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Utilizing Macro- and Microstructural Characterization in Root Cause Analysis (RCA) of a Shaft-Bearing Assembly Failure

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Abstract

Detailed failure analysis was carried out on a pump-shaft-assembly containing a step shaft, one single row bearing (SRB) and one double row bearing (DRB). Furthermore, the present failure was associated with a fire incident at a petroleum processing plant. Experimental techniques used included visual inspection, stereoscopy, optical and scanning electron microscopy (SEM), chemical analysis and mechanical testing. Major final failure modes observed included abrasive wear, macro denting, plastic deformation, contact stress fatigue and microstructural and property modifications. Present results indicated the main factor causing assembly failure is the presence of a high-magnitude axial load. Present evidence suggested this extremely high axial load itself to be the result of a pump malfunction—blocking of the pump discharge—which is believed to be the root cause of the present failure. Heat was found to be a main player in the present failure progression. Macro- and microstructural analysis, however, confirmed this heat to be of a frictional origin and not due to the observed fire. This was manifested through the inhomogeneity of the macro- and microstructural modification patterns observed at different locations within the assembly. The fire itself is believed to be due to the exposure of the used lubricant to extremely high temperatures (790–820 °C) beyond its self-igniting temperature range as indicated by the observed microstructural modification and associated softening in the different bearing elements. Some practical recommendations are provided towards the end of this article regarding the present failure.

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Acknowledgments

The authors would like to express their sincere gratitude for SKF, Sven Wingquists gata 2, 415 50 Gothenburg, Sweden for generously granting permission to parts of their literature in this article.

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Authors and Affiliations

  1. Industrial Engineering Department, University of Jordan, Amman, 11942, Jordan

    Abdul Kareem Abdul Jawwad

  2. Industrial Engineering Department, College of Engineering-Rabigh, King Abdul-Aziz University, Jeddah, Saudi Arabia

    Bassam Hasanain & Abdullah Aldamak

  3. Industrial Engineering Department, Jeddah College of Engineering, University of Business and Technology, Jeddah, Saudi Arabia

    Siraj Zahran

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  1. Abdul Kareem Abdul Jawwad
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Correspondence to Abdul Kareem Abdul Jawwad.

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Bearing damage and failures – modes and causes [20] Published with written (email) permission dated 12,12,2022

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Abdul Jawwad, A.K., Hasanain, B., Aldamak, A. et al. Utilizing Macro- and Microstructural Characterization in Root Cause Analysis (RCA) of a Shaft-Bearing Assembly Failure. J Fail. Anal. and Preven. 23, 948–969 (2023). https://doi.org/10.1007/s11668-023-01650-7

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