Bearing Problems With Centrifugal Pums

Bearing problems with centrifugal pums
Cause and solution...

Does the ball bearing deserve its reputation in the process pump market as one of the two parts (besides the
mechanical seal) of a pump that fails the most? As one of the parts manufactured to the most exacting tolerances
and specifications, we already have the perception that it does...
To investigate this claim, we need some understanding of what bearings do in a pump, the tests they undergo and
what we need to do to ensure they last.
The bearings in each process pump perform three important functions:

1. They place the rotating element in its correct position in relation to the stationary parts of the pump.
2. They ensure that the shaft can rotate with the least amount of friction to maximise the efficiency of the pump.
3. They absorb all radial and axial loads transmitted by the shaft during the different operating points on the
pump curve.
The most widely used bearing in the pumping world is probably the angular contact bearing.
Single
This bearing can be configured in three different ways to meet the expected loads.
The tandem arrangement can take axial loads in only one direction, but equally distributed between the two
bearings.
The « face to face / X » or « back to back / O » arrangement can take axial forces in both directions but only with
one bearing at a time.
ATTENTION: These arrangements are NOT equal as sometimes wrongly claimed. And certainly NOT in the
centrifugal « end-suction » pump.
Forces on single angular contact bearing

A = axial load; R = radial load
By: Wim De Mesmaeker / Service Manager KSB Service Belgium

The O arrangement is the only one that can absorb a
tilting moment. Consequently, it should be used when
the bearing is close to the source of a tilting moment.
Since this can occur as a result of shaft misalignment,
the O arrangement should always be used in an end-
suction pump, where the bearing is close to the shaft
coupling, allowing axial play of a few tenths of a mm to
allow for thermal expansion, for example.
« End-suction » pump (KSB type MCPK)
The bearings in a double-suction type pump or a

bearing type pump are located at both ends of the
shaft. Due to its construction, this type of pump does
not suffer (much) axial forces because these are
balanced by the shape of the impeller.
An angular contact bearing is therefore not required.
« Double-suction » pump (KSB type Omega)
The X arrangement blocks the axial play, so there can

be no expansion towards the balancer or diffusers.
Since we usually work with a « slide bearing » in the
suction, there is no tilting moment.
« Multistage » pump (KSB type Multitec) « O » axial play « X » stop without play

In order for angular contact bearings to provide long-term, trouble-free service, it must be recognised that they
are only one part of the overall bearing arrangement.
Other important aspects are the support and protection (care) of these bearings.
A) Supporting the bearings

The support includes a strong shaft and solid housing to minimise the effect of externally induced stresses or
vibrations.
A strong shaft that minimises the effect of vibration is essential for the support of the pump bearings. Therefore,
the shaft slenderness ratio (L3/D4) should be kept as low as possible. So a short, thick shaft will be stiffer than a
long, narrow one (for the same material, of course).
In the practice of some companies making their own spare shafts, it should be noted that the machining profile,
the accuracy of the bearing adjustments and the steel quality are essential for reliable operation. It goes without
saying that the material composition, fit and tolerances are inherent to the OEM‘s design and therefore any
counterfeit axle represents a danger to both the reliability and stability of the design.
B) Lubrication of the bearings

The lubricant separates the rolling elements and raceway contact, and minimises the effect of friction. Lubricant
selection is a (practical) consideration of viscosity, and depends on the operating temperature, bearing size and
rotational speed.
1) Grease lubrication
Lubricating grease is essentially a soap thickener in a mineral or synthetic oil.
When selecting the right grease, the base oil must be capable of meeting the lubrication requirements of the
bearing.
Two golden rules must be followed when using grease;
a. Do not apply too much grease to a bearing, as the grease will overheat and the lubricating effect
will be reduced.
b. Do not mix different types of grease, as many of the ingredients and preservatives are
incompatible.
Unfortunately, we very often see serious errors when it comes to grease lubrication, with reduced service life,
defects and consequent damage to the pumps.

Error No. 1
Lubrication based on TIME instead of PERFORMANCE
It seems sensible to lubricate a bearing once a week or once a month. Performing planned maintenance at
regular intervals is an age-old concept. Bearings, however, need to be lubricated for one reason only: to reduce
friction.
As long as the lubricant performs this function well, there is no reason to replace it or add more. If we lubricate
too often, the consequences are catastrophic. Lubricating a bearing because it is calendar time is a first mistake.
Check, measure and determine friction levels using condition monitoring (vibration, temperature, ultrasonic, etc.)
to know when it is time to lubricate.
Error No. 2
Over- and under-lubrication
The second mistake to avoid is adding too much or too little lubricant. Too much lubricant builds up pressure,
pushing the rolling elements through the liquid layer against the outer ring.
The bearing now has to work much harder to push the rolling elements through a plug of lubricant. The
increased friction and pressure from too much lubricant causes the temperature inside the bearing to rise. The
excess heat can reduce the effectiveness of the lubricant causing the oil to separate from the thickener.
Burns grease, too much, too hot and too long... . A life-lubricated bearing does not need to be lubricated
Not adding enough lubricant has the same life-shortening effect. How do we know if the right amount
of lubricant has been added? The practical tip here is to do condition monitoring (ultrasonic, vibration
measurement, temperature monitoring,...) and to monitor when new lubricant is added... dose by dose. And of
course, if you have a CLOSED (2RS- and ZZ-types) bearing then the dosed grease will find its way out but never
lubricate the bearing...

