Centrifugal Pump Set Failure Modes and Causes

Magnetic Motor Rotor Shaft Pump Shaft Pump

Field Coupling Impeller

Pump Set Pump Set

failure modes failure mechanism

No Liquid Delivered Pump not primed

Liquid returned backward
Suction valve shut
Discharge valve shut
Suction piping blocked
Discharge piping blocked
Insufficient NPSH available
Motor failure
Impeller jammed by foreign body
Impeller seized
Supply tank / vessel empty
No liquid supply in pipe
Motor wired wrongly
Specific gravity higher than specified
Viscosity higher than specified
Volute shattered
Drive coupling broken
Drive shaft broken
Bearings in housing seized
Bearings in motor seized
Motor power supply loss

Insufficient Flow Speed tuned down

Discharge valve partially closed
Cavitation
Gas / vapour entrainment (poor suction piping design)
Turbulence (fittings / valves too close to pump suction)
Turbulence (restriction in line prior pump suction)
 Broken impeller
Bent vanes
Incorrect impeller
Incorrect impeller diameter
System head too high
Instrumentation error
Suction valve blocked
Suction valve partially closed
Discharge valve blocked
Discharge valve partially closed
Suction piping blocked
Discharge piping blocked
Motor wired wrongly
Motor rotating backwards
Rotational speed too low
Excessive air / vapour trapped in liquid
Insufficient NPSH available
Impeller clogged
Specific gravity higher than specified
Viscosity higher than specified

Intermittent Flow Air leak in suction line

Excessive air / vapour trapped in liquid
Loss of prime e.g. liquid rans back through check / foot valve

Insufficient Pressure Instrumentation error

Broken impeller
Bent vanes
Incorrect impeller
Incorrect impeller diameter
Cavitation
Rotating backwards
Rotational speed too low
Insufficient NPSH available
Assembled incorrectly

Pump Leaking Mechanical seal passes

Stuffing box packing excessively worn (for packed gland)
Stuffing box bore damaged (for packed gland)
Pump shaft surface damaged (for packed gland)
Packing installed incorrectly (for packed gland)
Flange leaks (flange not sealing)
Flange leaks (gasket not sealing)
Assembled incorrectly
Volute cracked
Volute corroded
Volute eroded
Inadequate foundation size and design

5 72
Sources of Information:

http://www.vibanalysis.co.uk/technical
http://www.elongo.com/pdfs/BearingFailures990519.pdf
The McNally Institute CD
http://www.delzer.com/Rexnord/falk/108010.pdf
Pump Liquid Flow
Impeller
 Impeller Impeller
failure modes failure mechanism

Chamber / Vane Wear Erosion (high flow rate)

Erosion (internal flow recirculation)
Erosion (suspended material on fluid)
Pump-out vanes worn (if part of impeller design)
Blocked balance holes between inlet and back of impeller (if part of impeller design)
Cavitation

Corrosion Chemical corrosion

Galvanic corrosion

Cavitation Damage Long suction pipe

Small diameter suction pipe
Blocked suction pipe
Partially closed valve in suction line
NPSH available is to little
Liquid temperature rise

Loose on Shaft Assembled incorrectly

Taper seat damaged
Nut corroded
Nut under torqued
Incorrect impeller bore

Wear Ring Damage Recirculation

Solids suspended in product
Erosion (high flow rate)
Cavitation (pressure falls across cut water, like in a labyrinth)
Incorrect impeller bore alignment

5 24
t of impeller design)
 Volute Volute
failure modes failure mechanism

Wear Ring Damage Recirculation

Solids suspended in product
Erosion (high flow rate)
Cavitation

Cut Water Wear Erosion (high flow rate)

Erosion (internal flow recirculation)
Cavitation

Corrosion Chemical corrosion

Galvanic corrosion

Cracked Pipe stress

Soft foot dsitortion

3 11
 Shaft Shaft
failure modes failure mechanism

Snapped Shaft Bending fatigue (surface crack initiated)

Bending fatigue (surface corrosion initiated)
Bending fatigue (surface damage initiated)
Tortional fatigue (surface crack initiated)
Tortional fatigue (surface corrosion initiated)
Tortional fatigue (surface damage initiated)
Shaft diameter too small for application
Shaft material tensile strength too low for application
Shaft rotating while bent by service load
Equipment jammed by product
Equipment bearing seized
Overloaded during operation
Chemical attack
Galvanic corrosion
Temperature changes metallurgical properties
Stress raiser, scratches, mechanical damage (e.g. Pipe wrench used to turn seized shaft)
Stress raiser, excessive interference fit with mating component
Stress raiser, welding heat affected zone
Fillet radius too small
Fretting and pitting corrosion
Surface defects such as welding inclusions
Deep machining marks or scratches
Poor blending of fillet radius into journal
Wear grooves at or close to fillet radius

