Alexandria Engineering Journal (2013) 52, 241248

Alexandria University

Alexandria Engineering Journal

www.elsevier.com/locate/aej
www.sciencedirect.com

REVIEW

Bearing problems eects on the dynamic performance

of pumping stations
Mostafa A. Abu-Zeid

a,*

, S.M. Abdel-Rahman

Mechanical & Electrical Department, Ministry of Water Resources & Irrigation, Egypt
Mechanical & Electrical Research Institute, National Water Research Center, Ministry of Water Resources & Irrigation,
Delta Barrage, Egypt

Received 13 January 2013; revised 3 February 2013; accepted 10 February 2013

Available online 9 March 2013

KEYWORDS
Pumps;
Water saving;
Bearing performance;
Vibration performance

Abstract Egypt has a limited water resource and depends mainly on the Nile to satisfy its demands
where agriculture consumes more than 80% of the water resources. There are more than 2000
pumping stations in Egypt of different systems operating under different conditions. Pumping stations are subjected to mechanical, electrical, and structural problems affecting behavior, efciency,
safety, and reliability of these stations. These stations are a part of probably the largest network of
its kind as the entire volume of water owing down the Nile (over 55.5 billion cubic meters) has to
be pumped twice, once for irrigation and then back from the eld to the drains.
Pumping stations use large number of bearings with different types and applications. These bearings have a clear effect on the performance and efciency of the pumps. Pump bearings in the arid
regions are greatly affected by temperature, water quality, lubricants, and maintenance operations.
This research focuses on analysis of damaged rolling element bearings of pumping system. The
objective of the research is to enhance and control dynamic performance of pumping stations by
avoiding damage and failure of bearings. The research proves that damaged bearings generate periodic, non-periodic, and transient forces causing high amplitude of vibration at high frequencies and
increasing energy consumption. Bearing faults increase vibration level 85%, where power consumption increases 14% and pump efciency decreases 18%. It is very important to take care of bearings
during installation, alignment, balancing, and maintenance to assure safe and efcient pump operation for long period. As pump efciency decreases, water power decreases and/or consumed power
increases affecting water distribution and management system. Bearing faults break pumping system for long period affecting irrigation system. Optimum operation of pumping stations helps to
save and manage water requirement for development and extension projects in arid regions. The

* Corresponding author. Tel.: +20 1117777570; fax: +20 222069266.

E-mail address: abuzeidm@link.net (M.A. Abu-Zeid).
Peer review under responsibility of Faculty of Engineering, Alexandria
University.

Production and hosting by Elsevier

1110-0168 2013 Faculty of Engineering, Alexandria University. Production and hosting by Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.aej.2013.02.002

242

M.A. Abu-Zeid, S.M. Abdel-Rahman

measurements are performed on full scale model in the eld, which proves reliable results on similar
pumping stations.
2013 Faculty of Engineering, Alexandria University. Production and hosting by Elsevier B.V.
All rights reserved.

Contents
1.
2.
3.
4.
5.
6.
7.
8.

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Failure causes of rolling element bearings . . . . . . . . . . . . . . . . . . . . .
Problem identication and research methodology . . . . . . . . . . . . . . . .
Calculating excitation frequencies of the pump system . . . . . . . . . . . .
Results of overall vibration level measurements . . . . . . . . . . . . . . . . .
Vibration analysis of the pump system . . . . . . . . . . . . . . . . . . . . . . .
Results of hydraulic performance of the pump system and discussions .
Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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242
242
243
244
245
246
247
247
248

