1、Designation: D8128 17Standard Guide forMonitoring Failure Mode Progression in IndustrialApplications with Rolling Element Ball Type Bearings1This standard is issued under the fixed designation D8128; the number immediately following the designation indicates the year oforiginal adoption or, in the c
2、ase of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon () indicates an editorial change since the last revision or reapproval.INTRODUCTIONOil analysis is a part of condition based maintenance programs. Despite being widely used
3、 forseveral decades, there is no systematic approach in selecting oil tests based on failure mode analysis.Most users select tests primarily based on oil degradation criteria, minimizing the potential fordetecting surface damage and limiting the potential benefits of the oil analysis program. This g
4、uideprovides justification for oil analysis in industrial applications from a failure standpoint to include bothrolling element bearing wear and fluid deterioration.1. Scope1.1 This guide approaches oil analysis from a failure stand-point and includes both the rolling element ball type bearingwear a
5、nd fluid deterioration in industrial application.1.2 This guide pertains to improving equipment reliability,reducing maintenance costs and enhancing the condition-basedmaintenance program primarily for industrial machinery byapplying analytical methodology to oil analysis program forthe purpose of d
6、etecting specific failure modes.1.3 This guide reinforces requirements for appropriateassembly, operation within the original design envelope as wellas the need for condition-based and time-based maintenance.1.4 This guide covers the principles of Failure Mode andEffect Analysis (FMEA) as described
7、in Guide D7874 and itsrelationship to rolling element ball type bearing wear inindustrial application and its fluid deterioration.1.5 This standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility of the user of this standard to establis
8、h appro-priate safety, health, and environmental practices and deter-mine the applicability of regulatory limitations prior to use.1.6 This international standard was developed in accor-dance with internationally recognized principles on standard-ization established in the Decision on Principles for
9、 theDevelopment of International Standards, Guides and Recom-mendations issued by the World Trade Organization TechnicalBarriers to Trade (TBT) Committee.2. Referenced Documents2.1 ASTM Standards:2D445 Test Method for Kinematic Viscosity of Transparentand Opaque Liquids (and Calculation of Dynamic V
10、iscos-ity)D664 Test Method for Acid Number of Petroleum Productsby Potentiometric TitrationD1500 Test Method for ASTM Color of Petroleum Products(ASTM Color Scale)D6304 Test Method for Determination of Water in Petro-leum Products, Lubricating Oils, and Additives by Cou-lometric Karl Fischer Titrati
11、onD6595 Test Method for Determination of Wear Metals andContaminants in Used Lubricating Oils or Used HydraulicFluids by Rotating Disc Electrode Atomic Emission Spec-trometryD7042 Test Method for Dynamic Viscosity and Density ofLiquids by Stabinger Viscometer (and the Calculation ofKinematic Viscosi
12、ty)D7414 Test Method for Condition Monitoring of Oxidationin In-Service Petroleum and Hydrocarbon Based Lubri-cants by Trend Analysis Using Fourier Transform Infrared(FT-IR) SpectrometryD7483 Test Method for Determination of Dynamic Viscosityand Derived Kinematic Viscosity of Liquids by Oscillat-ing
13、 Piston ViscometerD7596 Test Method for Automatic Particle Counting andParticle Shape Classification of Oils Using a Direct1This guide is under the jurisdiction of ASTM Committee D02 on PetroleumProducts, Liquid Fuels, and Lubricants and is the direct responsibility of Subcom-mittee D02.96.04 on Gui
14、delines for In-Services Lubricants Analysis.Current edition approved Oct. 1, 2017. Published October 2017. DOI: 10.1520/D8128-17.2For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact ASTM Customer Service at serviceastm.org. For Annual Book of ASTMStandards volume informati
15、on, refer to the standards Document Summary page onthe ASTM website.Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United StatesThis international standard was developed in accordance with internationally recognized principles on standardization e
16、stablished in the Decision on Principles for theDevelopment of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.1Imaging Integrated TesterD7685 Practice for In-Line, Full Flow, Inductive Sensor forFerromagnetic and
17、 Non-ferromagnetic Wear Debris De-termination and Diagnostics for Aero-Derivative and Air-craft Gas Turbine Engine BearingsD7690 Practice for Microscopic Characterization of Par-ticles from In-Service Lubricants by Analytical Ferrogra-phyD7874 Guide for Applying Failure Mode and Effect Analy-sis (FM