Keyway Broken Keyway fatigue

Improper keyway design
Inadequate shoulder fillet radius
Machining defects (residual stresses induced)
Machining dimension /tolerance error
Overloaded during operation

2 30
o turn seized shaft)
Shaft Seal (Mechanical)
failure modes

Accelerated Seal Face Wear

Edge Chipping
Seal Face Cracked / Fractured

Open Seal Face - Axial

 Open Seal Face - Radial

Static O-Ring Seal Failure

Dynamic O-Ring Seal Failure

 Product Leakage

Seal Embrittlement

Fractured Spring

Clogged Spring

Axial Shear

Torsional Shear

Seal Face Distortion

Slow Mechanical Response

 Bellows Cracked

16
 Shaft Seal (Mechanical)
failure mechanism

Abrasives suspended in the process fluid

Abrasives in solution in the process fluid (crystallisation)
Abrasives from the environment such as sand and dirt
Abrasives from the environment such as product
Adhesive wear at start-up (faces contacting)
Carbonisation on faces (high temperature, high contact load)
Stuck faces (film transfer of seal face material-of-construction)
Scale build-up (filming)
Vaporisation between faces (high temperature, high contact load)
Vaporisation between faces (loss of lubrication film)
Dirt dragged or blown across the faces when they separate
Blistered carbon face from air trapped in carbon expanding and blowing out
Surface finish deterioration
Pump shaft out-of-roundness
Blistering (seal face sub-surface vaporisation)
Excessive start-up torque
Excessive shaft end play
Seal installation misalignment
Pump shaft misalignment to driver
Pump shaft bent
Shaft bent due to overhang because impeller is located too far away from the bearing
Selective leaching is picking up elements from the piping system and depositing them on the seal face
One or both of the seal faces is not lapped flat to within three helium light bands (0,000033" or 1 micron)
Mishandling damage to a lapped face
Damaged faces during delivery
Uneven clamping not 'equal and opposite' across the stationary face
One or both of the faces is being distorted by a temperature differential
Water hammer pressure surge
Carbon in metal holder under residual stress and not stress relieved remove residual stress in the lapped face
Oxidizing agents and halogens attack all forms and grades of carbon-graphite
De-ionized water can attack carbon seal
Chemicals attack carbon seal
Silicon carbide seal attacked by acidic liquid
Solvent flushed through pipes for cleaning attacked seal material
Poor / wrong carbon grade selected
Corrosion rate increased by temperature rise (10 degree Centigrade rise doubles corrosion rate in many fluids)
The plating or hard coating is coming off from the hard face
Rotating face is not centered in the stationary face and is running off the edge of the stationary face
Dirt or solids are clogging the movable components
Foreign object has passed into the seal chamber and is interfering with the free movement of the seal
Solids have packed up in front of the inner seal in a "back to back" dual seal design

Seal face rocks due to installation misalignment

Vaporisation on seal faces
Pump shaft excess whip
Pump shaft excess deflection
Vibration transferred to seal (pipe harmonics)
Vibration transferred to seal (out-of-balance)
Vibration transferred to seal (loose mounting)
Vibration transferred to seal (running at critical speed)
Vibration transferred to seal (Cavitation)
Vibration transferred to seal (Running well off BEP (for single volute))
Water hammer pressure surge

Run dry (no product)

Run dry (no barrier / quench fluid)
Run dry (cavitation)
Run dry (pump-out vanes create low pressure / vacuum)
Thermal shock (distortion from sudden high temperature rise)
High temperature differential across the ceramic
Excessive fluid pressure on seal
Water hammer pressure surge
Excessive pressure velocity (high pressure at slow rotational speed)
Stress corrosion cracking
Barrier / quench fluid failure
The elastomer is swelling up under a carbon face.
The shaft is hitting the stationary face or the rotating seal face is hitting a stationary object
Product is solidifying between the faces and they are breaking at start up
Excessive vibration is causing the drive or anti-rotation pins to crack the face
Cracked during assembly / disassembly. Inspect crack for tell-tale signs of discolouration deep inside seal indicating breakage
Shaft / sleeve is oversize
Fretting corrosion between seal and shaft
A gasket or fitting is protruding into the stuffing box and touching seal component

