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Proven Solutions to Improve Productivity and Lower Costs

Chesterton Reliability Programs Bearing Life Extension. Proven Solutions to Improve Productivity and Lower Costs. Chesterton Bearing Reliability Program. Extend Bearing Life Increase Productivity Reduce Grease Consumption Reduce Operational Costs. Courtesy Bardon Bearing.

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Proven Solutions to Improve Productivity and Lower Costs

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  1. Chesterton Reliability ProgramsBearing Life Extension Proven Solutions to Improve Productivity and Lower Costs

  2. Chesterton Bearing Reliability Program Extend Bearing Life Increase Productivity Reduce Grease Consumption Reduce Operational Costs

  3. Courtesy Bardon Bearing Courtesy Timken Bearing Bearings Are Designed To Last ! SKF : Bearing life is designed to be 50,000 hours ! or 5.7 years of Continuous Service Bearing Life ( L10) is based on bearing design not environmental factors Under Ideal conditions, bearings eventually fail from fatigue <9% of Bearings Reach their L10 Design Life

  4. SPEED- Doubling Speed, cuts life in half. Halving speed increases life 2 X LOAD- Doubling the load cuts life to 1/8 Halving load increases life by 8X for Ball Bearings, 10X for Roller Bearings VIBRATION- Increase in vibration by 2X reduces Bearing life by 75% MOISTURE- 200 ppm water reduces Bearing Life 48% HARD CONTAMINANTS- Dust, Debris can result in immediate failure FATIGUE – ONLY 9% Ultimate L10 Life Expectancy General Relationships on Bearing Life

  5. Are You Satisfied with the Bearing Life in Your Plant?

  6. Do your bearings survive under the following conditions? • Water/steam • High temperature/high speed • Heavy load/High pressure • Start/Stop/Standby Service • Rigorous environments • Corrosive Vapors • Food Sanitizers Published Data can be used to Judge Grease Performance

  7. Most Bearings Fail Early – Why? B 20% A 20% C 15% I 10% H <1% D 20% G 5% E 5% F 5% aged lubricant A mounting error F unsuitable lubricant B subsequent damages 80% G poor lubrication C 20% material- and mfg defects H hard contaminants D poor choice of bearings(design, size, load carrying capabilities) I liquid contaminants E 80% of Bearing Failures are Lubrication Related In Industry, Most Bearings Fail Due To Some Form of CORROSION, Accelerated by Heat,Load and Environment Data courtesy of INA, FAG

  8. Performance Criteria and The Correct Grease Must First Determine the Operating Environment Property • Temperature Drop Point/Oil Separation • Extreme Pressure, Wear 4 Ball EP and Anti Wear • Speed Shear Resistance/Oil Separation • Moisture Water Washout • Corrosive Environment Corrosion Resistance/Salt Fog • Compatibility with existing grease Thickener Selection OPTIMUM PERFORMANCE is a Result of Proper Selection of Base Oils, Thickeners, and Robust Additive Design…and Precise Manufacturing Techniques Published Data can be used to Judge Grease Performance

  9. Test Criteria for Optimum Bearing Reliability Grease Should Meet or Exceed All

  10. Conventional Lip Seals Percent Failure vs. Hours to Leakage 100 CR 80 60 NATIONAL % FAILURE 40 20 3000 1000 2000 4000 TIME HOURS TO FAILURE NATIONAL (Mean Life 645 hours) CR (Mean Life 1844 hours) Lip Seals are Used to Protect 95% of Rotary Shaft Bearings Keep Lubricant IN and try to Keep Water Out ! Lip Seals Protect for < 3000 hrs, BUT bearings are designed for 50,000 hrs ! You can see leakage OUT…But you cannot see Leakage IN Chilled Water Pump

  11. How Much Moisture is TOO MUCH? 0.01% = 100 ppm 0.05% = 500 ppm 0.10% = 1.000 ppm 0.15% = 1.500 ppm 0.25% = 2.500 ppm 0.50% = 5.000 ppm 1.00% = 10.000 ppm The Effect of Water in Oil on the Bearing Life Ref. SKF Water Reacts To Steel Bearings Rust, Corrode And Pit To Protect, The Grease Must Passivate The Bearing With Active, Corrosion Inhibitors And Functional Additives

  12. Effects of Corrosion The Primary Challenge to Bearings in Industry

  13. The Facts of Unsatisfactory Bearing Life We Have To Deal With… 95% of All Rotary Shaft Bearing are protected with Elastomeric Lip Seals ! Bearings Are Designed To Last ! SKF : they have a design life of 50.000 hours ! Effective life is less than 3000 hours! They damage shaft / allow oil to leak out and Environment leak in! Almost 90% of the Bearings fail ….. …. they do NOT reach the design life ! 80 % of premature bearing failure are caused by faulty lubrication and/or contamination !