1. Introduction
Rolling element bearings are among the most common components to be found in industrial rotating machinery. They are
found in industries from agriculture to aerospace, in equipment as diverse paper mill to the space shuttle main engine turbo machinery [5]. A bearing is a mechanical device designed to
reduce friction in a part of a machine where another part turns
or slides. There are four types of bearings, plain bearings, ball
bearings, roller bearings, and thrust bearings. Bearings are
among the most important components in the vast majority
of machines and exacting demands are made upon their carrying capacity and reliability. Bearings used in pumping stations
must be able to support the hydraulic loads imposed on the
impeller, the mass of the impeller and shaft, as well as the loads
from the drive system. Bearings must also keep the axial movement and lateral deection of the shaft within acceptable limits
to maximize the service life of the shaft seal. Bearings have
great inuence on the performance and operating efciency,
whereas bearing faults are considered a distinct indicator of
decreasing pump performance and increasing the vibration
leading to failure and breakdown [7].
Most pumping plants use rolling element bearings which
are designed to operate for high speed and high performance
conditions. Rolling element bearings are manufactured under
very stringent quality control standards. Under ideal operating
conditions, bearing can last through many years of continuous
use. Operating conditions are rarely ideal, so most bearings
never achieve their potential as far as useful life is concerned.
The life of a rolling element bearing depends on the conditions
under which it is manufactured, the care exercised in storing
and handling it, installation practice, load conditions, and
the operating environment. Due to the fact that a rolling element bearing restricts rotor motion, forces generated by the
rotor are transferred through the rolling elements to the bearings outer ring which is tted to the bearing housing. Because
of this transmission, a direct measurement at the bearing outer
ring or casing (housing) is the primary accepted method for
monitoring machines with rolling element bearings. Another
characteristic that is a unique and normal to rolling element
bearings is the generation of vibrations at specic bearing-re-

lated frequencies. These frequencies are generated by the bearing based on the bearings geometry, number of rolling
elements, and the speed at which the shaft is rotating.
Without the help of a good predictive maintenance program, vibration problems associated with bearings of critical
machines can be difcult to understand and analyze. Good design, good maintenance of a pump, prime mover and piping results in a longer component life, reducing operating costs
through lower maintenance costs, lower power costs, and best
operating efciency for the pumping system. A method has
been developed to accurately identify the presence, type, and
magnitude of defects within rolling element bearings from
enveloped random vibration spectra. Envelope spectrum
proves a good tool for diagnosing bearing problems [1]. In
most practical cases, a failing bearing will have several defects.
In this case, components of all the defect types are added linearly in the envelope spectrum [3]. Vibration analysis has been
used as a condition monitoring tool for bearing fault detection
and diagnosis, probably ever since the rst use of bearings
when the symptoms were something sounds strange [5].
Electrical energy to drive a pump represents the major factor in the whole life operating cost of the pump system. The
total operating cost includes 87% to power consumption,
8% to maintenance and only 5% to the equipment. With this
high cost of power consumption, it is important to avoid any
operating conditions that affect pump performance and to improve the operation protability of the pump. Pumping stations in Egypt consume 1700 GW h per year costing more
than 300 millions Egyptian pounds. This high rate of energy
consumption could be reduced through different aspects [2].
2. Failure causes of rolling element bearings
Rolling element bearings generally consist of two rings, an inner and an outer ring, between which a set of balls or rollers
rotate in raceways. Under normal operating conditions of balanced load and good alignment, fatigue failure begins with a
small ssure, located between the surface of the raceway and
the rolling elements, which gradually propagate to the surface,

Bearing problems effects on the dynamic performance

generating detectable vibration and increasing noise level [8].
Bearings fail due to fatigue, caused by the high cyclic stresses
between the rolling elements and raceways, even if operated
under ideal design conditions. Design life calculations can be
performed to ascertain the minimum number of hours of operation that the bearing should achieve when properly installed
and operated within its design limits. Most rolling element
bearing installed in the eld failed prematurely and the most
premature bearing failures can be one of environmental, industrial, or operating state factors. Environmental state factors include shipping damage, storage damage, and external
contamination. Industrial state factors include interchangeability, insufcient clearance, incorrect placement oil grooves,
and unstable surface nish. Operating state factors include
excessive temperature, improper lubrication, excessive loading,
exposure to vibration due to external excitation, and passage
of electric current through the bearing.
Each of the different causes of bearing failure produces its
own characteristic damage, known as primary damage, which
gives rise to secondary, failure-inducing damage-aking and
cracks. Even the primary damage may necessitate scrapping
the bearings on account of excessive internal clearance, vibration, noise, and so on. A failed bearing frequently displays a
combination of primary and secondary damage. Rolling element bearing damage may be classied into two main types:
primary damage and secondary damage. Primary damage includes wear, indentations, surface distress, corrosion, and electric current damage. Secondary damage includes aking,
cracks, and cage damage. Regardless of the failure mechanism,
defective rolling element bearings generate mechanical vibrations at the rotational speeds of each component. These characteristic frequencies, which are related to the raceways and
the balls or rollers, can be calculated from the bearing dimensions and the rotational speed of the machine. Mechanical
vibration analysis techniques are commonly used to monitor

Figure 1

Pump unit system.

