failure modes failure mechanism No Liquid Delivered Pump not primed Liquid returned backward Suction valve shut Discharge valve shut Suction piping blocked Discharge piping blocked Insufficient NPSH available Motor failure Impeller jammed by foreign body Impeller seized Supply tank / vessel empty No liquid supply in pipe Motor wired wrongly Specific gravity higher than specified Viscosity higher than specified Volute shattered Drive coupling broken Drive shaft broken Bearings in housing seized Bearings in motor seized Motor power supply loss Insufficient Flow Speed tuned down Discharge valve partially closed Cavitation Gas / vapour entrainment (poor suction piping design) Turbulence (fittings / valves too close to pump suction) Turbulence (restriction in line prior pump suction) Broken impeller Bent vanes Incorrect impeller Incorrect impeller diameter System head too high Instrumentation error Suction valve blocked Suction valve partially closed Discharge valve blocked Discharge valve partially closed Suction piping blocked Discharge piping blocked Motor wired wrongly Motor rotating backwards Rotational speed too low Excessive air / vapour trapped in liquid Insufficient NPSH available Impeller clogged Specific gravity higher than specified Viscosity higher than specified Intermittent Flow Air leak in suction line Excessive air / vapour trapped in liquid Loss of prime e.g. liquid rans back through check / foot valve Insufficient Pressure Instrumentation error Broken impeller Bent vanes Incorrect impeller Incorrect impeller diameter Cavitation Rotating backwards Rotational speed too low Insufficient NPSH available Assembled incorrectly Pump Leaking Mechanical seal passes Stuffing box packing excessively worn (for packed gland) Stuffing box bore damaged (for packed gland) Pump shaft surface damaged (for packed gland) Packing installed incorrectly (for packed gland) Flange leaks (flange not sealing) Flange leaks (gasket not sealing) Assembled incorrectly Volute cracked Volute corroded Volute eroded Inadequate foundation size and design 5 72 Sources of Information: http://www.vibanalysis.co.uk/technical http://www.elongo.com/pdfs/BearingFailures990519.pdf The McNally Institute CD http://www.delzer.com/Rexnord/falk/108010.pdf Impeller Impeller failure modes failure mechanism Chamber / Vane Wear Erosion (high flow rate) Erosion (internal flow recirculation) Erosion (suspended material on fluid) Pump-out vanes worn (if part of impeller design) Blocked balance holes between inlet and back of impeller (if part of impeller design) Cavitation Corrosion Chemical corrosion Galvanic corrosion Cavitation Damage Long suction pipe Small diameter suction pipe Blocked suction pipe Partially closed valve in suction line NPSH available is to little Liquid temperature rise Loose on Shaft Assembled incorrectly Taper seat damaged Nut corroded Nut under torqued Incorrect impeller bore Wear Ring Damage Recirculation Solids suspended in product Erosion (high flow rate) Cavitation (pressure falls across cut water, like in a labyrinth) Incorrect impeller bore alignment 5 24 Blocked balance holes between inlet and back of impeller (if part of impeller design) Volute Volute failure modes failure mechanism Wear Ring Damage Recirculation Solids suspended in product Erosion (high flow rate) Cavitation Cut Water Wear Erosion (high flow rate) Erosion (internal flow recirculation) Cavitation Corrosion Chemical corrosion Galvanic corrosion Cracked Pipe stress Soft foot dsitortion 3 11 Shaft Shaft failure modes failure mechanism Snapped Shaft Bending fatigue (surface crack initiated) Bending fatigue (surface corrosion initiated) Bending fatigue (surface damage initiated) Tortional fatigue (surface crack initiated) Tortional fatigue (surface corrosion initiated) Tortional fatigue (surface damage initiated) Shaft diameter too small for application Shaft material tensile strength too low for application Shaft rotating while bent by service load Equipment jammed by product Equipment bearing seized Overloaded during operation Chemical attack Galvanic corrosion Temperature changes metallurgical properties Stress raiser, scratches, mechanical damage (e.g. Pipe wrench used to turn seized shaft) Stress raiser, excessive interference fit with mating component Stress raiser, welding heat affected zone Fillet radius too small Fretting and pitting corrosion Surface defects such as welding inclusions Deep machining marks or scratches Poor blending of fillet radius into journal Wear grooves at or close to fillet radius Keyway Broken Keyway fatigue Improper keyway design Inadequate shoulder fillet radius Machining defects (residual stresses induced) Machining dimension /tolerance error Overloaded during operation 2 30 Stress raiser, scratches, mechanical damage (e.g. Pipe wrench used to turn seized shaft) Shaft Seal (Mechanical) failure modes Accelerated Seal Face Wear Edge Chipping Seal Face Cracked / Fractured Open Seal Face - Axial Open Seal Face - Radial Static O-Ring Seal Failure Dynamic O-Ring Seal Failure Product Leakage Seal Embrittlement Fractured Spring Clogged Spring Axial Shear Torsional Shear Seal Face Distortion Slow Mechanical Response Bellows Cracked 16 Shaft Seal (Mechanical) failure mechanism Abrasives suspended in the process fluid Abrasives in solution in the process fluid (crystallisation) Abrasives from the environment such as sand and dirt Abrasives from the environment such as product Adhesive wear at start-up (faces contacting) Carbonisation on faces (high