Pump shaft end play

Trust movement
Water hammer pressure surge
Thermal growth differential
Impeller adjustment towards wet end of pump opens seal faces
Product is vaporizing and separating the faces allowing solid material to blow across the lapped face
Dynamic elastomer not free to move due to oversize shaft
Dynamic elastomer not free to move due rough surface finish
Dynamic elastomer not free to move due to sticking to shaft from high surface temperature
Dynamic elastomer not free to move due to contaminants locking it in place
Chipper edges causing face separation
Spiral failure where seal component stick and cause internal twist
Springs stick and prevent dynamic movement
Seal as mishandled during installation
Elastomer seals on a porous carbon surface rather than a hard metal surface. When the shaft rotation stops the elastomer rela
Set screws have come loose
Set screws corroded
Initial setting of seal incorrect and once experiencing a little wear the spring load has gone
Axial temperature growth of the shaft has altered the original setting
Shaft sleeve moved when the impeller was tightened to the shaft
Seal was set-screwed to a hardened shaft or sleeve and has slipped due to vibration
Spring has been painted and cannot compress fully
Cartridge seal static seal has jammed and preventing proper location of faces
Inner seal of a dual seal application was not balanced in both directions and is opening up with reversing pressure
Single spring found in some seal designs was wound in the wrong direction for the shaft rotation
Rotating bellows seal has lost cooling and the anti-vibration lugs are engaging the shaft. Normal shaft movement or vibration w

Pump shaft bent (excess run-out)

Pump shaft excess whip
Pump shaft excess deflection
Out-of-balance impeller

Fretting corrosion under seal (by axial movement transmitted to the seal)
Excessive elastomer temperature
Excessive fluid pressure
Installation error (elastomer damage)
Corrosive attack (incompatible chemical)
Water hammer
Compression set (extreme temperature operation causes elastomer elasticity memory loss)
Compression set (product is too hot)
Elastomer swollen by incompatible chemical product
Elastomer has extruded because of high pressure or excessive clearance.
Elastomer is cracked from too long on the shelf (particularly Buna-N (nitrile rubber))
Elastomer is cracked (High heat hardens elastomer and cracks)
Elastomer is cracked (cryogenic temperatures)
The elastomer is twisted, cut or damaged on installation
Shaft is corroded, damaged, or fretted under the elastomer
Seal body O-ring groove is damaged or coated with a solid material
Wrong lubricant was used at installation to aid fitting the elesomer on the shaft
Oxidizers can attack the carbon black in O-rings and other elastomers
Distorted sleeve or shaft

Fretting corrosion (axial movement transmitted to the seal)

Excessive elastomer temperature
Excessive fluid pressure
Installation error (elastomer damage)
Corrosive attack (incompatible chemical)
Water hammer pressure surge
Compression set (extreme temperature operation causes elastomer elasticity memory loss)
Compression set (product is too hot)
Elastomer swollen by incompatible chemical product
Solids attached at dynamic elastomerand preventing it from moving
Elastomer has extruded because of high pressure or excessive clearance.
Elastomer is cracked from too long on the shelf (particularly Buna-N (nitrile rubber))
Elastomer is cracked (High heat hardens elastomer and cracks)
Elastomer is cracked (cryogenic temperatures)
The elastomer is cut or damaged on installation
Oxidizers can attack the carbon black in O-rings and other elastomers
Insufficient seal face compression
Installation error (wrongly located on shaft)
Installation error (mounting screws loosen)
Loss of spring tension
Foreign material contamination on faces
Uinbalanced seals in dual seal applications
Application changes from vacuum to a positive pressure. O-rings are the only common elastomers that seal in both directions.
The glue between the carbon and its metal holder is not compatible with the product
Differential expansion between 'pressed-in' carbon and its metal holder
Out-of-roundness of 'shrunk-in' carbon caused by the tolerace on the carbon outside diameter and the metal holder inside diam
Gland gasket has failed
Cracked bellows
Barrier / quench leck misdiagnosed as product leak

Contaminants in pumped fluid

Contaminants in barrier / flush fluid
Pumped fluid / seal material-of-construction chemical incompatibility
Thermal degradation of material-of-construction
Idle periods between use

Material flaw
Manufacturing flaw
Stress corrosion due to tooling marks
Corrosive attack
Seal installation misalignment