243
these frequencies in order to determine the condition of the
bearing [8].
3. Problem identication and research methodology
Evaluation of hydraulic and dynamic performance is done regularly for one of the largest irrigation pumping station in
Egypt. The pumping station consists of 10 vertical-axial ow
pump type, with 2 m head, 16 m3/s discharge, and 90 rpm
speed. The motor is 650 kW power, 1485 rpm speed, 11,000
volt, 41 A current, and the gearbox reduction speed ratio is
1:16.6. Vibration measured at the different components of
the pump unit (pumpmotorgearbox), as shown in Fig. 1,
in the radial and axial directions, showed a high level of vibration and high noise at the primary operational stage, where
continuous operation at this condition is serious as secondary
faults may be developed and pump breakdown is predicted
soon. Vibration signals were analyzed by fast Fourier transform (FFT), using data collector/analyzer type B&K 2526
and machine monitoring software type B&K 7107, to dene
the sources of high vibration. Exciting frequencies of the different pumping system components (motor, pump, gearbox,
impeller, couplings, and bearings) are dened based on their
speed, specications, and geometry, to determine the sources
of high vibration and the faulted elements. The analysis shows
that the bearing of the motor-drive-end (MDE) is damaged
and is the source of high vibration. Vibration measurements
were done and repeated at (MDE) position. Hydraulic performance was recorded at this condition. The damaged bearing,
which is a double row spherical roller bearing, was replaced
and vibration analysis was repeated and compared before
and after bearing replacement. Hydraulic performance including ow, head, water power, and electric power consumption
was compared before and after bearing replacement. Percentage decrease in vibration level and energy consumption is evaluated. Vibration analysis enhances both hydraulic and
dynamic performance and assures safety and reliability of
the pumping station as it detects faults early and diagnoses
the faults which help to correct and x the problems.

Figure 2

Rolling contact bearing components.

244

M.A. Abu-Zeid, S.M. Abdel-Rahman

(a) radial direction

Figure 3

Vibration level (mm/s) before and after replacing the bearing.

(a) radial direction

Figure 4

(b) axial l direction

(b) axial direction

Vibration level (lm) before and after replacing the bearing.

4. Calculating excitation frequencies of the pump system

Exciting frequencies of the pump system were calculated to
dene the source of high vibration prior to dynamic analysis.
Frequencies of the components of the pump system are calculated as follows:
 Motor frequency = 1485/60 rpm = 24.75 Hz
 Pump
frequency = 1/16.6 1485 rpm = 89.5 rpm =
1.492 Hz
 Gear mesh frequency = 17 teeth 1485 rpm = 25,245
rpm = 420.75 Hz

=282 teeth 89.5 rpm = 25,239 rpm = 420.65 Hz
 Blade frequency = 4 vanes 89.5 = 358 rpm = 5.96 Hz
Knowing the ball passing frequencies for the outer and inner races and the rolling elements, rotational frequency is often
helpful for analyzing the vibration generated from the rolling
bearings and providing additional clues to the cause of defect.
The rotational frequencies generated by a defective bearing include four major frequencies: ball passing frequency of outer
race, ball passing frequency of inner race, ball defect

frequency, and cage defect frequency. These rotational frequencies can be calculated according to the dimensions of
the bearing components, as shown in Fig. 2, including the ball
diameter (Db), number of balls (n), the pitch diameter (P), the
contact angle (b), and shaft r.p.m (N) as follows [4]:
Rotational frequency of outer race


nN
Db
Fouter
1
cos b
2  60
P
Rotational frequency of inner race


nN
Db
Finner
cos b
1
P
2  60
Rotational frequency of rolling element
!
 2
PN
Db
2
Fball
cos b
1
p
d  60
Rotational frequency of cage


N
Db
Fcage
cos b
1
P
2  60

Bearing problems effects on the dynamic performance

245

Radial direction

Axial direction

Radial direction
Figure 5

(a) Bearing rotational frequencies before replacement. (b) Bearing rotational frequencies after replacement.

