Transcript Lubricant Seminar

Chesterton Reliability Programs
Bearing Life Extension
Proven Solutions to Improve Productivity and Lower Costs
CHESTERTON
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1
Chesterton Bearing Reliability Program
Extend Bearing Life
Increase Productivity
Reduce Grease
Consumption
Reduce Operational
Costs
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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
Courtesy Timken Bearing
Courtesy Bardon Bearing
<9% of Bearings Reach their L10 Design Life
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General Relationships on Bearing Life

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
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Are You Satisfied with the Bearing Life in
Your Plant?
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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
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Most Bearings Fail Early – Why?
B 20%
A 20%
C 15%
D 20%
A
E 5%
aged lubricant
F
D hard contaminants
E
liquid contaminants
mounting error
G subsequent damages
B unsuitable lubricant
C poor lubrication
F 5%
I 10%
H <1%
G 5%
80%
H material- and mfg defects
poor choice of bearings
I (design, size,
load carrying capabilities)
20%
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
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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
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Test Criteria for Optimum Bearing Reliability
Grease Should Meet or Exceed All
Performance
Target
Li 12
Mineral
Li Cpx
Mineral
Al-Cpx
min oil
280
293
13
280
>310
Fail
280
310
20-30
280
340
20-30
<1
8
5
5
1000
<50
<50
<50
Oil Separation (ASTM D 1742)
% Wt
<2
8
1.1
4
Timken E.P. (ASTM D 2059)
Fail load, lbs
>60
40
51
55
Four Ball E.P. (ASTM D 2596)
Load Wear Index (kg)
Weld Point (kg)
65 to 140
620 to 800
40
250
72
500
63
315
<0.5
0.5-0.7
0.5-0.7
0.5-0.7
PHYSICAL PROPERTIES:
Shear Stability (ASTM D217)
Worked Penetration 77° / 25 °C
60 strokes
100,000 strokes
Change, >30 is borderline failure
Water Washout Test (ASTM D 1264)
% loss 175°F / 79°C
Corrosion Resistance , 5% salt fog, (ASTM B117), hrs
Four Ball Wear Test (ASTM D 2266)
Scar Diameter, mm
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Lip Seals are Used to Protect 95% of Rotary Shaft Bearings
Keep Lubricant IN and try to Keep Water Out !
NATIONAL
40
60
80
CR
NATIONAL (Mean Life 645 hours)
CR (Mean Life 1844 hours)
20
Conventional
Lip Seals
% FAILURE
100
Percent Failure vs. Hours to Leakage
1000
2000
3000
4000
TIME HOURS TO FAILURE
Lip Seals Protect for < 3000 hrs, BUT bearings are designed for 50,000 hrs !
Chilled Water
Pump
You can see leakage OUT…But
you cannot see Leakage IN
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How Much Moisture is TOO MUCH?
The Effect of Water in Oil on the Bearing Life
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
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
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Effects of Corrosion
The Primary Challenge to Bearings in Industry
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The Facts of Unsatisfactory Bearing Life We
Have To Deal With…
Bearings Are Designed To Last !
SKF : they have a design life of 50.000 hours !
95% of All Rotary Shaft Bearing
are protected with Elastomeric Lip Seals !
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 !
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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
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Grease Tests - Corrosion Resistance
ASTM B 117 Salt Fog Test
ASTM B117
Typical Grease - 50 hrs
615 “family” -1000 hrs
After 48
hours
5% Salt Water, 35OC
1000
hours
ASTM
B117
615 HTG
Li Cplx,
synthetic
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Corrosion Protection
Salt Fog Performance - ASTM B117
Lithium
Complex
Film Thickness
12 microns
37 microns
Aluminum
Complex
1000 hours
ASTM B117
# 615 Family
20x Better
0
200
400 600 800
Hours to Failure
1000 1200
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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.
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Chesterton QBT Grease Family
o
o

Very High Dropping Point, 300 C ( 570 F)

Temperature Range - 40 C to 204 C (- 40 F to 400 F)