Pumped fluid contaminated with solids

Barrier / flush fluid contaminated with solids

Excessive pressure loading

Improper lubrication causes excessive torque

Excessive fluid pressure surges

Excessive fluid pressure on seal

Foreign material trapped between faces
Excessive pressure velocity (high pressure at slow rotational speed)
Insufficient seal face lubrication film thickness

Excessive squeeze on seal faces

Excessive seal swell
Seal extrusion
Metal-to-metal contact due to out of alignment
Seal rub (shaft deflection causes the mechanical seal to contact the bore of the stuffing box)
Internal erosion (barrier / flush fluid contaminated with solids)
The product interfers with the free movement of the components. The fluid is crystallising, solidifying, viscous
A gasket or fitting is protruding into the stuffing box and touching seal component
Foreign object has passed into the seal chamber and is interfering with the free movement of the seal
Stress corrosion cracking

178
 This illustration describes a mechanical seal that can be classified into several diff

the lapped face

te in many fluids)
p inside seal indicating breakage prior installation

rotation stops the elastomer relaxes and flows into the carbon surface irregularities
 h reversing pressure

mal shaft movement or vibration will cause the faces to open

mers that seal in both directions. Wedges, U cups, and chevrons do not have this ability

and the metal holder inside diameter

difying, viscous
n be classified into several different categories:
Roller Bearings Roller Bearings
failure modes failure mechanism

Bearing Wear Abrasive particles, such as grit or swarf that have entered the bearing
Lack of cleanliness before and during mounting operation
Ineffective seals
Lubricant contaminated by worn particles from brass cage
Lubrication contamination (wear particles)
Lubricant additives gradually been used up
Lubricant has lost its chemical lubricating properties
Lubricant loss through seal
Lubricant has leaked away
Lubrication contamination (external liquid ingress)
Lubrication contamination (liquid product ingress)
Lubrication contamination (dust and dirt ingress)
Lubrication contamination (solid product ingress)
Lubrication contamination (sand and material from within castings, flaking protective coa
Bent shafts
Skewed ring from burrs or dirt on bearing mounting surfaces and bearing abutment surfa
Shaft shoulders which are not perpendicular to the bearing abutment surface
Locking nut faces which are not perpendicular to the bearing seating face
Non-concentric bores on which the bearings are mounted leading to an angular axis of ro
Reverse Loading Failure is one such failure which occurs due to the bearing getting load
Bad bearing supplied (especially cheap bearings made of inferior material)
Solids were introduced into the system during the assembly process because of a lack o
Shaft coupling bore machined off-center / skewed

Bearing Overheated Clearance looseness (shaft shrinkage)

Clearance looseness (housing expansion)
Clearance looseness (loose fit shaft)
Clearance looseness (loose fit housing)
Spalling of race ways
Inadequate or improper lubrication
Excessive preload on account of fits being too tight
Insufficient heat transmission from housing due to build-up of material and product over
Rapid cooling of housing causes shrinkage and reduction in clearance
Incorrect viscosity of the lubricant
Incorrect lubricant chemistry
Form 'varnish' residue and 'coke' at elevated temperature that destroys the ability of the
Oil level too low
Oil level too high
Plugged oil return holes
Over greased bearing
Under greasing bearing
Suction pressure too high and causing axial thrust
Out-of-balance rotating element
Hydrogen embrittlement or blistering by water within microscopic cracks on raceways an
Insufficient clearance in labyrinth seals
Base frame distorted
Process temperature conducted along shaft
Normal aspiration as the pump cooled down, and the moisture laden atmosphere entere
Axially mislocated shaft coupling
Grease or lip seals too tight
 Brinell and False Brinell Hit during mounting / installation
Dented by self-weight load when standing-still
Dented by vibration impact loads when standing-still e.g. machinery transported on roug
Situated close to machinery producing vibrations
Mounting pressure applied to the wrong ring during installation
Excessively hard drive-up on tapered seating during installation
Overloading while not running
Excessive preload on account of fits being too tight
Smearing on installation produces microscopic surface cracks
Stuffing box packing overtightened