This method is expected to be more accurate compared to

the previous methods, and the calculated frequencies are most
closely to the actual rotational frequencies because it takes into
consideration more specied dimensions like the contact angle
and the pitch diameter. The calculated frequencies for the
motor-drive-end bearing (MDE) are the following:





Rotational
Rotational
Rotational
Rotational

Axial direction

frequency
frequency
frequency
frequency

of
of
of
of

outer race F(outer): 345 Hz

inner race F(inner): 460 Hz
rolling element F(ball): 145 Hz
cage F(cage):16.3 Hz

5. Results of overall vibration level measurements

Overall vibration levels measured on the damaged motordrive-end bearing (MDE) in the radial direction show that

the overall vibration level is about 4.5 mm/s, as shown in

Fig. 3. This vibration level is dangerous according to the standard specication [6], which species 1.4 mm/s for long life
bearings in pumps as a maximum value for working with efcient performance rates. Dynamic analysis proves that that
there is a defect in this motor-drive-end bearing which works
in the primary operational stage. This damaged bearing results
mainly due to improper lubrication of the bearing where the
pump operated for long time with excessive loadings conditions. In this study, vibration analysis was focused on the motor-drive-end area in the radial and axial directions to evaluate
the dynamic behavior of the motor bearing. Because the axial
ow pump xation is at the bottom of the pump system, so the
pump system acts as a cantilever xed at the pump end and
free at the motor. As a result and due to the high torque of
the motor operation, the motor becomes more sensitive to
vibration than other components.

246

M.A. Abu-Zeid, S.M. Abdel-Rahman

After replacing this defective bearing with a new one, the

results of the measurements showed a decrease in vibration level to values less than 0.7 mm/s. As a result of replacing the
bearing, the vibration level decreases about 85% in the radial
direction. On the other hand, the vibration level measured in
the axial direction of the damaged bearing was about
1.9 mm/s and it decreased to 1.3 mm/s after replacing the bearing. This means the vibration level decrease about 32% in the
axial direction and 85% in the radial direction. Hence, the radial direction can be considered a good indicator for measuring the vibration level compared with the axial direction.
The overall vibration level on the MDE measured in terms of
displacement (lm) shows the same trend. Maximum vibration
displacement measured is 200 lm. It is found that the vibration
level measured in the radial direction, as shown in Fig. 4, decreases about 70% after replacing the defective bearing; however, in the axial direction, the vibration level decreases about
11%. This conrms that the radial direction is an effective indicator and sensitive to bearing state than the axial direction.
6. Vibration analysis of the pump system
Dynamic analysis is very important to dene the exciting frequencies and determine the level of vibration at each specic
frequency. Also, it is required to dene all the working frequencies to control vibration levels and solve vibration problems. So it is evident that the dynamic analysis is important
to increase operation life, enhance performance of the station
and to decrease losses.

Table 1

The defective part in the bearing has the most severe inuence on the vibration amplitude and causes bearing deterioration. As shown in Fig. 5a for the damaged bearing, the
rotational frequencies of the rolling elements are dened in
the spectrum with high level of vibration. The vibration velocity at the rolling elements rotational frequency reaches a value
of 230.6 lm/s at 145 Hz in the radial direction. This signicant
vibration velocity level implies the source of the problem in the
rolling elements. On the other hand in the axial direction, it
could be seen that the vibration velocity at the frequency of
the inner race reaches a value of 106.3 lm/s at 460 Hz. This
is because the defect in the rolling elements affects the inner
race and causes initial deterioration appearing as an increase
in the vibration amplitude at the frequency of the inner race
element. When this defect appears the predicted residual service, life of the bearing decreases by not less than two times.
After replacing the defect bearing with a new one, the vibration signal is measured in radial and axial directions as shown
in Fig. 5b. The results reveal that the vibration velocities are
signicantly decreased at the rotational frequencies, and the
motor is operating satisfactorily. But it is obvious that the
most signicant decrease in vibration velocities is at the rotational frequency of the rolling elements and decreased 90%.
Visual diagnosis of the faulted bearing showed a severe
wear. This class of bearing problem is due to various passive
treatments such as improper lubrication, which lead to the
wear in the rolling elements. The contacts areas of the rolling
elements are dull and roughened. Abraded matter turns the lubricant dark in color. The grease is also solidied. In many
cases, moisture leads to consistency growing watery lubricant.