temperature, high contact load) Stuck faces (film transfer of seal face material-of-construction) Scale build-up (filming) Vaporisation between faces (high temperature, high contact load) Vaporisation between faces (loss of lubrication film) Dirt dragged or blown across the faces when they separate Blistered carbon face from air trapped in carbon expanding and blowing out Surface finish deterioration Pump shaft out-of-roundness Blistering (seal face sub-surface vaporisation) Excessive start-up torque Excessive shaft end play Seal installation misalignment Pump shaft misalignment to driver Pump shaft bent Shaft bent due to overhang because impeller is located too far away from the bearing Selective leaching is picking up elements from the piping system and depositing them on the seal face One or both of the seal faces is not lapped flat to within three helium light bands (0,000033" or 1 micron) Mishandling damage to a lapped face Damaged faces during delivery Uneven clamping not 'equal and opposite' across the stationary face One or both of the faces is being distorted by a temperature differential Water hammer pressure surge Carbon in metal holder under residual stress and not stress relieved remove residual stress in the lapped face Oxidizing agents and halogens attack all forms and grades of carbon-graphite De-ionized water can attack carbon seal Chemicals attack carbon seal Silicon carbide seal attacked by acidic liquid Solvent flushed through pipes for cleaning attacked seal material Poor / wrong carbon grade selected Corrosion rate increased by temperature rise (10 degree Centigrade rise doubles corrosion rate in many fluids) The plating or hard coating is coming off from the hard face Rotating face is not centered in the stationary face and is running off the edge of the stationary face Dirt or solids are clogging the movable components Foreign object has passed into the seal chamber and is interfering with the free movement of the seal Solids have packed up in front of the inner seal in a "back to back" dual seal design Seal face rocks due to installation misalignment Vaporisation on seal faces Pump shaft excess whip Pump shaft excess deflection Vibration transferred to seal (pipe harmonics) Vibration transferred to seal (out-of-balance) Vibration transferred to seal (loose mounting) Vibration transferred to seal (running at critical speed) Vibration transferred to seal (Cavitation) Vibration transferred to seal (Running well off BEP (for single volute)) Water hammer pressure surge Run dry (no product) Run dry (no barrier / quench fluid) Run dry (cavitation) Run dry (pump-out vanes create low pressure / vacuum) Thermal shock (distortion from sudden high temperature rise) High temperature differential across the ceramic Excessive fluid pressure on seal Water hammer pressure surge Excessive pressure velocity (high pressure at slow rotational speed) Stress corrosion cracking Barrier / quench fluid failure The elastomer is swelling up under a carbon face. The shaft is hitting the stationary face or the rotating seal face is hitting a stationary object Product is solidifying between the faces and they are breaking at start up Excessive vibration is causing the drive or anti-rotation pins to crack the face Cracked during assembly / disassembly. Inspect crack for tell-tale signs of discolouration deep inside seal indicating breakage prior installation Shaft / sleeve is oversize Fretting corrosion between seal and shaft A gasket or fitting is protruding into the stuffing box and touching seal component Pump shaft end play Trust movement Water hammer pressure surge Thermal growth differential Impeller adjustment towards wet end of pump opens seal faces Product is vaporizing and separating the faces allowing solid material to blow across the lapped face Dynamic elastomer not free to move due to oversize shaft Dynamic elastomer not free to move due rough surface finish Dynamic elastomer not free to move due to sticking to shaft from high surface temperature Dynamic elastomer not free to move due to contaminants locking it in place Chipper edges causing face separation Spiral failure where seal component stick and cause internal twist Springs stick and prevent dynamic movement Seal as mishandled during installation Elastomer seals on a porous carbon surface rather than a hard metal surface. When the shaft rotation stops the elastomer relaxes and flows into the carbon surface irregularities Set screws have come loose Set screws corroded Initial setting of seal incorrect and once experiencing a little wear the spring load has gone Axial temperature growth of the shaft has altered the original setting Shaft sleeve moved when the impeller was tightened to the shaft Seal was set-screwed to a hardened shaft or sleeve and has slipped due to vibration Spring has been painted and cannot compress fully Cartridge seal static seal has jammed and preventing proper location of faces Inner seal of a dual seal application was not balanced in both directions and is opening up with reversing pressure Single spring found in some seal designs was wound in the wrong direction for the shaft rotation Rotating bellows seal has lost cooling and the anti-vibration lugs are engaging the shaft. Normal shaft movement or vibration will cause the faces to open Pump shaft bent (excess run-out) Pump shaft excess whip Pump shaft excess deflection Out-of-balance impeller Fretting corrosion under seal (by axial movement transmitted to the seal) Excessive elastomer temperature