Creeping Slippage Ring fit is oversize

Ring fit is worn
Fretting corrosion

Smearing rollers and raceways Smeared roller ends from sliding under heavy axial loading and with inadequate lubricati
Roller acceleration on entry into the loaded zone due to too much clearance
Load is too light for the speed
As bearings are being mounted, the ring with the roller and cage assembly is entered as
Blows applied to the wrong ring or heavy preloading without rotating the bearing
External surfaces of heavily loaded bearings from movement of the bearing ring relative
Slip fit is too loose on sliding ring
Smearing Thrust Ball Bearings due to rotational speed is too high in relation to the loadin

Surface Distress Cracks Inadequate lubrication

Improper lubrication

Corrosion - Deep seated rust Presence of water, moisture over a long period of time
Presence of corrosive substances

Corrosion - Fretting Fit too loose

Shaft seating with errors of form
Housing seating with errors of form

Electrical Erosion Electrical fluting due to passage of electric current through rotating ring
Electrical fluting due to passage of electric current through non-rotating ring
Earthing problem in equipment

Raceway Spalling Excessive preload on account of fits being too tight

Excessive drive-up on a tapered seating
Excessive preload adjustment e.g. Single row angular contact ball bearings or taper rolle
Temperature differential between inner and outer rings too great
Foreign particles in the lubricant, metal particles from within the system, etc allow wear p
Cavitation induced stress overload
Vibration induced stress from running off BEP
Clearance tightness (shaft expansion)
Clearance tightness (housing shrinkage)
Clearance tightness (tight shaft fit)
Clearance tightness (tight housing fit)
Pinched bearing (shaft ovality excessive)
Pinched bearing (housing ovality excessive)
Pinched bearing (pipe stress distortion)
Pinched bearing (Soft foot causing frame distortion)
Distorted bore of Plummer blocks from mounting on an uneven base becoming oval whe
 Incorrect mounting, which results in axial loading, e.g. excessive preloading of angular c
The non-locating bearing has jammed.
Axial freedom of movement has not been sufficient to accommodate the thermal expans

Cracked Rings Blows, with a hammer or hardened chisel, have been directed against the ring when the
Fatigue cracks (installation misalignment cyclic overloading)
Fatigue cracks (differential frame growth misalignment cyclic overloading)
Fatigue cracks (bent shaft cyclic overloading)
Fatigue cracks (shaft deflection from running off BEP)
Fatigue cracks (Smearing during installation causes surface crack initiation)
Fatigue cracks (Fretting corrosion caused crack initiation)
Clearance tightness (shaft expansion)
Clearance tightness (housing shrinkage)
Clearance tightness (tight shaft fit)
Clearance tightness (tight housing fit)
Sliding under heavy axial loading and with inadequate lubrication

Cage Damage Fatigue cracks (vibration forces of inertia are so great as to cause fatigue cracks to form
Fatigue cracks (run at speeds in excess of cage design subjecting it to heavy forces of in
Fatigue cracks (bearing rings are fitted out of alignment with each other, the path of the r
Severe acceleration and retardation, in conjunction with fluctuations in speed cause forc
Inadequate lubrication
Abrasive particles
Fragments of flaked material or other hard particles may become wedged between the c
Bearing is severely misaligned

Seized Bearing Metal to metal contact cause micro-welding

Clearance tightness causes lack of rolling element rotation
Inadequate lubrication (viscosity too low)
Inadequate lubrication (moisture in lubricant)
Excessive mechanical overload (bearing too small in surface area)
Excessive mechanical overload (high operating load)
Rolling element jammed and not rolling due to solid contaminant
Rolling element jammed and not rolling due mechanical stress
Grease or lip seal contact on the shaft, right next to the bearings. These seals can add a
Lock nut came loose

13 129
 Category

Lube contamination by inclusion

Lube contamination by inclusion
Lube contamination by ingress
Lube contamination by ingress
Lube contamination by ingress
Lube chemical degradation
Lube chemical degradation
Lubricant loss
Lubricant loss
Lube contamination by ingress
Lube contamination by ingress
Lube contamination by ingress
Lube contamination by ingress
ings, flaking protective coatings, rust from inside casLube contamination by ingress
Installation error
and bearing abutment surfaces Installation error
butment surface Installation error
seating face Installation error
ding to an angular axis of rotation of the shaft and thuInstallation error
to the bearing getting loaded in the opposite directioInstallation error
erior material) Material strength failure
rocess because of a lack of cleanliness Lube contamination by inclusion
Installation error