Error no. 3
The right grease
The third error is not following/read the OEM‘s maintenance instructions. Who better than the designer knows
what the pump needs? The lubricant supplier? The stockist?
Lubricants usually have a mineral oil base and a chemical thickener, the latter also known as „metal soap“. The
different compositions make the type of lubricant suitable for certain operating conditions, including high or low
temperatures, speed and load.
Lubricants can therefore be divided into different types.
► Lithium grease
Thickener: Lithium soap
Base oil: Mineral oil, ester oil, polyatomic ester oil or silicone oil
► Sodium fat (fibre fat)

Thickener: Sodium soap
Base oil: Mineral oil
► Calcium fat (cup fat)

Thickener: Calcium soap
► Mixed fat
Thickener: Sodium + Calcium soap, Lithium + Calcium soap, etc.
► Complex fat
Thickener: Calcium complex soap, Lithium complex soap, Al complex etc.
► Soap-free fat
Thickener: Urea, bentonite, carbon, fluorine compounds, etc.
Base oil: Synthetic oil

So there
there is plenty of choice. The following extract from the OEM‘s maintenance instructions gives you the answer:
7.2.3.2 Grease quality
Optimal grease properties for rolling bearings
Table 22: Quality of grease according to DIN 51825
Insurance basis NLGI-class Penetration at 25° C Drop point

mm/10
• Resin and acid-free

• Must not be allowed to dry out
• Protects against rust
The recommendation of the OEM, easy anyway...
2) Oil lubrication
Mineral oils are still the most commonly used lubricant in general purpose pumps, while synthetic oils tend to be
more resistant to higher temperatures and require less frequent changes in these applications. Again, the OEM
provides the answer via the manual that invariably comes with the pump.
The oil level in the bearing housing should be maintained around the centre line of the lowest ball in the barrel
ring, and the oil should be able to enter the bearing from both sides.
Oil sump diameter min/max oil level Automatic oil levele Sight glass / bullseye simple and effective
In addition to oil bath lubrication, oil mist, oil splash and oil flush systems are some other popular ways of oil
lubrication.

3) The « life-lubricated » bearings (closed bearings with suffix 2RS,2RSH,2Z,...)
Other methods of securing the lubricant and protecting it from external contaminants include sealing the
bearings themselves, or the bearing housing.
Sealed bearings have seals on each side of the bearing and are considered sealed for the life of the bearing.
Sealed bearings
In these bearings, the bearing cavity is filled to approximately 25 - 35 per cent with grease.
How is the service life of a bearing defined?

Bearing life is defined as the number of revolutions a bearing can make before fatigue occurs in one of its
elements.
It is generally defined in terms of millions of revolutions or in hours.
It is generally based on 90 % reliability.
Lh = (106/60N)*(C/P)a
where,
Lh = Service life in hours
N = Speed
C = Dynamic load capacity
P = Load or equivalent load
a = Constant; 3 for ball bearing/= 3.3 for roller bearings (source SKF)
Estimated life per application Dynamic load rating in the

bearing catalogue (source: SKF)
By : Wim De Mesmaeker / Service Manager KSB Service Belgium
Most common bearing damages were covered in this article but unfortunately there are still some.
(source: machinerylubrication)

Conclusion
► Install the correct bearing, in the correct location, in the correct arrangement.
► Mount the OEM bearing correctly in a strong OEM housing and on a strong OEM shaft.
► Use a suitable lubricant, recommended by the OEM.
► Protect that lubricant constantly from contamination.
► And yes, the OEM usually knows better.
With this article, we hope to eliminate the unjustified reputation of the bearings in your pumps, and together with
you increase the reliability of your pump.
Source
• SKF, October 2018, https://www.skf.com, website.

People Passion Performance
Service Center Wavre

Stay informed! Zoning Industriel Sud
www.ksbbelgium.be
1301 Wavre / Bierges
[email protected]
Tél. +32 (0) 10 43 52 11
Fax +32 (0) 10 43 52 55
Service Center St-Gillis-Waas
05.2021 / Non-contractual document non contractuel / © N.V. KSB Belgium S.A. / Subject to technical modifications
Kluizenhof 35
9170 Sint-Gillis-Waas
[email protected]
Tél. +32 (0) 3 663 8600
Fax +32 (0) 3 663 8601
N.V. KSB Belgium S.A.

Zoning Industriel Sud · B-1301 Wavre / Bierges
Tél. : +32 (0) 10 43 52 11 · Fax : +32 (0) 10 43 52 55
www.ksbbelgium.be

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Bearing problems with centrifugal pums

Cause and solution...

The bearings in each process pump perform three important functions:

Forces on single angular contact bearing

By: Wim De Mesmaeker / Service Manager KSB Service Belgium

« End-suction » pump (KSB type MCPK)

The bearings in a double-suction type pump or a

« Double-suction » pump (KSB type Omega)

The X arrangement blocks the axial play, so there can

By: Wim De Mesmaeker / Service Manager KSB Service Belgium

A) Supporting the bearings

B) Lubrication of the bearings

By: Wim De Mesmaeker / Service Manager KSB Service Belgium

By: Wim De Mesmaeker / Service Manager KSB Service Belgium

Lubricants can therefore be divided into different types.

► Sodium fat (fibre fat)

► Calcium fat (cup fat)

By: Wim De Mesmaeker / Service Manager KSB Service Belgium

7.2.3.2 Grease quality

Optimal grease properties for rolling bearings

Table 22: Quality of grease according to DIN 51825

Insurance basis NLGI-class Penetration at 25° C Drop point

• Resin and acid-free

The recommendation of the OEM, easy anyway...

By: Wim De Mesmaeker / Service Manager KSB Service Belgium

How is the service life of a bearing defined?

Estimated life per application Dynamic load rating in the

By: Wim De Mesmaeker / Service Manager KSB Service Belgium

Service Center Wavre

Service Center St-Gillis-Waas

N.V. KSB Belgium S.A.

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