Vibration level changes with MDE Bearing frequencies before and after replacement.

Bearing rotational frequencies (Hz)

Vibration levels measured in

axial direction (lm/s)
Damaged bearing

New bearing

Damaged bearing

New bearing

Frequency for the outer race 345 Hz

Frequency for the inner race 460 Hz
Ball rotational frequency 145 Hz
Cage rotational frequency 16.3 Hz

105.8
75.1
230.6
11.235

89.6
34.6
22.3
11.235

15
54
90

58.2
106.3
49.6
11.23

23.6
19.22
17.4
11.23

59
82
71

(a) before replacement bearing

Figure 6

Vibration levels measured in

radial direction (lm/s)

(b) after replacement

Vibration spectrum before and after replacement bearing in the radial direction.

Bearing problems effects on the dynamic performance

Table 2 Vibration level decrease with exciting frequency after
bearing replacement.
Excitation
frequency (Hz)

Axial vibration
level decrease %

Radial vibration
level decrease %

24.40
48.70
51.50
58
122
116
230
274
307
545
688
810
865
1370

30
54
50
59
17
57
25
81
35
89
89
81
82
55

73
42
39
89
72
81
78
13
45
62
93
86
72
51

If foreign particles are the cause of wear, the rolling element

surfaces will be particularly badly scored.
Vibration level changes with motor-drive-end bearing frequencies before and after replacement are shown in Table 1.
In the view of the results, it is obvious that the defected bearing
has a signicant effect on the ball rotational frequency while it
has a negligible effect on the cage rotational frequency in both
the radial and axial directions. Vibration amplitude decreased
90% at ball rotational frequency and decreased 54% at inner
race frequency after bearing replacement. Inuence of the defected bearing is considerable on the rotational frequencies of
the ball and the inner race compared to the rotational frequency of the outer race. Thus, the vibration amplitude measured at the ball rotational frequencies is a good indicator of
the state of bearings.
Vibration spectra measured on the pump system before
changing the defective bearing show exciting frequencies at
the motor running speed and its harmonics with vibration
amplitude about 1 mm/s in the radial and axial directions as
shown in Fig. 6a. This gives an indication that there was a
mechanical problem. This may be due to unbalance and misalignment resulting from xture and assembling operations.
So, it is important to conrm the safety of assembling operations by vibration measurements and construct vibration spectra for the new pumping stations. After changing the defected
bearing, vibration measurements, as shown in Fig. 6b, indicate
that the vibration level at the exciting frequencies decreases
obviously as the amplitude of vibration decreases from

