 Day Source: NLGI, Lubricating Grease Guide
- 18. CHESTERTON LUBRI-CUP® Demand Feed System - Patented Metering System, Slowly Feeds Grease Only as Needed Prevents Over or Under Filling of Bearings – Eliminates Cause of Over 40% of Bearing Failures Low Feed Pressure Prevents Bearing Seal Failure Time Interval for Relubrication Increased by 6x Reduces Labor Cost to Regrease by Over 80% Can Be Mounted at Any Angle Transparent Grease Reservoir - Easy to See Grease Level Easy to Refill in Place
- 19. CHESTERTON REFILLING THE LUBRI-CUP® Refilling Lubri-Cup® with 615
- 20. CHESTERTON BEARING LIFE EXTENSION with LUBRICUP and 615 GREASE
- 21. CHESTERTON 615 HTG – Vibration Analysis Dryer Fan, Horizontal Bearing, Paper Mill 10.000 7.500 5.000 2.5000 20/10/99 14/11/99 09/12/99 03/01/00 28/01/00 Vibration, Khz 615 HTG APPLIED MPM Multiparamater Receiver, Wilcoxon Model 782A Sensor Alarm@4.0Khz Acceptable@3.0Khz
- 22. CHESTERTON 615 Additive Plating Technology 615 smoothes out surface roughness, reduces wear and vibration. Extends bearing life.
- 23. CHESTERTON 615 Additive Plating Technology
- 24. CHESTERTON 615 HTG – Technology Overview Chesterton's 615 is formulated using a surplus of Lubricity, EP and Anti-Wear additives, blended into a highly refined G III base oil, and thickened with a metallic organo- sulfonate complex. The resulting grease is "Best in Class" with respect to EP, Lubricity, Corrosion & Water Resistance. Unlike conventional Aluminum, Calcium, & Lithium soap and complexed thickeners, Chesterton 615 is immune to hydrolysis or water breakdown. The grease remains functional even in heavy water contaminated bearings and equipment. Chesterton's 615, with QBT (Quiet Bearing Technology) uses state of the art tribological technology to reduce vibration and ultra-sonic bearing noise. Proprietary polar and non-polar additives and thickener chemically fuse to the metal surfaces filling in asperities to form a "wear shield" on the metal surfaces. This fusion of lubricating additives and thickeners to the molecular surface of the metal, protects the bearings from WEAR, PRESSURE and WATER CORROSION.