Why Bearings Presenter NA

Chesterton Reliability Programs
Bearing Life Extension
Proven Solutions to Improve Productivity and Lower

CHESTERTON
Costs
Copyright 2009 A.W. Chesterton, All rights Reserved
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
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

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
Most Bearings Fail Early Why?

B 20%
A 20%
C 15%
D 20%
A
E 5%
aged lubricant
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
CHESTERTON
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 Designand Precise Manufacturing
Techniques
Published Data can be used to Judge Grease Performance
CHESTERTON
Test Criteria for Optimum Bearing Reliability

Grease Should Meet or Exceed All
CHESTERTON
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 OUTBut

you cannot see Leakage IN
CHESTERTON
10
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
CHESTERTON
11
Effects of Corrosion
The Primary Challenge to Bearings in
Industry
CHESTERTON
12
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 !
CHESTERTON
13
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
14
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
CHESTERTON
15
Corrosion Protection
Salt Fog Performance - ASTM B117
Film Thickness
1000hours
ASTM
B117
20x Better
CHESTERTON
16
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
17
Chesterton QBT Grease Family
Very High Dropping Point, 300oC ( 570oF)
Temperature Range - 40oC to 204oC (- 40oF to 400oF)
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
18
Grease Compatibility
613
615
622
625 629
630
633
635
Aluminum Complex
Barium Complex
Calcium Stearate
Calcium 12 Hydroxy
Calcium Complex
Calcium Sulfonate
Clay Non-soap
Lithium Stearate
Lithium 12 Hydroxy
Lithium Complex
Polyurea, Conventional
Polyurea, Shear Stable
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
CHESTERTON
19
Industrial Grease Program
CHESTERTON
20
Food Grade Grease Program
CHESTERTON
21
CriticalLubricantPerformanceTests
CHESTERTON
22
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)
CHESTERTON
23
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
24
Useful Temperature Limit is a Function of

Shear and Oxidative Stability, Not
Dropping Point
Temperature Range, oC
-40
Calcium
Clay
Lithium
40
80
120
160
240
-23o to 93oC (-9 to 199 F)

-23o to 177oC (9 to 350 F)
-18o to 138oC (- 0.4 to 280 F)
Aluminum
Complex
-23o to 170oC (- 10 to 338 F)
Polyurea
-34o to 177oC (- 29 to 350 F)
Calcium
Sulfonate
-34o to 204oC (- 29 to 399 F)
Synthetic
Polymer
200
- 40o to 204oC (- 40 to 399 F)
CHESTERTON
25
Ability to Take Load and Prevent Wear

4-Ball Grease Tests
1200rpm
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
CHESTERTON
26
Water Washout Resistance

ASTMD1264(DIN51807)
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
CHESTERTON
27
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.
CHESTERTON
28
PhotosofTypesofBearingFailure
CHESTERTON
29
Types of Corrosion
Required Conditions
Chemical
Galvanic
Oxygen
Localized Pitting
Moisture
Embrittlement
Intergranular
Salts
Yellow Metal
Chemicals
High Temperature Oxidation
Temperature
Abrasive Corrosion
Environment
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
CHESTERTON
30
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
CHESTERTON
31
Common Examples of CorrosionPitting, Fretting, Wear !
Watermarks
Speckling
Wear
Black oxide
CHESTERTON
32
Common Examples of CorrosionPitting, Fretting, Wear !

Hydrogen
Imbrittlement
Yellow Metal
staining
Abrasion
Corrosion
Fretting
CHESTERTON
33
QBTDescribedandVibrationAnalysis
CHESTERTON
34
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
35
615 HTG QBTAdditives 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
Alarm@4.0Khz
Acceptable@3.0Khz
2.500
20/10/99
14/11/99
09/12/99
03/01/00
28/01/00
MPM Multiparamater Receiver, Wilcoxon Model 782A Sensor

CHESTERTON
36
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
CHESTERTON
37

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Chesterton Reliability Programs

Bearing Life Extension

Proven Solutions to Improve Productivity and Lower

Chesterton Bearing Reliability

Bearings Are Designed To Last !

Courtesy Timken Bearing

Courtesy Bardon Bearing

<9% of Bearings Reach their L10 Design Life

General Relationships on Bearing Life

SPEED- Doubling Speed, cuts life in half.

LOAD- Doubling the load cuts life to 1/8 Halving

VIBRATION- Increase in vibration by 2X reduces

MOISTURE- 200 ppm water reduces Bearing Life

HARD CONTAMINANTS- Dust, Debris can result

FATIGUE ONLY 9% Ultimate L10 Life

Are You Satisfied with the Bearing Life in

Do your bearings survive under the

High temperature/high speed

Heavy load/High pressure

Published Data can be used to Judge Grease Performance

Most Bearings Fail Early Why?

H material- and mfg defects

80% of Bearing Failures are Lubrication Related

Performance Criteria and The Correct

Drop Point/Oil Separation

Extreme Pressure, Wear

4 Ball EP and Anti Wear

Shear Resistance/Oil Separation

Corrosion Resistance/Salt Fog

Compatibility with existing grease

OPTIMUM PERFORMANCE is a Result of Proper

Test Criteria for Optimum Bearing Reliability

Lip Seals are Used to Protect 95% of Rotary Shaft Bearings

NATIONAL (Mean Life 645 hours)

Percent Failure vs. Hours to Leakage

TIME HOURS TO FAILURE

You can see leakage OUTBut

How Much Moisture is TOO MUCH?

Water Reacts To Steel Bearings Rust, Corrode And Pit

The Facts of Unsatisfactory Bearing Life We Have

Bearings Are Designed To Last !

95% of All Rotary Shaft Bearing

Effective life is less than 3000 hours!

Attack the Root Causes and

Grease Tests - Corrosion Resistance

ASTM B 117 Salt Fog Test

5% Salt Water, 35OC

Chesterton QBT Additive Plating

QBT smoothes out surface roughness, reduces wear and vibration.

QBT works even in the presence of up to 30% water contamination.

Chesterton QBT Grease Family

Very High Dropping Point, 300oC ( 570oF)

Temperature Range - 40oC to 204oC (- 40oF to 400oF)

Excellent Shear Resistance, Virtually No Thinning

Resists Oxidation, Ozone Degradation

Excellent Shock Load and Wear Properties, 4 Ball Weld Load,

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

Excellent Corrosion Resistance, 1000 Hrs Salt Fog Test

Polyurea, Shear Stable

C = Compatible. Grease may be installed directly

Industrial Grease Program