Bearing Damage and Failure Analysis
Premature bearing failure can occur for a variety of reasons. Each failure leaves its own special imprint on the bearing. By examining a failed or damaged bearing, it is possible in the majority of cases to establish the root cause and define corrective actions to prevent a recurrence.
(Rolling) bearings are among the most important components in the vast majority of rotating equipment. Exacting demands are made on their load carrying capability, running accuracy, vibration levels, environmental conditions, friction and frictional heat, life and reliability. Despite, or perhaps because of these high requirements, unplanned downtime as a result of the failure of the bearing can always occur.
Failures will generally cause economic losses due to loss of production, consequential damage of adjacent parts, and the cost of repairs – unplanned repairs are always many times more expensive than planned repairs.
Premature bearing failure can result from a variety of causes and each failure can leave its own unique mark on the bearing. Therefore, examination of a failed or damaged bearing can help to establish the root cause and define corrective actions to prevent a recurrence.
Our solution
By finding the root cause of a bearing damage, actions can be taken to prevent a recurrence of the problem. Bearing damage analysis is therefore an essential part of a Condition Monitoring (CM) program. In such programs, a deviating bearing condition can be determined in a (very) early stage, which means that targeted interventions can be taken.
However, such measurements do not always clarify the reason for this abnormal condition. By gaining insight into the source of the failure and acting accordingly, you simply increase the reliability and availability of the asset and installation.
Many factors can affect the service life of a bearing and its ability to reach its optimal life expectancy;
- Bearing (manufacturing) quality
- Storage
- Industry/application*
- Mounting
- Lubrication
- Sealing solution
* For example: In the pulp and paper industry, a major cause of bearing failure is contamination and inadequate lubrication.
The time span between the first (initial) damage and the bearing becoming unserviceable can vary considerably. At higher speeds, it can take a few seconds. In large, slow rotating machines, it can take months to years. Estimating at what stage in its life a bearing may need to be replaced can only be achieved through monitoring such as (continuous) vibration, temperature and/or noise measurements.
Offering
As an independent service provider, AVT Reliability (formerly Van Geffen Reliability) carries out bearing damage analysis in accordance with ISO 15243, which is based on 6 failure modes:
- Fatigue
- Wear
- Corrosion
- Electrical erosion
- Plastic deformation
- Fracture and cracking
In our inspection center the bearings, which are preferably offered in original condition, are visually inspected. Depending on the investigation and source of the problem, lubricant analysis and/or geometrical check of the bearing (housing and shaft) could also be part of the investigation.
The end product consists of a report in which conclusions are substantiated by means of images. Based on the final conclusion, recommendations follow with suggestions for improvement to prevent similar problems in the future with the ultimate goal of increasing the availability of the installation.
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