Excessive fluid pressure Installation error (elastomer damage) Corrosive attack (incompatible chemical) Water hammer Compression set (extreme temperature operation causes elastomer elasticity memory loss) Compression set (product is too hot) Elastomer swollen by incompatible chemical product Elastomer has extruded because of high pressure or excessive clearance. Elastomer is cracked from too long on the shelf (particularly Buna-N (nitrile rubber)) Elastomer is cracked (High heat hardens elastomer and cracks) Elastomer is cracked (cryogenic temperatures) The elastomer is twisted, cut or damaged on installation Shaft is corroded, damaged, or fretted under the elastomer Seal body O-ring groove is damaged or coated with a solid material Wrong lubricant was used at installation to aid fitting the elesomer on the shaft Oxidizers can attack the carbon black in O-rings and other elastomers Distorted sleeve or shaft Fretting corrosion (axial movement transmitted to the seal) Excessive elastomer temperature Excessive fluid pressure Installation error (elastomer damage) Corrosive attack (incompatible chemical) Water hammer pressure surge Compression set (extreme temperature operation causes elastomer elasticity memory loss) Compression set (product is too hot) Elastomer swollen by incompatible chemical product Solids attached at dynamic elastomerand preventing it from moving Elastomer has extruded because of high pressure or excessive clearance. Elastomer is cracked from too long on the shelf (particularly Buna-N (nitrile rubber)) Elastomer is cracked (High heat hardens elastomer and cracks) Elastomer is cracked (cryogenic temperatures) The elastomer is cut or damaged on installation Oxidizers can attack the carbon black in O-rings and other elastomers Insufficient seal face compression Installation error (wrongly located on shaft) Installation error (mounting screws loosen) Loss of spring tension Foreign material contamination on faces Uinbalanced seals in dual seal applications Application changes from vacuum to a positive pressure. O-rings are the only common elastomers that seal in both directions. Wedges, U cups, and chevrons do not have this ability The glue between the carbon and its metal holder is not compatible with the product Differential expansion between 'pressed-in' carbon and its metal holder Out-of-roundness of 'shrunk-in' carbon caused by the tolerace on the carbon outside diameter and the metal holder inside diameter Gland gasket has failed Cracked bellows Barrier / quench leck misdiagnosed as product leak Contaminants in pumped fluid Contaminants in barrier / flush fluid Pumped fluid / seal material-of-construction chemical incompatibility Thermal degradation of material-of-construction Idle periods between use Material flaw Manufacturing flaw Stress corrosion due to tooling marks Corrosive attack Seal installation misalignment Pumped fluid contaminated with solids Barrier / flush fluid contaminated with solids Excessive pressure loading Improper lubrication causes excessive torque Excessive fluid pressure surges Excessive fluid pressure on seal Foreign material trapped between faces Excessive pressure velocity (high pressure at slow rotational speed) Insufficient seal face lubrication film thickness Excessive squeeze on seal faces Excessive seal swell Seal extrusion Metal-to-metal contact due to out of alignment Seal rub (shaft deflection causes the mechanical seal to contact the bore of the stuffing box) Internal erosion (barrier / flush fluid contaminated with solids) The product interfers with the free movement of the components. The fluid is crystallising, solidifying, viscous A gasket or fitting is protruding into the stuffing box and touching seal component Foreign object has passed into the seal chamber and is interfering with the free movement of the seal Stress corrosion cracking 178 This illustration describes a mechanical seal that can be classified into several different categories: Cracked during assembly / disassembly. Inspect crack for tell-tale signs of discolouration deep inside seal indicating breakage prior installation Elastomer seals on a porous carbon surface rather than a hard metal surface. When the shaft rotation stops the elastomer relaxes and flows into the carbon surface irregularities Inner seal of a dual seal application was not balanced in both directions and is opening up with reversing pressure Rotating bellows seal has lost cooling and the anti-vibration lugs are engaging the shaft. Normal shaft movement or vibration will cause the faces to open Application changes from vacuum to a positive pressure. O-rings are the only common elastomers that seal in both directions. Wedges, U cups, and chevrons do not have this ability Out-of-roundness of 'shrunk-in' carbon caused by the tolerace on the carbon outside diameter and the metal holder inside diameter This illustration describes a mechanical seal that can be classified into several different categories: Roller Bearings Roller Bearings failure modes failure mechanism Bearing Wear Abrasive particles, such as grit or swarf that have entered the bearing Lack of cleanliness before and during mounting operation Ineffective seals Lubricant contaminated by worn particles from brass cage Lubrication contamination (wear particles) Lubricant additives gradually been used up Lubricant has lost its chemical lubricating properties Lubricant loss through seal Lubricant has leaked away Lubrication contamination (external liquid ingress) Lubrication contamination (liquid product ingress) Lubrication contamination (dust and dirt ingress) Lubrication contamination (solid product ingress) Lubrication contamination (sand and material from within castings, flaking protective coatings, rust from inside castings, etc) Bent shafts Skewed ring from burrs or dirt on bearing mounting surfaces and bearing abutment surfaces Shaft shoulders which are not perpendicular to the bearing abutment surface Locking nut faces which are not perpendicular to the bearing seating face Non-concentric bores on which the bearings are mounted leading to an angular axis of rotation of the shaft and thus misaligning the rotating axis of the bearings Reverse Loading Failure is one such failure which occurs due to the bearing getting loaded in the opposite direction in which it is intended to bear the load. This type of failure is quite common in angular contact and thrust bearings Bad bearing supplied (especially cheap bearings made of inferior material) Solids were introduced into the system during the assembly process because of a lack of cleanliness Shaft coupling bore machined off-center / skewed Bearing Overheated Clearance looseness (shaft shrinkage) Clearance looseness (housing expansion) Clearance looseness (loose fit shaft) Clearance looseness (loose fit housing) Spalling of race ways Inadequate or improper lubrication Excessive preload on account of fits being too tight Insufficient heat transmission from housing due to build-up of material and product over casing Rapid cooling of housing causes shrinkage and reduction in clearance Incorrect viscosity of the lubricant Incorrect lubricant chemistry Form 'varnish' residue and 'coke' at elevated temperature that destroys the ability of the grease or oil to lubricate the bearing Oil level too low Oil level too high Plugged oil return holes Over greased bearing Under greasing bearing Suction pressure too high and causing axial thrust Out-of-balance rotating element Hydrogen embrittlement or blistering by water within microscopic cracks on raceways and rolling elements Insufficient clearance in labyrinth seals Base frame distorted Process temperature conducted along shaft Normal aspiration as the pump cooled down, and the moisture laden atmosphere entered the bearing case Axially mislocated shaft coupling Grease or lip seals too tight Brinell and False Brinell Hit during mounting / installation Dented by self-weight load when standing-still Dented by vibration impact loads when standing-still e.g. machinery transported on rough roads Situated close to machinery producing vibrations Mounting pressure applied to the wrong ring during installation Excessively hard drive-up on tapered seating during installation Overloading while not running Excessive preload on account of fits being too tight Smearing on installation produces microscopic surface cracks Stuffing box packing overtightened Creeping Slippage Ring fit is oversize Ring fit is worn Fretting corrosion Smearing rollers and raceways Smeared roller ends from sliding under heavy axial loading and with inadequate lubrication Roller acceleration on entry into the loaded zone due to too much clearance Load is too light for the speed As bearings are being mounted, the ring with the roller and cage assembly is entered askew, without being rotated during insertion Blows applied to the wrong ring or heavy preloading without rotating the bearing External surfaces of heavily loaded bearings from movement of the bearing ring relative to its shaft or housing Slip fit is too loose on sliding ring Smearing Thrust Ball Bearings due to rotational speed is too high in relation to the loading. The centrifugal force then impels the balls to the outer part of the shallow raceways. There the balls do not roll satisfactorily and a great deal of sliding occurs at the ball-to-raceway contacts Surface Distress Cracks Inadequate lubrication Improper lubrication Corrosion - Deep seated rust Presence of water, moisture over a long period of time Presence of corrosive substances Corrosion - Fretting Fit too loose Shaft seating with errors of form Housing seating with errors of form Electrical Erosion Electrical fluting due to passage of electric current through rotating ring Electrical fluting due to passage of electric current through non-rotating ring Earthing problem in equipment Raceway Spalling Excessive preload on account of fits being too tight Excessive drive-up on a tapered seating Excessive preload adjustment e.g. Single row angular contact ball bearings or taper roller bearings Temperature differential between inner and outer rings too great Foreign particles in the lubricant, metal particles from within the system, etc allow wear particles to be jammed between roller and race causing impact stress Cavitation induced stress overload Vibration induced stress from running off BEP Clearance tightness (shaft expansion) Clearance tightness (housing shrinkage) Clearance tightness (tight shaft fit) Clearance tightness (tight housing fit) Pinched bearing (shaft ovality excessive) Pinched bearing (housing ovality excessive) Pinched bearing (pipe stress distortion) Pinched bearing (Soft foot causing frame distortion) Distorted bore of Plummer blocks from mounting on an uneven base becoming oval when the base bolts are tightened Incorrect mounting, which results in axial loading, e.g. excessive preloading of angular contact ball bearings and taper roller bearings. The non-locating bearing has jammed. Axial freedom of movement has not been