18、EA) to In-Service Lubricant Testing2.2 ISO Standards:3ISO 4407 Hydraulic Fluid PowerFluid contaminationDetermination of particulate contamination by the count-ing method using an optical microscopeISO 11500 Hydraulic Fluid PowerDetermination of theparticulate contamination level of a liquid sample b
19、yautomatic particle counting using the light-extinctionprincipleISO 16232-7 Road VehiclesCleanliness of components offluid circuitsPart 7: Particle sizing and counting bymicroscopic analysisISO 16700 Microbeam analysisScanning electronmicroscopyGuidelines for calibrating image magnifica-tionISO 2459
20、7 Microbeam analysisScanning electronmicroscopyMethods of evaluating image sharpness3. Terminology3.1 Definitions:3.1.1 bearing failure, nthe termination of the bearingsability to perform its design function.3.1.2 bearing failure initiation, nthe moment a bearingstarts to perform outside of its desi
21、gn function measured byperformance characteristics.3.1.3 causes of failure, nunderlying source(s) for eachpotential failure mode that can be identified and described byanalytical testing.3.1.4 design function, nfunction or task that the system orcomponents should perform.3.1.5 detection ability numb
22、er D, nranking number thatdescribes the ability of a specific fluid test to successfullydetect a failure modes cause or effects.Ascale is used to gradedetection ability numbers.3.1.6 dynamic viscosity , nratio of applied shear stressand the resulting rate of shear.3.1.6.1 DiscussionIt is also someti
23、mes called absoluteviscosity. Dynamic viscosity is a measure of the resistance toflow of the liquid at a given temperature. In SI, the unit ofdynamic viscosity is the Pascalsecond (Pas), often conve-niently expressed as milliPascalsecond (mPas), which has theEnglish system equivalent of the centipoi
24、se (cP).3.1.7 effects of failure, npotential outcome(s) of eachfailure mode on the system or component.3.1.8 elastohydrodynamic lubrication (EHD), na condi-tion where extremely high fluid interface pressure developed inconcentrated rolling element contact causes the viscosity of thelubricant to incr
25、ease by several orders of magnitude and for thesurfaces to deform them appreciably in proportion to thethickness of a fluid film between the surfaces.3.1.9 failure-developing period (FDP), nperiod fromcomponents incipient failure to functional failure.3.1.10 failure mode, nthe physical description o
26、f themanner in which failure occurs.3.1.11 failure mode and effect analysis (FMEA),nanalytical approach to determine and address methodicallyall possible system or component failure modes and theirassociated causes and effects on system performance.3.1.11.1 DiscussionThis approach can be used to eva
27、luatedesign and track risk-reducing improvements to equipmentreliability.3.1.12 hydrodynamic lubrication (HD), nlubrication re-gime where the load carrying surfaces are separated by arelatively thick film of lubricant formed by a combination ofsurface geometry, surface relative motion, and fluid vis
28、cosity.3.1.13 kinematic viscosity , nthe ratio of the dynamicviscosity () to the density of the fluid ().3.1.13.1 DiscussionIn SI, the unit of kinematic viscosityis m2/s, often conveniently expressed as mm2/s, which has theEnglish system equivalent of the centistoke (cSt).3.1.14 severity number S, n
29、ranking number that de-scribes the seriousness of the consequences of each failuresmodes, causes and effects on potential injury, component orequipment damage, and system availability.4. Summary of Guide4.1 This guide is designed to assist users in the conditionassessment of rolling element ball typ
30、e bearing applications byselecting oil tests associated with specific failure modes, causesor effects for the purpose of detecting the earliest stage offailure development.4.2 There are a number of different industrial systems withrolling element bearings. A simple horizontal bearing housingutilizin
31、g rolling element ball type bearings lubricated by oilsplash will be discussed. This is a typical arrangement formany industrial overhang pump applications.4.3 The focus of this guide is to select oil tests capable ofdetecting and monitoring progression of specific rolling ele-ment ball type bearing
32、 failure modes, their causes and effectsas well as lubricating oil deterioration related to these failures.5. Significance and Use5.1 This guide is intended as a guideline for justification ofoil test selection for monitoring rolling element ball typebearing conditions in industrial applications. Co
33、ntinuousbenchmarking against similar applications is required to ensurelessons learned are continuously implemented.5.2 Selection of oil tests for the purpose of detecting rollingelement ball type bearing failure modes requires good under-standing of equipment design, operating requirements and3Avai
34、lable from American National Standards Institute (ANSI), 25 W. 43rd St.,4th Floor, New York, NY 10036, http:/www.ansi.org.D8128 172surrounding conditions. Specifically, detailed knowledge isrequired on bearing design configuration, dimensionaltolerances, load directions, design limitations, lubricat
