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CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 1 Proven Solutions to Improve Productivity and Lower Costs Chesterton Reliability Programs.

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Presentation on theme: "CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 1 Proven Solutions to Improve Productivity and Lower Costs Chesterton Reliability Programs."— Presentation transcript:

1 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 1 Proven Solutions to Improve Productivity and Lower Costs Chesterton Reliability Programs Bearing Life Extension

2 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 2 Chesterton Bearing Reliability Program Extend Bearing Life Increase Productivity Reduce Grease Consumption Reduce Operational Costs

3 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 3 Bearings Are Designed To Last ! SKF : Bearing life is designed to be 50,000 hours ! or 5.7 years of Continuous Service Under Ideal conditions, bearings eventually fail from fatigue Courtesy Timken Bearing Courtesy Bardon Bearing Bearing Life ( L 10 ) is based on bearing design not environmental factors <9% of Bearings Reach their L10 Design Life

4 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 4 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

5 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 5 Are You Satisfied with the Bearing Life in Your Plant?

6 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 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 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 7 80% of Bearing Failures are Lubrication Related In Industry, Most Bearings Fail Due To Some Form of CORROSION, Accelerated by Heat, Load and Environment Most Bearings Fail Early – Why? Data courtesy of INA, FAG B 20% A 20% C 15% D 20% E 5% F 5% G 5% I 10% H <1% aged lubricant A unsuitable lubricant B hard contaminants D liquid contaminants E C poor lubrication 80% mounting error F subsequent damages G material- and mfg defects H poor choice of bearings (design, size, load carrying capabilities) I 20%

8 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 8 Performance Criteria and The Correct Grease Property  TemperatureDrop Point/Oil Separation  Extreme Pressure, Wear4 Ball EP and Anti Wear  SpeedShear Resistance/Oil Separation  MoistureWater Washout  Corrosive EnvironmentCorrosion Resistance/Salt Fog  Compatibility with existing greaseThickener Selection Must First Determine the Operating Environment Published Data can be used to Judge Grease Performance OPTIMUM PERFORMANCE is a Result of Proper Selection of Base Oils, Thickeners, and Robust Additive Design…and Precise Manufacturing Techniques

9 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 9 Test Criteria for Optimum Bearing Reliability Grease Should Meet or Exceed All

10 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 10 You can see leakage OUT…But you cannot see Leakage IN Chilled Water Pump Conventional Lip Seals CR (Mean Life 1844 hours) NATIONAL (Mean Life 645 hours) % FAILURE TIME HOURS TO FAILURE NATIONAL CR Percent Failure vs. Hours to Leakage Lip Seals Protect for < 3000 hrs, BUT bearings are designed for 50,000 hrs ! Lip Seals are Used to Protect 95% of Rotary Shaft Bearings Keep Lubricant IN and try to Keep Water Out !

11 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 11 How Much Moisture is TOO MUCH? 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 0.01% = 100 ppm 0.05% = 500 ppm 0.10% = ppm 0.15% = ppm 0.25% = ppm 0.50% = ppm 1.00% = ppm The Effect of Water in Oil on the Bearing Life

12 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 12 Effects of Corrosion The Primary Challenge to Bearings in Industry

13 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 13 The Facts of Unsatisfactory Bearing Life We Have To Deal With… 95% of All Rotary Shaft Bearing are protected with Elastomeric Lip Seals ! are protected with Elastomeric Lip Seals ! Bearings Are Designed To Last ! SKF : they have a design life of 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 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 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 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 15 Grease Tests - Corrosion Resistance 1000 hours ASTM B117 ASTM B117 Typical Grease - 50 hrs 615 “family” hrs 5% Salt Water, 35 O C ASTM B 117 Salt Fog Test After 48 hours 615 HTG Li Cplx, synthetic

16 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 16 Corrosion Protection Salt Fog Performance - ASTM B hours ASTM B117 Film Thickness 20x Better

17 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 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 © Copyright 2009 A.W. Chesterton, All rights Reserved 18 Chesterton QBT Grease Family  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, 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 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 19 Grease Compatibility Aluminum ComplexIACAIAAA Barium ComplexICICCCCC Calcium StearateACICICCC Calcium 12 HydroxyCACAAAAA Calcium ComplexIIIICIII Calcium SulfonateACACICCC Clay Non-soapIIIIAIII Lithium StearateCAIAIAAA Lithium 12 HydroxyCAIAIAAA Lithium ComplexCCCCICCC Polyurea, ConventionalIIIIIIII Polyurea, Shear StableCCCCICCC 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 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 20 Industrial Grease Program

21 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 21 Food Grade Grease Program

22 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 22 Critical Lubricant Performance Tests

23 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 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 units on penetration scale. BE CAREFUL NOT TO CHANGE NLGI in SERVICE

24 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 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 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 25 Calcium Clay Lithium Aluminum Complex Polyurea Calcium Sulfonate Synthetic Polymer Temperature Range, o C o to 138 o C (- 0.4 º to 280 º F) -23 o to 93 o C (-9º to 199º F) -34 o to 177 o C (- 29 º to 350 º F) -34 o to 204 o C (- 29 º to 399 º F) - 40 o to 204 o C (- 40º to 399º F) -23 o to 177 o C (9º to 350º F) -23 o to 170 o C (- 10 º to 338 º F) Useful Temperature Limit is a Function of Shear and Oxidative Stability, Not Dropping Point

26 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 26 A. ASTM D ball EP Maximum load, before seizure, kg 1200 rpm Typical Grease 250kg “615 Family” 620 to 800kg 1 hour 1200 rpm, at 40 kg, ave. scar in mm Typical Grease 0.5 to 0.7 mm 615 “family” 0.40 mm B. ASTM D ball Scar Diameter, mm Ability to Take Load and Prevent Wear 4-Ball Grease Tests

27 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 27 Water Washout Resistance ASTM D1264 (DIN 51807)  Typical Water Resistant Grease 3 to 5%  Exceptional 1-2%  629 < 0.2% 25 x Better  615 and QBT Family % 100 x Better Water, 80 o C (175 o F) Grease Packed Bearings 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 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 28 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.

29 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 29 Photos of Types of Bearing Failure

30 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 30 Types of Corrosion  Chemical  Galvanic  Localized Pitting  Embrittlement  Intergranular  Yellow Metal  High Temperature Oxidation  Abrasive Corrosion  Required Conditions –Oxygen –Moisture  Accelerants for Corrosion –Salts –Chemicals –Temperature –Environment –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

31 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 31 Bearing Corrosion is a Failure of the Grease Film to Protect 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 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”

32 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 32 “Watermarks” Black oxide “Speckling” Common Examples of Corrosion- Pitting, Fretting, Wear ! Wear

33 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 33 Common Examples of Corrosion- Pitting, Fretting, Wear ! Fretting Hydrogen Imbrittlement Yellow Metal staining Abrasion Corrosion

34 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 34 QBT Described and Vibration Analysis

35 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved 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 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved HTG –QBT™Additives at Work Dryer Fan, Horizontal Bearing, Paper Mill /10/99 14/11/99 09/12/9903/01/00 28/01/00 Vibration, Khz 615 HTG with new bearing MPM Multiparamater Receiver, Wilcoxon Model 782A Sensor Li Cpx with new bearing Vibration Analysis > 300% Increase in MTBR

37 CHESTERTON © Copyright 2009 A.W. Chesterton, All rights Reserved HTG Family with QBT™ 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 Extreme Pressure (EP) 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. Unique Combination of Performance


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