proven solutions to improve productivity and lower costs

CHESTERTON

© Copyright 2009 A.W. Chesterton, All rights Reserved 1

Proven Solutions to Improve Productivity and Lower Costs

Chesterton Reliability ProgramsBearing Life Extension

CHESTERTON


Chesterton Bearing Reliability Program

Extend Bearing Life

Increase Productivity

Reduce Grease Consumption

Reduce Operational Costs

CHESTERTON


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 BearingCourtesy Bardon Bearing

Bearing Life ( L10) is based on bearing design not environmental factors

<9% of Bearings Reach their L10 Design Life

CHESTERTON


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

CHESTERTON


Are You Satisfied with the Bearing Life in Your Plant?

CHESTERTON


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

CHESTERTON


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 lubricantA

unsuitable lubricantB

hard contaminants D

liquid contaminantsE

C poor lubrication 80%

mounting errorF

subsequent damagesG

material- and mfg defectsH

poor choice of bearings(design, size, load carrying capabilities)

I

20%

CHESTERTON


Performance Criteria and The Correct Grease

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

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

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Test Criteria for Optimum Bearing Reliability

Grease Should Meet or Exceed All

CHESTERTON


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)%

FA

ILU

RE

10

08

06

04

02

0

1000 2000 3000 4000TIME 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 !

CHESTERTON


How Much Moisture is TOO MUCH?

Ref. SKF

Water Reacts To Steel Bearings Rust, Corrode And PitTo Protect, The Grease Must Passivate The Bearing With Active, Corrosion

Inhibitors And Functional Additives

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

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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…

95% of All Rotary Shaft Bearing 95% of All Rotary Shaft Bearing

are protected with Elastomeric Lip Seals !are protected with Elastomeric Lip Seals !

Bearings Are Designed To Last !Bearings Are Designed To Last !SKF : they have a design life of 50.000 hours ! SKF : they have a design life of 50.000 hours !

Effective life is less than 3000 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 !

CHESTERTON


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

CHESTERTON


Grease Tests - Corrosion Resistance

1000 hours ASTM B117

ASTM B117

Typical Grease - 50 hrs

615 “family” -1000 hrs

5% Salt Water, 35OC

ASTM B 117 Salt Fog Test

After 48 hours

615 HTGLi Cplx, synthetic

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Corrosion ProtectionSalt Fog Performance - ASTM B117

1000 hours ASTM B117

0 200 400 600 800 1000 1200

# 615 Family

AluminumComplex

LithiumComplex

Hours to Failure

12 microns

37 microns

Film Thickness

20x Better

CHESTERTON


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.

CHESTERTON


Chesterton QBT Grease Family

Very High Dropping Point, 300oC ( 570

oF)

Temperature Range - 40oC to 204

oC (- 40

oF to 400

oF)

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

CHESTERTON


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 directlyA = Acceptable. 10% Reduction in Consistency. Grease normally, observe 24 Hrs. Re-grease if oil bleedI = Incompatible. Old grease must be removed from lines and bearing housing

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Industrial Grease Program

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Food Grade Grease Program

CHESTERTON


Critical Lubricant Performance Tests

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Grease must be stable and not thin out…Shear Stability, ASTM D217Change 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

CHESTERTON


…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%

CHESTERTON


Calcium

Clay

Lithium

Aluminum

Complex

Polyurea

Calcium

Sulfonate

Synthetic

Polymer

Temperature Range, oC-40 0 40 80 120 160 200 240

-18o to 138oC (- 0.4 º to 280 º F)

-23o to 93oC (-9º to 199º 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)

-23o to 177oC (9º to 350º F)

-23o to 170oC (- 10 º to 338 º F)

Useful Temperature Limit is a Function of Shear and Oxidative Stability, Not

Dropping Point

CHESTERTON


A. ASTM D2596 4-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 D2266 4-ball Scar Diameter, mm

Ability to Take Load and Prevent Wear 4-Ball Grease Tests

CHESTERTON


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 - 0.05% 100 x Better

Water, 80oC (175oF)

Grease Packed Bearings

Water Reacts To Steel. Bearings Rust, Corrode And PitTo Protect, The Grease Must Passivate The Bearing With Active, Corrosion Inhibitors And

Functional Additives

CHESTERTON


Short Term Corrosion Resistance TestsMany “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.

CHESTERTON


Photos of Types of Bearing Failure

CHESTERTON


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 PitTo Protect, The Grease Must Passivate The Bearing With Active, Corrosion Inhibitors And

Functional Additives

CHESTERTON


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”

CHESTERTON


“Watermarks”

Black oxide

“Speckling”

Common Examples of Corrosion-Pitting, Fretting, Wear !

Wear

CHESTERTON


Common Examples of Corrosion-Pitting, Fretting, Wear !

Fretting

Hydrogen Imbrittlement

Yellow Metal staining

Abrasion Corrosion

CHESTERTON


QBT Described and Vibration Analysis

CHESTERTON


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.

CHESTERTON


615 HTG –QBT™Additives at Work Dryer Fan, Horizontal Bearing, Paper Mill

10.000

7.500

5.000

2.500

20/10/99 14/11/99 09/12/99 03/01/00 28/01/00

Vib

ratio

n,

Kh

z

615 HTG with new bearing

MPM Multiparamater Receiver, Wilcoxon Model 782A Sensor

[email protected]

[email protected]

Li Cpx with new bearing

Vibration Analysis> 300% Increase in MTBR

CHESTERTON


615 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) - 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.

Unique Combination of Performance

proven solutions to improve productivity and lower costs

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