sufficient to accommodate the thermal expansion. Cracked Rings Blows, with a hammer or hardened chisel, have been directed against the ring when the bearing was being mounted Fatigue cracks (installation misalignment cyclic overloading) Fatigue cracks (differential frame growth misalignment cyclic overloading) Fatigue cracks (bent shaft cyclic overloading) Fatigue cracks (shaft deflection from running off BEP) Fatigue cracks (Smearing during installation causes surface crack initiation) Fatigue cracks (Fretting corrosion caused crack initiation) Clearance tightness (shaft expansion) Clearance tightness (housing shrinkage) Clearance tightness (tight shaft fit) Clearance tightness (tight housing fit) Sliding under heavy axial loading and with inadequate lubrication Cage Damage Fatigue cracks (vibration forces of inertia are so great as to cause fatigue cracks to form in the cage material, after a time leading to cage fracture) Fatigue cracks (run at speeds in excess of cage design subjecting it to heavy forces of inertia that may lead to fractures) Fatigue cracks (bearing rings are fitted out of alignment with each other, the path of the rollers take an oval configuration. If the cage is centred on the rollers, it has to change shape for every revolution it performs) Severe acceleration and retardation, in conjunction with fluctuations in speed cause forces of inertia. These give rise to considerable pressure on cage contacting surfaces, with consequent heavy wear Inadequate lubrication Abrasive particles Fragments of flaked material or other hard particles may become wedged between the cage and a rolling element, preventing the latter from rotating round its own axis Bearing is severely misaligned Seized Bearing Metal to metal contact cause micro-welding Clearance tightness causes lack of rolling element rotation Inadequate lubrication (viscosity too low) Inadequate lubrication (moisture in lubricant) Excessive mechanical overload (bearing too small in surface area) Excessive mechanical overload (high operating load) Rolling element jammed and not rolling due to solid contaminant Rolling element jammed and not rolling due mechanical stress Grease or lip seal contact on the shaft, right next to the bearings. These seals can add as much as 38C (100F) to the shaft temperature Lock nut came loose 13 129 Category Lube contamination by inclusion Lube contamination by inclusion Lube contamination by ingress Lube contamination by ingress Lube contamination by ingress Lube chemical degradation Lube chemical degradation Lubricant loss Lubricant loss Lube contamination by ingress Lube contamination by ingress Lube contamination by ingress Lube contamination by ingress Lubrication contamination (sand and material from within castings, flaking protective coatings, rust from inside castings, etc) Lube contamination by ingress Installation error Skewed ring from burrs or dirt on bearing mounting surfaces and bearing abutment surfaces Installation error Shaft shoulders which are not perpendicular to the bearing abutment surface Installation error Installation error Non-concentric bores on which the bearings are mounted leading to an angular axis of rotation of the shaft and thus misaligning the rotating axis of the bearings Installation error Reverse Loading Failure is one such failure which occurs due to the bearing getting loaded in the opposite direction in which it is intended to bear the load. This type of failure is quite common in angular contact and thrust bearings Installation error Material strength failure Solids were introduced into the system during the assembly process because of a lack of cleanliness Lube contamination by inclusion Installation error Incorrect fits and tolerance Incorrect fits and tolerance Incorrect fits and tolerance Incorrect fits and tolerance Lube contamination by inclusion Lube contamination by inclusion Lube chemical degradation Insufficient heat transmission from housing due to build-up of material and product over casing Temperature change Temperature change Lube chemical degradation Lube chemical degradation Form 'varnish' residue and 'coke' at elevated temperature that destroys the ability of the grease or oil to lubricate the bearing Lube chemical degradation Lubricant loss Lubricant excessive Lubricant excessive Lubricant excessive Lubricant insufficient Operational induced stress Unbalance Hydrogen embrittlement or blistering by water within microscopic cracks on raceways and rolling elements Lube contamination by ingress Incorrect fits and tolerance Incorrect fits and tolerance Temperature change Normal aspiration as the pump cooled down, and the moisture laden atmosphere entered the bearing case Lube contamination by ingress Installation error Installation error Installation error Operational induced stress Dented by vibration impact loads when standing-still e.g. machinery transported on rough roads Operational induced stress Operational induced stress Installation error Installation error Operational induced stress Incorrect fits and tolerance Installation error Installation error Incorrect fits and tolerance Incorrect fits and tolerance Incorrect fits and tolerance Smeared roller ends from sliding under heavy axial loading and with inadequate lubrication Incorrect fits and tolerance Roller acceleration on entry into the loaded zone due to too much clearance Incorrect fits and tolerance Incorrect fits and tolerance As bearings are being mounted, the ring with the roller and cage assembly is entered