A collaborative bearing failure analysis was conducted by SKF, Sweden, and its authorized distributor, Bearings Services Durban, at one of South Africa\u2019s leading sugar refineries in KwaZulu-Natal. The analysis not only identified the root cause of the bearing failure but also included corrective measures to prevent future occurrences. The analysis also offered insights into how various factors can contribute to premature bearing failure, providing significant value to the customer.<\/p>\n
The Tongaat Hulett Refinery plant located in Rossburgh, Durban, experienced significant downtime on its production line due to a premature bearing failure on a mainline pump. The refinery\u2019s maintenance engineer, Adarsh Madanlal explains that the pump tripped and refused to start. \u201cUpon removal and stripping, we noticed that the bearing had failed. Furthermore, a day after commissioning, a high frequency noise was detected and the oil turned black. Despite draining and changing the oil every Thursday, it kept turning black the following day. After evaluating all plant conditions, we were unable to determine the root cause of the bearing failure as all available evidence was inconclusive.\u201d<\/p>\n
The refinery subsequently reached out to SKF for assistance. \u201cIt was evident that understanding the root cause of these repeated bearing failures was critical to enable our customer to resolve the issue effectively,\u201d says Shaniel Rambally, Bearings Services Durban branch manager. \u201cThe following day, we recommended that an ISO bearing damage analysis be performed on multiple bearings. Upon acceptance by the refinery team, the bearings were duly collected and sent to SKF for analysis; the ensuing report was completed and forwarded to our customer in an impressive turnaround time of 12 working days.\u201d<\/p>\n
Based on the information provided and the condition of the bearings, SKF specialists concluded that the root cause for the damage can be classi\ufb01ed according to the ISO Failure Mode Classi\ufb01cations ISO\/15243 as rolling contact fatigue failure type.<\/p>\n
SKF territory sales manager, Titus Kasie explained that rolling contact fatigue is caused by repeated stresses that develop in the contacts between the rolling elements and the raceways. \u201cFatigue manifests visibly as a change in the microstructure and is a result of inadequate lubricant film thickness.\u201d<\/p>\n
Madanlal and his team were thoroughly impressed by the astoundingly detailed results and feedback they received from SKF. The comprehensive, fact-based report provided an in-depth breakdown of the findings. It was also presented in clear detail, making it easily interpretable even for those without expertise in this particular field.<\/p>\n
Madanlal also emphasized that the value of this investigation went beyond identifying the root cause of the failure; it provided valuable insights into corrective practices, helping to mitigate the risk of similar issues in the future. The report also gave the refinery a good understanding of how other factors can contribute to premature bearing failure.<\/p>\n
\u201cWhile bearing failure analysis is a specialized field that is not widely recognized, it\u2019s importance is evident from this constructive outcome, particularly in FMCG plants, where it plays a crucial role in optimizing operational efficiencies. We wish to see these services being fully utilized by more plants and industries in the future. Overall, we complement Bearing Services and SKF for their exceptional customer service and high level of quality products. Tongaat Hulett relies on various SKF product solutions from our bearing, power transmission and MaPro portfolios, and we greatly value our long-term partnership,\u201d concluded Rambally.<\/p>\n
For more information:<\/p>\n
SKF<\/p>\n