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
o
o
o
o
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Grease Compatibility
613
615
622
625 629
630
633
635
Aluminum Complex
I
A
C
A
I
A
A
A
Barium Complex
I
C
I
C
C
C
C
C
Calcium Stearate
A
C
I
C
I
C
C
C
Calcium 12 Hydroxy
C
A
C
A
A
A
A
A
Calcium Complex
I
I
I
I
C
I
I
I
Calcium Sulfonate
A
C
A
C
I
C
C
C
Clay Non-soap
I
I
I
I
A
I
I
I
Lithium Stearate
C
A
I
A
I
A
A
A
Lithium 12 Hydroxy
C
A
I
A
I
A
A
A
Lithium Complex
C
C
C
C
I
C
C
C
Polyurea, Conventional
I
I
I
I
I
I
I
I
Polyurea, Shear Stable
C
C
C
C
I
C
C
C
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
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Industrial Grease Program
635 SXC
PAO
633 SXCM
PAO
615 HTG
Mineral
Li 12
Mineral
Li Cpx
Mineral
Al-Cpx
min oil
280
293
13
325
340
15
280
291
11
280
>310
Fail
280
310
20-30
280
340
20-30
Water Washout Test (ASTM D 1264)
% loss 175°F / 79°C
<0.05
<2.0
<0.05
8
5
5
Corrosion Resistance, 5% salt fog, (ASTM B117), hrs
>1000
>1000
>1000
<50
<50
<50
Oil Separation (ASTM D 1742)
% Wt
nil
nil
0,2
8
1.1
4
Timken E.P. (ASTM D 2059)
Fail load, lbs
65
65
65
40
51
55
Four Ball E.P. (ASTM D 2596)
Load Wear Index (kg)
Weld Point (kg)
130
800
140
800
80
620
40
250-400
72
250-500
63
250-500
Four Ball Wear Test (ASTM D 2266)
Scar Diameter, mm
0.40
0.38
0.40
0.5-0.7
0.5-0.7
0.5-0.7
PHYSICAL PROPERTIES:
Shear Stability (ASTM D217)
Worked Penetration 77° / 25 °C
60 strokes
100,000 strokes
Change, >30 is borderline failure
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Food Grade Grease Program
630 SXCF
PAO
625 CXF
Mineral
Li 12
Mineral
Li Cpx
Mineral
Al-Cpx
min oil
280
287
7
280
287
7
280
>310
fail
280
310
30
280
350
70
Water Washout Test (ASTM D 1264)
% loss 175°F/ 79°C
<0.05
<0.05
8
5
5
Corrosion Resistance, 5% salt fog, (ASTM B117), hrs
>1000
>1000
<50
<50
<50
Oil Separation (ASTM D 1742)
% Wt
0.1
0.2
8
1.1
4
Timken E.P. (ASTM D 2059)
Fail load, lbs
>60
>65
40
51
55
Four Ball E.P. (ASTM D 2596)
Load Wear Index (kg)
Weld Point (kg)
92
620
92
620
40
250
72
500
63
315
Four Ball Wear Test (ASTM D 2266)
Scar Diameter, mm
0.42
0.38
0.47
0.45
0.4
PHYSICAL PROPERTIES:
Shear Stability (ASTM D217)
Worked Penetration 77°F / 25 °C
60 strokes
100,000 strokes
Change, >30 is borderline failure
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Critical Lubricant Performance Tests
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Grease must be stable and not thin out…
Shear Stability, ASTM D217
Change in Penetration after Shear
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
Measured in units of 0,1 mm (4 mil)
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…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%
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Useful Temperature Limit is a Function of Shear
and Oxidative Stability, Not Dropping Point
o
Temperature Range, C
-40
Calcium
0
40
o
80
120
160
o
o
o
-23 to 177 C (9º to 350º F)
Lithium
-18o to 138oC (- 0.4 º to 280 º F)
Aluminum
Complex
-23 to 170 C (- 10 º to 338 º F)
Polyurea
-34 to 177 C (- 29 º to 350 º F)
Synthetic
Polymer
240
-23 to 93 C (-9º to 199º F)
Clay
Calcium
Sulfonate
200
o
o
o
o
o
o
-34 to 204 C (- 29 º to 399 º F)
o
o
- 40 to 204 C (- 40º to 399º F)
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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
“615 Family”
250kg
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
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Water Washout Resistance
ASTM D1264 (DIN 51807)
Grease Packed Bearings
Water, 80oC
(175oF)




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 Reacts To Steel. Bearings Rust, Corrode And Pit
To Protect, The Grease Must Passivate The Bearing With Active, Corrosion Inhibitors And
Functional Additives
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Short Term Corrosion Resistance Tests
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
EMCOR
Humidity Cabinet
Copper Strip Test
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.
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Photos of Types of Bearing Failure
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Types of Corrosion

Chemical

Galvanic
– Oxygen

Localized Pitting
– Moisture

Embrittlement

Intergranular
– Salts

Yellow Metal
– Chemicals

High Temperature Oxidation
– Temperature

Abrasive Corrosion
– Environment


Required Conditions
Accelerants for Corrosion
– Dissimilar Metals
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
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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
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“Watermarks”
Common Examples of CorrosionPitting, Fretting, Wear !
“Speckling”
Wear
Black oxide
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Common Examples of CorrosionPitting, Fretting, Wear !
Hydrogen
Imbrittlement
Yellow Metal
staining
Abrasion
Corrosion
Fretting
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QBT Described and Vibration Analysis
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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.
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615 HTG –QBT™Additives at Work
Dryer Fan, Horizontal Bearing, Paper Mill
10.000
Vibration Analysis
> 300% Increase in MTBR
7.500
Li Cpx with
new
bearing
Vibration,
Khz
615 HTG with new bearing
5.000
[email protected]
[email protected]
2.500
20/10/99
14/11/99
09/12/99
03/01/00
28/01/00
MPM Multiparamater Receiver, Wilcoxon Model 782A Sensor
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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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