Table 3

247
1 mm/s to 0.7 mm/s, indicating safety and reliability of the
pump unit. The vibration level measured at the running speed
decreases about 73% after replacement, as shown in Table 2.
Also, the vibration level decreases at the frequencies of the
rotating parts and its harmonics by percentages within 10
93% at high frequencies (688 Hz).
7. Results of hydraulic performance of the pump system and
discussions
Increasing efciency of the pumping stations is necessary to
optimize the operational functions of these stations. Efciency
of the pumping stations is greatly affected by bearing problems. Bearings defect is a symptom of less performance efciency and high vibration level. Electric power consumption
and pump performance measurements were recorded before
replacement and after bearing replacement.
The results, as shown in Table 3, reveal that the electric
power consumption before changing the defective bearing
was high and the pump efciency was low due to high vibration results from the defective bearing that lead to high losses
of energy. After changing the bearing, it is obvious that the
electric power consumption decreases and the pump efciency
increases. This ascertains that with the utilization of good
bearing, the pump will run smooth with less vibration. The result shows that decreasing vibration level reduces consumption
power and decreases replacement and maintenance costs.
Bearing faults affect power consumption and hence pump
efciency.
Comparing the measurements taken before and after
replacement of the defective bearing, it could be seen that there
is a signicant decrease in the electric power consumption in a
percentage within 1014%. Also, the overall pump efciency
increases signicantly after bearing replacement up to 18%.
This ascertains that the power consumption of pumps increases considerably by operating pumps in rough dynamic
conditions affecting pump performance, efciency, reliability,
availability, and maintenance costs. Optimum operation of
pumping stations helps to save and manage water requirement
for development and extension projects in arid regions.
8. Conclusions

 Defective bearings cause considerable increase in vibration

amplitudes and decrease the service life of bearings at high
speed pumping stations.

Electric power consumption before and after replacement.

Discharge (m3/s)

Head (m)

Water power (kW)

Electric power consumption (kW)

Before replacement

After replacement

Decrease %

12.38
14.4
15.1
16
17.2
18.21
19.35
20.13

2.31
2.16
2.11
2
1.94
1.87
1.68
1.51

280.54
305.13
312.55
313
327.34
334.5
335.38
342.6

425.06
476.76
487.59
496.82
507.5
515.4
526.49
542.94

382.55
424.31
425.83
427.27
435.13
448.39
464.34
477.94

10
11
12
14
14
13
11
12

248
 The statistical study of the recorded vibration level measured after replacement of the defective bearing shows
considerable decreasing in the vibration level reaching
85% in the radial direction and about 32% in the axial
direction.
 Signicant variations in the vibration level are measured in
radial direction compared with axial one, indicating that the
measurements in radial direction are good indicator for
describing degree of defectiveness of rolling bearings while
axial direction is good indicators for the occurrence of damage due to mechanical problems.
 Inuence of the defected bearing is considerable on the
rotational frequencies of the ball and the inner race compared to the rotational frequency of the outer race. Vibration amplitude decreased 90% at ball rotational frequency
and decreased 54% at inner race frequency after bearing
replacement.
 Replacing the faulted bearing has a signicant decrease in
the electric power consumption in a percentage within 10
14%. Also, the overall pump efciency increases signicantly after bearing replacement up to 18%.
 Optimum operation of pumping stations helps to save
and manage water requirement for development and
extension projects in arid regions. Pump performance,
efciency, reliability, and availability are increased; on
the other hand, maintenance and replacement costs are
reduced.

M.A. Abu-Zeid, S.M. Abdel-Rahman

References
[1] S.M. Abdel-Rahman, S.A. El-Shaikh, Diagnosis Vibration
Problems of Pumping Stations: Case Studies, in: 13th IWTC
(International Water Technology Conference), March 1215,
Hurghada, Egypt, 2009, pp. 419434.
[2] S.M. Abdel-Rahman, S.A. El-Shaikh, Effect of pumping stations
problems on efciency and power consumption, in: Cairo 11th
International Conference On Energy and Environment, March
1518, Hurghada, Egypt, 2009, p. 1.
[3] A.Y. Azovtsev, A.V. Barakov, A.I. Yudin, Automatic diagnostics
and condition prediction of rolling element bearings using
enveloping methods, in: 18th Annual Meeting of the Vibration
Institute, June 1999, p. 1.
[4] Bruel & Kjaer, Machine Condition Monitoring, Application note
BR 0267-13, B&K, Denmark, 2002.
[5] I. Howard, A Review of Rolling Element Bearing Vibration
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[6] ISO 10816, Mechanical VibrationEvaluation of Machine
Vibration by Measurements on Non-Rotating Parts, Part 1,
General Guidelines, 1995, p. 13.
[7] MERI, Detection and Diagnosis Faults of Bearings Used In
Pumping Stations, Technical Report, MERI (Mechanical &
Electrical Research Institute), Delta Barrage, Egypt, 2003, p. 2.
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