askew, without being rotated during insertion Installation error Blows applied to the wrong ring or heavy preloading without rotating the bearing Installation error External surfaces of heavily loaded bearings from movement of the bearing ring relative to its shaft or housing Incorrect fits and tolerance Incorrect fits and tolerance Smearing Thrust Ball Bearings due to rotational speed is too high in relation to the loading. The centrifugal force then impels the balls to the outer part of the shallow raceways. There the balls do not roll satisfactorily and a great deal of sliding occurs at the ball-to-raceway contacts Operational induced stress Lubricant insufficient Lube chemical degradation Lube contamination by ingress Lube contamination by ingress Incorrect fits and tolerance Incorrect fits and tolerance Incorrect fits and tolerance Electrical induced damage Electrical induced damage Electrical induced damage Incorrect fits and tolerance Incorrect fits and tolerance Excessive preload adjustment e.g. Single row angular contact ball bearings or taper roller bearings Incorrect fits and tolerance Incorrect fits and tolerance Foreign particles in the lubricant, metal particles from within the system, etc allow wear particles to be jammed between roller and race causing impact stress Lube contamination by ingress Operational induced stress Operational induced stress Incorrect fits and tolerance Incorrect fits and tolerance Incorrect fits and tolerance Incorrect fits and tolerance Incorrect fits and tolerance Incorrect fits and tolerance Incorrect fits and tolerance Incorrect fits and tolerance Distorted bore of Plummer blocks from mounting on an uneven base becoming oval when the base bolts are tightened Installation error Incorrect mounting, which results in axial loading, e.g. excessive preloading of angular contact ball bearings and taper roller bearings. Installation error Incorrect fits and tolerance Axial freedom of movement has not been sufficient to accommodate the thermal expansion. Installation error Blows, with a hammer or hardened chisel, have been directed against the ring when the bearing was being mountedInstallation error Installation error Incorrect fits and tolerance Installation error Operational induced stress Fatigue cracks (Smearing during installation causes surface crack initiation) Installation error Incorrect fits and tolerance Incorrect fits and tolerance Incorrect fits and tolerance Incorrect fits and tolerance Incorrect fits and tolerance Installation error Fatigue cracks (vibration forces of inertia are so great as to cause fatigue cracks to form in the cage material, after a time leading to cage fracture) Unbalance Fatigue cracks (run at speeds in excess of cage design subjecting it to heavy forces of inertia that may lead to fractures) Operational induced stress Fatigue cracks (bearing rings are fitted out of alignment with each other, the path of the rollers take an oval configuration. If the cage is centred on the rollers, it has to change shape for every revolution it performs) Installation error Severe acceleration and retardation, in conjunction with fluctuations in speed cause forces of inertia. These give rise to considerable pressure on cage contacting surfaces, with consequent heavy wear Operational induced stress Lubricant insufficient Lube contamination by inclusion Fragments of flaked material or other hard particles may become wedged between the cage and a rolling element, preventing the latter from rotating round its own axis Lube contamination by ingress Installation error Lube chemical degradation Incorrect fits and tolerance Lube chemical degradation Lube chemical degradation Design error Operational induced stress Lube contamination by ingress Incorrect fits and tolerance Grease or lip seal contact on the shaft, right next to the bearings. These seals can add as much as 38C (100F) to the shaft temperature Design error Installation error SKF List of bearing failure causes - Bearing failures and their causes - Product information 401 Wear Wear caused by abrasive particles Wear caused by inadequate lubrication Wear caused by vibration Indentations Indentations caused by faulty mounting or overloading Indentations caused by foreign particles Smearing Smearing of roller ends and guide flanges Smearing of rollers and raceways Raceway smearing at intervals corresponding to the roller spacing Smearing of external surfaces Smearing in thrust ball bearings Surface distress Corrosion Deep seated rust Fretting corrosion Damage caused by the passage of electric current Flaking (spalling) Flaking caused by preloading Flaking caused by oval compression Flaking caused by axial compression Flaking caused by misalignment Flaking caused by indentations Flaking caused by smearing Flaking caused by deep seated rust Flaking caused by fretting corrosion Flaking caused by fluting or craters Cracks Cracks caused by rough treatment Cracks caused by excessive drive-up Cracks caused by smearing Cracks caused by fretting corrison Cage damage Vibration Excessive speed Wear Blockage Other causes of cage damage SKF List of bearing failure causes - Bearing failures and their causes - Product information 401 Wear caused by abrasive particles Wear caused by inadequate lubrication Indentations caused by faulty mounting or overloading Indentations caused by foreign particles Smearing of roller ends and guide flanges Smearing of rollers and raceways Raceway smearing at intervals corresponding to the roller spacing Damage caused