  14. Attack the Root Causes and Maximize Bearing Life ! THE FINAL Protection to the Bearing is the Lubricant…The Root Cause of Poor Bearing Life is NOT LUBRICATION PRACTICES or Poor MAINTENANCE but Using Lubricants that are Deficient in PREVENTING CORROSION, WEAR, and PITTING. STOP CORROSION… INCREASE BEARING LIFE… IMPROVE MTBR… SAVE MONEY

  15. Grease Tests - Corrosion Resistance ASTM B 117 Salt Fog Test Li Cplx, synthetic 615HTG 5% Salt Water, 35OC After 48 hours ASTM B117 Typical Grease - 50 hrs 615 “family” -1000 hrs 1000 hours ASTM B117

  16. Corrosion ProtectionSalt Fog Performance - ASTM B117 1000 hours ASTM B117 Film Thickness 20x Better

  17. Chesterton QBT™ Additive Plating Technology QBT™ smoothes out surface roughness, reduces wear and vibration. This molecular surface chemistry passivates the steel and extends bearing life by reactively fusing a “wear shield” onto the contact surfaces. Micro porosity is “filled in” and reactive Fe++ ions are inhibited. QBT™ works even in the presence of up to 30% water contamination.

  18. Chesterton QBT Grease Family • Very High Dropping Point, 300oC ( 570oF) • Temperature Range - 40oC to 204oC (- 40oF to 400oF) • Excellent Shear Resistance, Virtually No Thinning • Resists Oxidation, Ozone Degradation • Excellent Shock Load and Wear Properties, 4 Ball Weld Load, 620 to 800Kg • Very High Timken O.K. Load 29 kg (65 lbs.) • Good Compatibility with Popular Greases • Very High Water Washout Resistance, Below 0.05% • Extreme Water Tolerance (Add 30% Water and Still Get 20 kg (45 lbs.) Timken) • Excellent Corrosion Resistance, 1000 Hrs Salt Fog Test

  19. Grease Compatibility C = Compatible. Grease may be installed directly A = Acceptable. 10% Reduction in Consistency. Grease normally, observe 24 Hrs. Re-grease if oil bleed I = Incompatible. Old grease must be removed from lines and bearing housing

  20. Industrial Grease Program

  21. Food Grade Grease Program

  22. Critical Lubricant Performance Tests

  23. Grease must be stable and not thin out… Shear Stability, ASTM D217 Change in Penetration after Shear Measured in units of 0,1 mm (4 mil) Grease Penetration Measured after 60, 10,000 and 100,000 strokes. A grease may “thins” with shear – higher penetration. Key aspect is to use low shear thinning greases to maintain NLGI in service Typical grease 7-10% change or 20-35 units on penetration scale. BE CAREFUL NOT TO CHANGE NLGI in SERVICE

  24. …and oil NOT separate, even in storage. Oil Separation, ASTM D1742 Measures % oil that separates to the top of the grease after heat aging. Typical grease 1 to 8% 615 “family” 0 to 0.2%

  25. Useful Temperature Limit is a Function of Shear and Oxidative Stability, Not Dropping Point Temperature Range, oC -40 0 40 80 120 160 200 240 -23o to 93oC (-9º to 199º F) Calcium Clay Lithium Aluminum Complex Polyurea Calcium Sulfonate Synthetic Polymer -23o to 177oC (9º to 350º F) -18o to 138oC (- 0.4 º to 280 º F) -23o to 170oC (- 10 º to 338 º F) -34o to 177oC (- 29 º to 350 º F) -34o to 204oC (- 29 º to 399 º F) - 40o to 204oC (- 40º to 399º F)

