Durban: A crucial sugar refinery in KwaZulu-Natal, Tongaat Hulett, averted potentially crippling production losses thanks to a meticulous bearing failure analysis conducted by SKF and their authorised distributor, Bearings Services Durban. The collaborative effort shed light on preventative measures, highlighting the often-overlooked importance of expert diagnostics in industrial settings.
The refinery’s mainline pump, a vital component of its production line, suffered repeated breakdowns, leading to significant downtime. Maintenance Engineer Adarsh Madanlal described the frustration of the situation: “The pump tripped and refused to start. Upon removal, we found a failed bearing. Even after changing the oil, it turned black within a day. We could not determine the cause, leaving us in a frustrating limbo.”
Faced with this persistent problem, Tongaat Hulett turned to SKF, their trusted partner for over a decade. Shaniel Rambally, Bearings Services Durban Branch Manager, recognised the urgency of the situation. “Understanding the root cause was critical,” he explained. “We recommended an ISO Bearing Damage Analysis on multiple bearings.”
The bearings were swiftly sent to SKF for analysis, with a detailed report delivered within an impressive 10-12 working days. SKF specialists concluded that the failure was due to rolling contact fatigue, a condition caused by repeated stress under inadequate lubrication.
“Fatigue manifests as a change in the structure and is a result of inadequate lubricant film thickness,” explained Titus Kasie, SKF Territory Sales Manager.
The refinery team was impressed by the thoroughness of the analysis. “The report was astoundingly detailed,” said Madanlal. “It was presented in a clear, accessible way, even for those without specialised knowledge.”
Crucially, the analysis went beyond identifying the problem. It provided practical guidance on corrective practices, helping to prevent future failures. “The report also gave us a good understanding of how other factors can contribute to premature bearing failure,” Madanlal added.
The experience highlighted the value of specialised bearing failure analysis, a service often underappreciated in the industry. “Its importance is evident from this constructive outcome, particularly in FMCG plants, where it plays a crucial role in optimising operational efficiencies,” Madanlal noted.
The success story underscores the importance of proactive maintenance and the value of expert partnerships in industrial settings. By identifying and addressing the root cause of equipment failures, companies can avoid costly downtime and ensure smooth, efficient operations.