by the passage of electric current Flaking caused by oval compression Flaking caused by axial compression Flaking caused by deep seated rust Flaking caused by fretting corrosion Flaking caused by fluting or craters Cracks caused by rough treatment Cracks caused by excessive drive-up Cracks caused by fretting corrison Flexible Drive Coupling Flexible Drive Coupling failure modes failure mechanism (Tyre Coupling) Premature Component Wear Shaft misalignment axial Shaft misalignment parallel Shaft misalignment angular Shaft thermal expansion Severe distortion under maximum instantaneous torque (wind-up) Erratic/pulsating/high-inertia loads Excessive back-lash within coupling for shock loads Rotational speed is beyond design RPM Loosening of the coupling's fastener to the shaft Changed assembly gap between hubs of the coupling Damaged or broken components Bore machined askew Bore machined non-concentric Excessive shaft end float Bent shafts, excessive run-out Excess back-lash between coupling parts / components Material-of-Construction incorrect for duty loads / torque Hub Damage Shaft out-of-round or incorrect form Split / cracked due to improper interference fit Movement of the hub on the shaft Shaft surface finish too rough and offers insufficient surface area for support Shaft not straight Shaft under bore nicked, hammer-rash or damaged Axial misalignment Concentrated heat on the hubs cause distortion Keyway Failure Excessive shaft interference fit High torque load transmitted through the key Excessively loose fitting key allows high impact on start / reverse Key Failure Excessively loose fitting key allows high impact on start / reverse Improper key material selected Corrosion Chemical attack High torque load transmitted through the key Elastometric Element Failure Excessive torque loading Atmospheric contamination / deterioration Chemical attack Overload Torsional vibrations (look for liquefaction of the material internal of the insert) Coupling out-of-balance Cracked due to rubber hardening from chemical contamination Elastomer material has limited service life Excessive high temperature Flange Fastener Failure High starting or impact loads occur in combination with reversing service or severe load fluctuations exist, fasteners have failed in reverse bending fatigue Bending fatigue loading may also be characterized by: fretting corrosion on the bolt body diameter, imbedding of the bolt washer face diameter into the sleeve, wallowing out of the sleeve flange holes and/or offset of the bolt body diameter. Insufficient fastener tightening torque System torsional vibration Reversing loads which exceed the flange joint capacity System was subjected to unexpected overloads Elongated bolt holes due to fastener impact (fastener loosened off) Elongated bolt holes due to fastener impact (fastened insufficiently tight) Cyclic fatigue life exceeded Shaft passes through natural frequncy and large vibrations / movements cause micro-motion of coupling flanges 6 52 Sources of Information: http://pt.rexnord.com/products/e-catalog/catalog/CachedImages/0000001/t004_r00171_v0.pdf http://motionsystemdesign.com/mag/couplings_shafts/ Flexible Drive Coupling failure mechanism (Gear Coupling) Gear couplings, frictional movment on teeth due to misalignment Gear couplings, loss of lubricant film Gear couplings, not relubricated as maintenance Gear couplings, contaminated lubricant Severe distortion under maximum instantaneous torque (wind-up) Gear couplings, sleeve seal cage end ring failures may result from high misalignment, improper gap setting and/or hub axial float Gear couplings, teeth lock-up due to excessive misalignment Gear couplings, teeth lock-up due to excessive misalignment Shaft surface finish too rough and offers insufficient surface area for support Excessively loose fitting key allows high impact on start / reverse Excessively loose fitting key allows high impact on start / reverse Torsional vibrations (look for liquefaction of the material internal of the insert) Cracked due to rubber hardening from chemical contamination High starting or impact loads occur in combination with reversing service or severe load fluctuations exist, fasteners have failed in reverse bending fatigue Bending fatigue loading may also be characterized by: fretting corrosion on the bolt body diameter, imbedding of the bolt washer face diameter into the sleeve, wallowing out of the sleeve flange holes and/or offset of the bolt body diameter. Elongated bolt holes due to fastener impact (fastener loosened off) Elongated bolt holes due to fastener impact (fastened insufficiently tight) Shaft passes through natural frequncy and large vibrations / movements cause micro-motion of coupling flanges Flexible Drive Coupling failure mechanism (Jaw Coupling) Jaw Coupling, elastomer compression set from over-torque Jaw Coupling, elastomer compression set from normal use Jaw Coupling, excessive hub spider leg wear Jaw Coupling, shaft radial misalignment Jaw Coupling, shaft angular misalignment Jaw Coupling, shaft axial misalignment Jaw Coupling, hub spider jaws sheared High starting or impact loads occur in combination with reversing service or severe load fluctuations exist, fasteners have failed in reverse bending fatigue Bending fatigue loading may also be characterized by: fretting corrosion on the bolt body diameter, imbedding of the bolt washer face diameter into the sleeve, wallowing out of the sleeve flange holes and/or offset of the bolt body diameter. Flexible Drive