Persistent bearing failure on a centralised extraction fan motor was negatively impacting machine reliability and subsequent operational efficiency for a leading battery manufacturer in East Africa. Despite replacing the motor’s bearings in December 2024, the vibration issues resurfaced within a month.
Since its inception, the battery manufacturer has been using SKF bearings, lubrication systems, maintenance products and mechanical maintenance services. Already well-acquainted with the quality and reliability that the SKF brand represents, the long-standing customer sought the bearing specialist’s expertise in diagnosing the root cause and providing a sustainable solution.
SKF Kenya carried out a thorough bearing failure analysis on the affected ORS 6321/C3 deep groove ball bearing with the intent to pinpoint the root cause of the motor’s persistent high vibration levels. “Our investigation revealed that the primary failure mode was current leakage erosion caused by inadequate electrical insulation. This resulted in wash-boarding on the raceways and eventual surface-initiated fatigue due to lubricant degradation, ultimately leading to bearing failure,” explains SKF Kenya’s Technical Sales Engineer, Polycarp Odima.
The SKF Kenya team recommended SKF INSOCOAT bearings with an insulation coating, hybrid bearings with ceramic rolling elements, and proper grounding of the equipment to prevent electrical discharge damage, as the optimal solution for our customer. Odima adds that as the customer’s current vibration unit is not showing accurate results, they also suggested the use of SKF’s vibration measurement tool – QuickCollect sensor.
Odima elaborates on the unique properties of SKF INSOCOAT bearings that make them the ideal solution for this application: “These bearings feature an electrically insulating coating on the outside surfaces of either the inner or outer bearing ring. This keeps stray electric currents from passing through the bearings, protecting them against electrical erosion damage and helping prevent lubricant degradation resulting from electric current discharge.” These bearings are ideal for larger-size electric motors and generators in railways, wind energy, construction and industrial pumps.
Once installed by Team SKF Kenya, the two SKF INSOCOAT bearings delivered immediate benefits to the customer including increased equipment reliability, improved efficiencies, extended bearing life, reduced maintenance, minimised downtime and subsequent improved production. “The transition to SKF INSOCOAT or hybrid bearings will also significantly reduce bearing replacement frequency and associated labour costs for our customer,” highlights Odima.
“At SKF, we recognise that sustainability is not only essential for our planet but also a critical factor for our customers’ success,” emphasises Odima. “By prioritising sustainable practices, we aim to minimise our environmental impact while enhancing the overall value we provide. Our innovative bearing solution delivers numerous sustainability benefits for our customer: –
- Extended bearing service life reduces material consumption and waste.
- Lower friction and improved bearing performance contribute to reduced power losses in the motor drive system and lower energy consumption.
- Bearing failure prevention minimises the risk of sudden breakdowns, driving productivity and ensuring safer operations.
“Moreover, the fact that we accurately diagnosed the problem, transformed the challenge into a sustainable solution and completed the installation, all within a short ten-day turnaround time, reinforced our customer’s confidence in SKF’s technical support and maintenance solutions,” accentuates Odima. “Through SKF’s expertise in failure analysis and condition monitoring, the customer now has a clear path to achieving sustainable, cost-effective, and reliable battery manufacturing operations. By choosing our bearings, customers can align their operations with sustainable principles, contributing to a more sustainable future while achieving their performance goals,” he concludes.
SKF Kenya provided product and operator training for the customer and is also responsible for aftermarket services, encompassing maintenance and repairs, while parts and spares for the battery producer will be supplied through SKF’s Authorised distribution channels.
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