Incorrect fits and tolerance

Incorrect fits and tolerance
Incorrect fits and tolerance
Incorrect fits and tolerance
Lube contamination by inclusion
Lube contamination by inclusion
Lube chemical degradation
material and product over casing Temperature change
Temperature change
Lube chemical degradation
Lube chemical degradation
t destroys the ability of the grease or oil to lubricate Lube chemical degradation
Lubricant loss
Lubricant excessive
Lubricant excessive
Lubricant excessive
Lubricant insufficient
Operational induced stress
Unbalance
opic cracks on raceways and rolling elements Lube contamination by ingress
Incorrect fits and tolerance
Incorrect fits and tolerance
Temperature change
e laden atmosphere entered the bearing case Lube contamination by ingress
Installation error
Installation error
 Installation error
Operational induced stress
hinery transported on rough roads Operational induced stress
Operational induced stress
Installation error
Installation error
Operational induced stress
Incorrect fits and tolerance
Installation error
Installation error

Incorrect fits and tolerance

Incorrect fits and tolerance
Incorrect fits and tolerance

nd with inadequate lubrication Incorrect fits and tolerance

much clearance Incorrect fits and tolerance
Incorrect fits and tolerance
age assembly is entered askew, without being rotate Installation error
otating the bearing Installation error
of the bearing ring relative to its shaft or housing Incorrect fits and tolerance
Incorrect fits and tolerance
high in relation to the loading. The centrifugal force tOperational induced stress

Lubricant insufficient
Lube chemical degradation

Lube contamination by ingress

Lube contamination by ingress

Incorrect fits and tolerance

Incorrect fits and tolerance
Incorrect fits and tolerance

Electrical induced damage

n-rotating ring Electrical induced damage
Electrical induced damage

Incorrect fits and tolerance

Incorrect fits and tolerance
t ball bearings or taper roller bearings Incorrect fits and tolerance
Incorrect fits and tolerance
he system, etc allow wear particles to be jammed Lube contamination by ingress
Operational induced stress
Operational induced stress
Incorrect fits and tolerance
Incorrect fits and tolerance
Incorrect fits and tolerance
Incorrect fits and tolerance
Incorrect fits and tolerance
Incorrect fits and tolerance
Incorrect fits and tolerance
Incorrect fits and tolerance
n base becoming oval when the base bolts are tigh Installation error
ive preloading of angular contact ball bearings and tInstallation error
Incorrect fits and tolerance
modate the thermal expansion. Installation error

d against the ring when the bearing was being moun Installation error
Installation error
overloading) Incorrect fits and tolerance
Installation error
Operational induced stress
rack initiation) Installation error
Incorrect fits and tolerance
Incorrect fits and tolerance
Incorrect fits and tolerance
Incorrect fits and tolerance
Incorrect fits and tolerance
Installation error

ause fatigue cracks to form in the cage material, afteUnbalance

cting it to heavy forces of inertia that may lead to fra Operational induced stress
each other, the path of the rollers take an oval configInstallation error
uations in speed cause forces of inertia. These giv Operational induced stress
Lubricant insufficient
Lube contamination by inclusion
ome wedged between the cage and a rolling element,Lube p contamination by ingress
Installation error

Lube chemical degradation

Incorrect fits and tolerance
Lube chemical degradation
Lube chemical degradation
Design error
Operational induced stress
Lube contamination by ingress
Incorrect fits and tolerance
ngs. These seals can add as much as 38°C (100°F) Design error
Installation error
SKF List of bearing failure causes -
Wear
Wear caused by abrasive particles
Wear caused by inadequate lubrication
Wear caused by vibration
Indentations
Indentations caused by faulty mounting or ove
Indentations caused by foreign particles
Smearing
Smearing of roller ends and guide flanges
Smearing of rollers and raceways
Raceway smearing at intervals corresponding
Smearing of external surfaces
Smearing in thrust ball bearings
Surface distress
Corrosion
Deep seated rust
Fretting corrosion
Damage caused by the passage of electric
Flaking (spalling)
Flaking caused by preloading
Flaking caused by oval compression
Flaking caused by axial compression
Flaking caused by misalignment
Flaking caused by indentations
Flaking caused by smearing
Flaking caused by deep seated rust
Flaking caused by fretting corrosion
Flaking caused by fluting or craters
Cracks
Cracks caused by rough treatment
Cracks caused by excessive drive-up
Cracks caused by smearing
Cracks caused by fretting corrison
Cage damage
Vibration
Excessive speed
Wear
Blockage
Other causes of cage damage
ing failure causes - Bearing failures and their causes - Product information 401

asive particles
dequate lubrication

by faulty mounting or overloading

by foreign particles

ds and guide flanges

nd raceways
t intervals corresponding to the roller spacing

the passage of electric current

val compression
xial compression
isalignment

eep seated rust

etting corrosion
uting or craters

ugh treatment
cessive drive-up

etting corrison
Flexible Drive Coupling Flexible Drive Coupling
failure modes failure mechanism (Tyre Coupling)

