Root Cause Investigation

Blower Motor
Motor Drive End and Non Drive End Grease and Bearing analysis
Blower Motor Root Cause Failure Analysis Report
Purpose
Vibration analysis of the blower motor unit indicated abnormal vibration and possible bearing
damage in the COMPANY motor. The bearings were removed prior to total failure and root
cause analysis was performed on both the drive end (DE) and non-drive end (NDE) bearings to
gain further information on the cause of the high vibration. Grease extracted from the bearings
was analyzed to look for wear, particulate contamination, or changes in grease physical
properties in order to determine the contributing causes of premature failure. Both submitted
bearings were inspected and evaluated based on visual observations. The information in this
report considers these data sources, along with submitted information from the client to
determine contributing factors and the most likely root causes of the abnormal vibrations
measured while these bearings were in operation.

Methodology
Grease analysis, including metal elemental analysis, Fourier Transform Infrared Spectroscopy
(FTIR), anti-oxidant additive analysis (RULER), microscopic inspection of separated particulate
(ferrography), and rheological analysis, were performed to analyze the samples submitted from
the COMPANY motor bearings. The drive end and non drive end bearings were also visually
inspected under controlled light and magnification to evaluate surface damage and wear
mechanisms to determine possible failure modes. The client provided photographs, engineering
drawings, and vibration spectra, which were considered to provide an operating context for the
equipment. Photographs were taken to document the condition of the rolling elements. The
specified grease to be used in the bearing is Mobil SHC 100, and a sample from the lab was used
in all baseline comparisons.

Results and Analysis

Grease Analysis of COMPANY Motor Non-Drive End (NDE)
Grease analysis was performed on the COMPANY Motor NDE sample to evaluate the wear,
contamination, consistency and chemical properties of the grease. The results of FTIR and
RULER analysis are shown below in Figures 1 and 2.

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 Figure 1: FTIR comparison spectrum

Figure 2: RULER Graph

The FTIR and RULER images from the NDE sample match well with the MOBIL SHC 100
baseline and indicate little to no organic contamination. The RULER Graph (Figure 2) shows
low anti-oxidant concentration, but this is not untypical in grease systems and because they are
replenished each time the bearing is relubricated, the remaining amount here is acceptable, and
would suggest that replenishment soon after this sample was taken would be appropriate.

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Analysis showed excessive wear, but this was most likely a symptom rather than a cause. There
was a very high iron concentration in the grease sample, which indicated the early stages of
failure of the bearing. RDE spectral analysis (elemental metals) also showed trace amounts of Si
and Al, which could indicate particulate contamination from the environment or storage, though
this would not be the root cause of failure. The analytical ferrography slides, shown on the next
page, confirm this as well. Figure 3 shows severe cutting wear and Figure 4 shows some abrasive
contaminates still in the lubricant.

RDE spectral analysis also showed high concentration of Barium, Boron, and Calcium, which
are typically found in additives packages or thickeners, but could also be from foreign particulate
contaminants. The consistency of the grease was also elevated, which could be a combination of
particulates, or a mixing of greases with a similar grease product with slight formulation
differences.

Figure 3: Severe cutting wear particle, which can be caused by

abrasive particulate, or abnormal angular contact of steel surfaces.

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 Figure 4: Abrasive contamination. Although not found in high
concentration in the sample, it could have been present at start up
and flushed away during subsequent relubrication. It was not a
major failure mode, and did not cause the high vibration, but could
have decreased the life of the bearing.

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Bearing Analysis of Unit 35 Non-Drive End
The unique wear along one circular track shown in Figure 5 indicates a lack of free rotation and
normal ball loading during use. Preferential loading like this is seen when the balls rotate with
the bearing, but are pinned to one orientation, most likely due to high axial loading. In some
cases, as shown in Figure 6, the wear path changed only once during use to result in 2 visible
loading tracks.

Figure 5

Figure 6

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Large amounts of fretting wear was noted on the outside of the outer race of the NDE bearing,
shown in Figure 7 and 8. While it looks similar to corrosion, it is usually due to vibration as the
bearing chatters in its housing due to poor fit and significant unloaded vibration.