Coupling failure mechanism (Disc Coupling) Disk couplings, cracking or breaks in the individual disk packs or bolts Disk couplings, check for loose disk pack bolts and/or nuts Disk couplings, disk cyclic fatigue due to excessive misalignment Bending fatigue loading may also be characterized by: fretting corrosion on the bolt body diameter, imbedding of the bolt washer face diameter into the sleeve, wallowing out of the sleeve flange holes and/or offset of the bolt body diameter. Electric Motor Electric Motor failure modes failure mechanism Over-Current Draw Mechanical overload Poor power conditioning Excessive effective service factor Over-voltage Voltage unbalance Brushes fail open Voltage surges Drop a phase due to winding failure Fail to Start Power provider interruption Under-voltage Cable mechanically damaged Cable burnt-out from overload Cable connection overheated Motor starter failure Rotor Damage Winding is saturated with water (ingress of water) Aspirated moisture (ingress of humidity) High operating temperature High ambient temperature Variable frequency drives are employed, insulation life expectancy will be reduced Chemical ingress degrades internals Dirt build-up on cooling fins Frequent stops and starts Starting method cause high starting loads Rotor faults, casting voids Rotor faults, broken rotor bars Insulation-to-ground faults Air gap faults, including eccentric rotors Overloading (load demands exceeding the rating of the motor) Improper matching of motor to load (inertia matching) Loose internal wiring connections Vibration / mechanical looseness Excessive starts and reversals Unequal voltage between phases Voltage surges, switching power circuits ,lightning strikes, capacitor discharges and solid-state power devices Nuisance tripping Transient voltage peaks Stator Damage Very high currents in the stator winding due to a locked rotor condition Dirt build-up on cooling fins Balance weight came loose and struck the winding Winding is saturated with water (ingress of water) Aspirated moisture (ingress of humidity) Moisture over motor allows short-circuit current to earth Terminal bolting to wrong connection Terminal bolting loose connection Loose internal wiring connections Insulation-to-ground faults Overloading (load demands exceeding the rating of the motor) Excessive starts and reversals Voltage surges, switching power circuits ,lightning strikes, capacitor discharges and solid-state power devices Nuisance tripping Transient voltage peaks Shorts between conductors or coils Rotor Bar Failure Poor welded connection Vibration due to misalignment Vibration transmitted by nearby equipment Vibration due to loose mountings Vibration from out-of-balance Frame distortion from softfoot Bearing Failure Excessive radial or axial loading Electric current flowing through bearings from inverters (Variable Frequency Drive waveforms) Insufficient bearing lubrication Excess bearing lubrication Lubricant is contaminated Incorrect lubricant Out-of-balance, rotor unbalanced Out-of-balance, balance weight lost Induced vibration Shaft misalignment Wrong coupling type or installation Belt misalignment Incorrect belt tension Defective bearing housings Defective shaft mounting Bad mechanical fits High static loading when stopped Frame warpage Broken mounts Base plate distortion Missing or deteriorated grouting Foundation deterioration Inadequate foundation size and design Bad or worn shaft Shaft, bent and run-out excessive Shaft, axial float excessive induced mechanical vibration Overhung loads Mechanical resonance Rotor deflection Shaft Broken Stress raiser, corrosion Stress raiser, chemical attack Stress raiser, scratches, mechanical damage (e.g. Pipe wrench used to turn seized shaft) Locked rotor Bending/ torsional fatigue from misalignment Massive imposed overload Keyway fatigue Improper keyway design Inadequate shoulder fillet radius Manufacturing defects (residual stresses induced) Overloaded during operation Fretting and pitting corrosion 7 100 5 Variable frequency drives are employed, insulation life expectancy will be reduced Overloading (load demands exceeding the rating of the motor) Voltage surges, switching power circuits ,lightning strikes, capacitor discharges and solid-state power devices Very high currents in the stator winding due to a locked rotor condition Overloading (load demands exceeding the rating of the motor) Voltage surges, switching power circuits ,lightning strikes, capacitor discharges and solid-state power devices Electric current flowing through bearings from inverters (Variable Frequency Drive waveforms) Stress raiser, scratches, mechanical damage (e.g. Pipe wrench used to turn seized shaft) Pump Set Base Frame Pump Set Base Frame failure modes failure mechanism Loose on Foundation Hold-down bolt nuts loose Hold-down bolts corroded Hold-down bolts pulled out of concrete Excessive machine vibration Warped Frame Foundation not level Pulled-down unequally on hold-down bolts Impact by object Corroded Frame Chemical attack Water sitting in contact with frame 3 9 1 2 Pump Set Foundation failure modes Broken Foundation Corroded Foundation Foundation Moves 3 1 Pump Set Foundation failure mechanism Impact by object Concrete shrink cracks Foundation support flexs Ground conditions unsuitable Chemical attack Ground strength weak Undersize foundation 7
Troubleshooting Rotating Machinery: Including Centrifugal Pumps and Compressors, Reciprocating Pumps and Compressors, Fans, Steam Turbines, Electric Motors, and More