Premature Component Wear Shaft misalignment axial

Shaft misalignment parallel
Shaft misalignment angular
Shaft thermal expansion
Severe distortion under maximum instantaneous torque (wind-up)
Erratic/pulsating/high-inertia loads
Excessive back-lash within coupling for shock loads
Rotational speed is beyond design RPM
Loosening of the coupling's fastener to the shaft
Changed assembly gap between hubs of the coupling
Damaged or broken components
Bore machined askew
Bore machined non-concentric
Excessive shaft end float
Bent shafts, excessive run-out
Excess back-lash between coupling parts / components
Material-of-Construction incorrect for duty loads / torque

Hub Damage Shaft out-of-round or incorrect form

Split / cracked due to improper interference fit
Movement of the hub on the shaft
Shaft surface finish too rough and offers insufficient surface area for support
Shaft not straight
Shaft under bore nicked, hammer-rash or damaged
Axial misalignment
Concentrated heat on the hubs cause distortion

Keyway Failure Excessive shaft interference fit

High torque load transmitted through the key
Excessively loose fitting key allows high impact on start / reverse

Key Failure Excessively loose fitting key allows high impact on start / reverse
Improper key material selected
Corrosion
Chemical attack
High torque load transmitted through the key

Elastometric Element Failure Excessive torque loading

Atmospheric contamination / deterioration
Chemical attack
Overload
Torsional vibrations (look for liquefaction of the material internal of the insert)
Coupling out-of-balance
Cracked due to rubber hardening from chemical contamination
Elastomer material has limited service life
Excessive high temperature
 Flange Fastener Failure High starting or impact loads occur in combination with reversing service or sev
Bending fatigue loading may also be characterized by: fretting corrosion on the
Insufficient fastener tightening torque
System torsional vibration
Reversing loads which exceed the flange joint capacity
System was subjected to unexpected overloads
Elongated bolt holes due to fastener impact (fastener loosened off)
Elongated bolt holes due to fastener impact (fastened insufficiently tight)
Cyclic fatigue life exceeded
Shaft passes through natural frequncy and large vibrations / movements cause

6 52

Sources of Information:
http://pt.rexnord.com/products/e-catalog/catalog/CachedImages/0000001/t004_r00171_v0.pdf
http://motionsystemdesign.com/mag/couplings_shafts/

ous torque (wind-up)
ficient surface area for support
ct on start / reverse
ct on start / reverse
e material internal of the insert)
cal contamination
Flexible Drive Coupling
failure mechanism (Gear Coupling)
Gear couplings, frictional movment on teeth due to misalignme
Gear couplings, loss of lubricant film
Gear couplings, not relubricated as maintenance
Gear couplings, contaminated lubricant
Gear couplings, sleeve seal cage end ring failures may result f
Gear couplings, teeth lock-up due to excessive misalignment
Gear couplings, teeth lock-up due to excessive misalignment
ation with reversing service or severe load fluctuations exist, fasteners have failed in reverse bending fatigue
rized by: fretting corrosion on the bolt body diameter, imbedding of the bolt washer face diameter into the sleeve, wallowing out of the sleev

astener loosened off)

astened insufficiently tight)

ge vibrations / movements cause micro-motion of coupling flanges

 Flexible Drive Coupling
failure mechanism (Jaw Coupling)

Jaw Coupling, elastomer compression set from over-torque

Jaw Coupling, elastomer compression set from normal use
Jaw Coupling, excessive hub spider leg wear
Jaw Coupling, shaft radial misalignment
Jaw Coupling, shaft angular misalignment
Jaw Coupling, shaft axial misalignment
Jaw Coupling, hub spider jaws sheared
erse bending fatigue
diameter into the sleeve, wallowing out of the sleeve flange holes and/or offset of the bolt body diameter.
 Flexible Drive Coupling
failure mechanism (Disc Coupling)

Disk couplings, cracking or breaks in the individual disk packs or bolts

Disk couplings, check for loose disk pack bolts and/or nuts
Disk couplings, disk cyclic fatigue due to excessive misalignment
the bolt body diameter.
Electric Motor Electric Motor
failure modes failure mechanism