  26. Ability to Take Load and Prevent Wear 4-Ball Grease Tests 1200 rpm A. ASTM D2596 4-ball EP Maximum load, before seizure, kg Typical Grease 250kg “615 Family” 620 to 800kg B. ASTM D2266 4-ball Scar Diameter, mm Typical Grease 0.5 to 0.7 mm 615 “family” 0.40 mm 1 hour 1200 rpm, at 40 kg, ave. scar in mm

  27. Typical Water Resistant Grease 3 to 5% Exceptional 1-2% 629 < 0.2% 25 x Better 615 and QBT Family - 0.05%100 x Better Water Washout ResistanceASTM D1264 (DIN 51807) Grease Packed Bearings Water, 80oC (175oF) Water Reacts To Steel. Bearings Rust, Corrode And Pit To Protect, The Grease Must Passivate The Bearing With Active, Corrosion Inhibitors And Functional Additives

  28. Short Term Corrosion Resistance Tests Copper Strip Test EMCOR Humidity Cabinet Many “mild” ASTM corrosion tests reported, D130 – Copper Strip Tarnish Test D1748 – Rust Protection in Humidity Cabinet D4627 – Iron Chip Corrosion Test D6138 – “Emcor Test’, 30 days, sealed bearings Standard Grease Corrosion Test Methods are Short Duration, Non Aggressive Exposures. Virtually any grease will “PASS” the test. However, the real world test of Industrial Exposure produces different results.

  29. Photos of Types of Bearing Failure

  30. Types of Corrosion • Required Conditions • Oxygen • Moisture • Accelerants for Corrosion • Salts • Chemicals • Temperature • Environment • Dissimilar Metals • Chemical • Galvanic • Localized Pitting • Embrittlement • Intergranular • Yellow Metal • High Temperature Oxidation • Abrasive Corrosion Water Reacts with Steel Bearings to Rust, Corrode And Pit To Protect, The Grease Must Passivate The Bearing With Active, Corrosion Inhibitors And Functional Additives

  31. Bearing Corrosion is a Failure of the Grease Film to Protect Moisture / Water – cause multiple types of corrosion 1. Low levels, ppm – condensation, lip seal leakage Result - hydrogen embrittlement , pitting, “watermarks”, “black oxide” 2. Higher levels – Grease washout Grease thinning, no film strength, bearing scars, cage wear Aggressive rusting of the carbon steel bearing, “red oxide” The grease is the last line of bearing protection For reliable performance the grease must have  Extremely low water washout  Excellent corrosion inhibition  Maintain a high lubricating film even when contaminated with water

  32. Common Examples of Corrosion-Pitting, Fretting, Wear ! “Watermarks” “Speckling” Wear Black oxide

  33. Common Examples of Corrosion-Pitting, Fretting, Wear ! Hydrogen Imbrittlement Abrasion Corrosion Yellow Metal staining Fretting

  34. QBT Described and Vibration Analysis

  35. Chesterton QBT™ – Technology Overview Chesterton's QBT™ Grease Family is formulated using a surplus of Lubricity, EP and Anti-Wear additives, blended into a highly refined 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 QBT™ based greases are immune to hydrolysis or water breakdown. The grease remains functional even in heavy water contaminated bearings and equipment. 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.

  36. 615 HTG –QBT™Additives at WorkDryer Fan, Horizontal Bearing, Paper Mill 10.000 7.500 5.000 2.500 14/11/99 09/12/99 03/01/00 28/01/00 20/10/99 Vibration Analysis > 300% Increase in MTBR Li Cpx with new bearing 615 HTG with new bearing Vibration, Khz Alarm@4.0Khz Acceptable@3.0Khz MPM Multiparamater Receiver, Wilcoxon Model 782A Sensor

  37. 615 HTG Family with QBT™ Unique Combination of Performance Extreme Pressure (EP) - 620 to 800kg vs. 250kg for typical greases Water Washout – as low as 0.05%, vs. 8% for typical lithium based grease Corrosion Protection – 1000 hours vs. 50 hours in ASTM B117 salt fog test. Industrial 615 HTG #2, 615 HTG #1, 635 SXC, Synthetic, Extreme Pressure, Corrosion Resistant Grease 633 SXCM, Synthetic, Extreme Pressure, Corrosion Resistant Grease with Moly Food Pharmaceutical, H1 625 CXF, Corrosion Resistant, Extreme Pressure, Food Grade Grease 630 SXCF, Synthetic, Ext. Pressure, Corrosion Resistant Food Grade Grease

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