Figure 7: Fretting wear Figure 8: Fretting wear

There was also some particle denting on the inner and outer race and scratches on the balls due to
abrasive particles in the lubrication. These features are shown on the following page. Both were
visible under magnification, but can be difficult to see in digital images.

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 Figure 9: Particle denting in the outer race of the NDE due to abrasive debris in the
lubricant. This type of wear is due to hard environmental contamination, such as
dust or dirt, as opposed to relatively softer steel pieces that result from wear.

Figure 10: Scratches on the surface of the bearing indicate a hard, abrasive,
environmental contaminate in the lubricant.

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Grease Analysis of COMPANY Motor Drive End (DE)
Grease analysis was performed on the COMPANY Motor DE sample to evaluate the wear,
contamination, consistency and chemical properties of the grease. The results of FTIR and
RULER analysis are shown below in Figures 11 and 12.

Figure 11: FTIR comparison spectrum

Figure 12: RULER Graph

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The FTIR and RULER images from the DE sample match well with the MOBIL SHC 100
baseline and indicate little to no organic contamination. The RULER Graph (Figure 2) shows
low anti-oxidant concentration, but this is not untypical in grease systems and because they are
replenished each time the bearing is relubricated, the remaining amount here is acceptable, and
would suggest that replenishment soon after this sample was taken would be appropriate.
Analysis showed less wear than the other bearing

Elemental spectroscopy of the drive end sample showed less wear than the NDE, within the
normal range, but the type of wear indicates a more severe failure mode. The gouging wear
shown in Figure 13 is a serious issue and caused by the large dents in the race of the bearing that
were created by false brinnelling.

Figure 13: Gouging wear cause as the rolling element

slide over a dent in the race and cut pieces of steel out of
the surface of both the race and the ball.

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 Figure 14: Red Oxide caused by false brinelling

Figure 15: Black Oxides caused by false brinelling

The black and red oxides seen in Figure 14 and 15 are indicative of wear generated following
false brinnelling of the races. These oxidized particles are caused as the bearing vibrates without
rotation of the shaft. This can happen in storage, but is typically due to vibration during standby
conditions, while an adjacent component is in operation. These types of particles were evident in
high concentration on the ferrography slide and with continued service would have rapidly
progressed to bearing failure.

RDE spectral analysis also showed high concentration of Barium, Boron, and Calcium, which
are typically found in additives packages or thickeners, but could also be from foreign particulate
contaminants.

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Bearing Analysis of COMPANY Motor Drive End
Brinelling or false brinelling, evident on the outer race of the DE, is shown in Figure 16 and 17
on the next page. The marks are created when the bearing is subjected to significant vibration
while it is not rotating, either from adjacent equipment or from improper storage. The vibration
would most likely come from the adjacent fan. While the design of the air handling unit should
have prevented this from happening while in service, by slow rotation of the standby unit due to
common plenum flow, this does not appear to have been the case. Also, the false brinnelling
marks seen on the DE bearing are not found in the center of the race, but rather skewed
significantly to one side. This implies that an axial load held the shaft in this thrusted position,
and may also account for the lack of free rotation while in standby.

Figure 16: False brinnelling on the outer race of the DE Figure 17: False brinnelling

Causal Factors and Root Causes

 Root Cause: Standby vibration while in standby generated false brinnell marks on the
inner and outer race of the bearings.
 Root Cause: Axial loading indicated by the false brinnell markings being off center on
the race in DE bearing, and defined wear tracks on the balls of NDE bearing. Also may
have contributed to lack of rotation in standby condition, leading to conditions required
for false brinnelling.

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  Causal Factor: Abrasive debris caused scratches on the surface of the rolling elements
and generated impact denting along the wear track, which would have lead to shortened
bearing life through fatigue failure.
 Causal Factor: Loose bearing fit in housing lead to fretting corrosion on outside of outer
race of NDE bearing.

Corrective Actions and Recommendations

1. Ensure free-rotation of fans as installed, and rotation during standby operation, either
induced by common plenum flow, or through periodic rotation.
2. Check installation for free coupling float, and relief of axial loading on motor bearings.
3. Maintain good housekeeping and take preventive measures to keep abrasive
contamination out of the bearing and lubrication supply, particularly during periods of
extended storage.
4. Verify proper housing and shaft fits for bearings.

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