Over-Current Draw Mechanical overload

Poor power conditioning
Excessive effective service factor
Over-voltage
Voltage unbalance
Brushes fail open
Voltage surges
Drop a phase due to winding failure

Fail to Start Power provider interruption

Under-voltage
Cable mechanically damaged
Cable burnt-out from overload
Cable connection overheated
Motor starter failure

Rotor Damage Winding is saturated with water (ingress of water)

Aspirated moisture (ingress of humidity)
High operating temperature
High ambient temperature
Variable frequency drives are employed, insulation life expectancy will be reduced
Chemical ingress degrades internals
Dirt build-up on cooling fins
Frequent stops and starts
Starting method cause high starting loads
Rotor faults, casting voids
Rotor faults, broken rotor bars
Insulation-to-ground faults
Air gap faults, including eccentric rotors
Overloading (load demands exceeding the rating of the motor)
Improper matching of motor to load (inertia matching)
Loose internal wiring connections
Vibration / mechanical looseness
Excessive starts and reversals
Unequal voltage between phases
Voltage surges, switching power circuits ,lightning strikes, capacitor discharges an
Nuisance tripping
Transient voltage peaks

Stator Damage Very high currents in the stator winding due to a locked rotor condition
Dirt build-up on cooling fins
Balance weight came loose and struck the winding
Winding is saturated with water (ingress of water)
Aspirated moisture (ingress of humidity)
Moisture over motor allows short-circuit current to earth
Terminal bolting to wrong connection
Terminal bolting loose connection
Loose internal wiring connections
 Insulation-to-ground faults
Overloading (load demands exceeding the rating of the motor)
Excessive starts and reversals
Voltage surges, switching power circuits ,lightning strikes, capacitor discharges an
Nuisance tripping
Transient voltage peaks
Shorts between conductors or coils

Rotor Bar Failure Poor welded connection

Vibration due to misalignment
Vibration transmitted by nearby equipment
Vibration due to loose mountings
Vibration from out-of-balance
Frame distortion from softfoot

Bearing Failure Excessive radial or axial loading

Electric current flowing through bearings from inverters (Variable Frequency Drive
Insufficient bearing lubrication
Excess bearing lubrication
Lubricant is contaminated
Incorrect lubricant
Out-of-balance, rotor unbalanced
Out-of-balance, balance weight lost
Induced vibration
Shaft misalignment
Wrong coupling type or installation
Belt misalignment
Incorrect belt tension
Defective bearing housings
Defective shaft mounting
Bad mechanical fits
High static loading when stopped
Frame warpage
Broken mounts
Base plate distortion
Missing or deteriorated grouting
Foundation deterioration
Inadequate foundation size and design
Bad or worn shaft
Shaft, bent and run-out excessive
Shaft, axial float excessive
induced mechanical vibration
Overhung loads
Mechanical resonance
Rotor deflection

Shaft Broken Stress raiser, corrosion

Stress raiser, chemical attack
Stress raiser, scratches, mechanical damage (e.g. Pipe wrench used to turn seize
Locked rotor
Bending/ torsional fatigue from misalignment
Massive imposed overload
Keyway fatigue
Improper keyway design
Inadequate shoulder fillet radius
 Manufacturing defects (residual stresses induced)
Overloaded during operation
Fretting and pitting corrosion

7 100
5
ation life expectancy will be reduced

ng of the motor)

ing strikes, capacitor discharges and solid-state power devices

a locked rotor condition

ng of the motor)

ing strikes, capacitor discharges and solid-state power devices

nverters (Variable Frequency Drive waveforms)

(e.g. Pipe wrench used to turn seized shaft)

Pump Set Base Frame Pump Set Base Frame
failure modes failure mechanism

Loose on Foundation Hold-down bolt nuts loose

Hold-down bolts corroded
Hold-down bolts pulled out of concrete
Excessive machine vibration

Warped Frame Foundation not level

Pulled-down unequally on hold-down bolts
Impact by object

Corroded Frame Chemical attack

Water sitting in contact with frame

3 9
1 2
Pump Set Foundation
failure modes

Broken Foundation

Corroded Foundation

Foundation Moves

3
1
 Pump Set Foundation
failure mechanism

Impact by object
Concrete shrink cracks
Foundation support flexs
Ground conditions unsuitable

Chemical attack

Ground strength weak

Undersize foundation