35、ionmechanisms, lubricant characteristics, and metallurgy of lubri-cated surfaces including bearing cages. Equipment criticalityand accessibility as well as application of other monitoringtechniques (for example, vibration, ultrasound or thermalimages) are also critical information in this analysis p
36、rocess. Inaddition, detailed knowledge on the lubricating oil is para-mount.5.3 To properly apply the FMEA methodology users mustunderstand the changes the system may encounter during alloperating modes, their impact on design functions and avail-able monitoring techniques capable of detecting these
37、 changes.To assist this approach, Section 6 will provide extensivedescriptions on the rolling element ball type bearing failuremodes, their causes and effects.5.4 It is recognized that in most industrial applicationsvibration monitoring is the primary condition monitoringtechnique applied to detect
38、failure modes, causes and effects inrolling element ball type bearingswhile oil analysis isprimarily used to monitor the lubricating oil properties. In therecent years, however, there is a trend toward using oil analysisin order to provide earlier detection of some failures of rollingelement ball ty
39、pe bearings. This is particularly applicable tocomplex dynamic systems such as compressors, gearboxes andsome gas turbines where obtaining vibration spectra and theiranalysis may be more difficult.6. Failure Modes and Their Effects for Rolling ElementBall Type Bearing Applications6.1 During normal o
40、peration, rolling element bearings op-erate primarily in the elastohydrodynamic (EHD) lubricationregime. However, in typical rolling element ball bearingapplication the lubrication between the rolling element andcage is usually controlled by the hydrodynamic (HD) lubrica-tion principle.6.2 The EHD o
41、il film thickness depends on the elasticdeformation of the rolling materials, bearing size, rollingspeed, dynamic viscosity of the lubricating oil at operatingtemperature and pressure, as well as the pressure-viscositycoefficient.6.3 The main failure modes of rolling element bearings arerapid or slo
42、w deterioration of the EHD film.6.4 The rapid breakdown of EHD film can be caused by asudden loss of lubricating oil available for splash lubrication, arapid change in bearing operating conditions that is outside theoriginal design basis, or accidental bearing material disintegra-tion.6.5 The slow d
43、eterioration of EHD oil film can be moni-tored by permanent sensors mounted on the bearing housing orby off-line, periodic oil sample analysis. Based on operatingexperience several causes are linked to this failure mode.6.6 Causes of Rolling Element Ball Type Bearing Failures:6.6.1 Change in Dynamic
44、 Viscosity of the LubricatingOilAlthough under the EHD theory dynamic viscosity valueis reduced (approximately to the power 0.7), this oil property isstill one of the main factors controlling the oil film thickness.In general, a reduction in dynamic viscosity will reduce oil filmthickness. Under sev
45、ere transient conditions, reduction of theoil film thickness may change the lubricating regime fromEHD to mixed or boundary, resulting in an increased the risk ofbearing surface contact and wear. Under the opposite conditionwhen the dynamic viscosity is too high, an increase in drag andfriction will
46、 result in local heat generation. This may increasethe rate of chemical reaction within the oil film. In condition-based maintenance programs for industrial applications, kine-matic viscosity at 40 C (or occasionally at 100 C) is used tomeasure this property. The assumption is that in most industria
47、lapplications, lubricant density is not significantly changed inthe measured temperature of interest (for example, 40 C or100 C) and trending kinematic viscosity can provide adequateprediction of the lubricants ability to form a reliable andsustainable EHD oil film. However, newer methods exist that
48、will measure dynamic viscosity directly (Test Method D7042).These methods may in time become commonly used in thisapproach.6.6.2 Deterioration of Lubricating Oil ChemistryTheEHD lubrication condition will also depend on the complexrelationship between properties of oil-to-metal adhesion andoil-to-oi
49、l cohesion. Applying a constant shear stress on thelubricating oil film may lead to physical damage to thelubricant molecules. The presence of atmospheric oxygen mayinitiate chemical reactions such as oxidation. High temperatureand pressure will accelerate these reactions and cause thermalbreakdown of lubricant molecules. Finally, lubricating oil willalso deteriorate by the additive depletion process (for example,due to expected performance). The depletion rate woulddepend on the additive type, applications, and operatingcondition
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