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HOW TO USE THIS EXCEL FILE

① HOW TO ADD NEW EQUIPMENT
 Step-1: Go to <Failure Modes> sheet and Click < ADD New Equipment> Button.

 Step-2: Enter <Equipment Name> and Click OK.

 Step-3: Once you Click OK, Blank NEW Worksheet will be created and activated.

 Step-4: In this NEW Worksheet ;

❶ List the <PROBLEMS> related to this Equipment as column headers

❷ List the <CAUSES> to Column B

❸ Put "X" to the intersection of the PROBLEMS and their related CAUSE.
For example; THE PROBLEM of Vibration, the related/possible CAUSES are marked with "X" ;
 Cage wear,
 Flats on races of rolling elements
 Race turning
 etc...
 Cage wear,
 Flats on races of rolling elements
 Race turning
 etc...

② HOW TO REVIEW FAILURE MODES

 Step-1: Go to <Failure Modes> sheet and Click <Equipment Dropdown List>.

 Step-2: Select an Equipment from <Equipment Dropdown List>.

 Step-3: Once you Select an Equipment, <the List of the PROBLEMS> related to this Equipment is Updated automatically
 Step-3: Once you Select an Equipment, <the List of the PROBLEMS> related to this Equipment is Updated automatically

 Step-4: Just Select a PROBLEM from the LIST to see the <List of the related/possible CAUSES> for this problem.
t is Updated automatically.
t is Updated automatically.

S> for this problem.

Select Equipment

ADD
ADD New
New Equipment
Equipment Go
Go To..
To..

List of THE PROBLEMS related to "Selected Equipment" (CLICK TO SEE THE POSSIBLE CAUSES)

List of The POSSIBLE CAUSES related to "Selected Problem"

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Common Failure Modes of Bag Filters THE PROBLEM

Intermittent Release of Dust-Laden Air

Continuous Release of Dust-Laden Air

Excessive Differential Pressure

Differential Pressure Too Low

Loss of Plant Air Pressure

Chronic Plugging of Bags

Fan/Blower Motor Trips

Premature Bag Failures

Fan Has High Vibration
Blow-Down Ineffective
Insufficient Capacity
THE CAUSES
Bag Material Incompatible for Application X X
Bag Plugged X X X
Bag Torn or Improperly Installed X X X X
Baghouse Undersized X X X
Blow-Down Cycle Interval Too Long X X
Blow-Down Cycle Time Failed or Damaged X X
Blow-Down Nozzles Plugged X
Blow-Down Pilot Valve Failed to Open (Solenoid Failure) X X
Dust Load Exceeds Capacity X
Excessive Demand X
Fan/Blower Not Operating Properly X
Improper or Inadequate Lubrication X
Leaks in Ductwork or Baghouse X X
Misalignment of Fan and Motor X
Moisture Content Too High X
Not Enough Blow-Down Air (Pressure and Volume) X X X
Not Enough Dust Layer on Filter Bags X X X X
Piping/Valve Leaks X
Plate-Out (Dust Build-up on Fan's Rotor) X
Plenum Cracked or Seal Defective X X X
Rotor Imbalanced X
Ruptured Blow-Down Diaphrams X X X
Suction Ductwork Blocked or Plugged X
Common Failure Modes of BEARINGS THE PROBLEM

Turning on the Shaft

Binding of the Shaft

Lubricant Leakage
Noisy Bearing
Overheating
Vibration
THE CAUSES
Inadequate or insufficient lubrication X
Dirt or chips in bearing X
Growth of race due to overheating X
Lubricant breakdown X X
Overfilling of lubricant X
Excessive lubrication X
Fatigued race or rolling elements X
Fretting wear X
Contamination by abrasive or corrosive materials X
Inadequate lubrication X
Grease churning due to too soft consistency X
Grease liquification or aeration X
Rotor unbalance X
Improper initial fit X
Housing distortion or out-of-round pinching bearing X
Pinched bearing X
Grease deterioration due to excessive operating temperature X
Oil foaming X
Out-of-round shaft X
Excessive shaft deflection X
Uneven shimming of housing with loss of clearance X
Contamination X
Operating beyond grease life X
Abrasion or corrosion due to contaminants X
Race misalignment X
Initial coarse finish on shaft X
Tight rubbing seals X
Seal rubbing X
Seal wear X
Housing distortion due to warping or out-of-round X
Housing resonance X
Seal rub on inner race X
Preloaded bearings X
Bearing slipping on shaft or in housing X
Wrong shaft attitude (bearing seals designed for horizontal mounting only) X
Seal rubbing or failure X
Cage wear X X
Cocked races X
Flatted roller or ball X
Seal failure X
Inadequate or blocked scavenge oil passages X
Flats on races or rolling elements X
Loss of clearance due to excessive adapter tightening X
Brinelling due to assembly abuse, handling, or shock loads X
Clogged breather X
Inadequate bearing clearance or bearing preload X
Race turning X X
Thermal shaft expansion X
Variation in size of rolling elements X
Oil foaming due to churning or air flow through housing X
Excessive clearance X
Out-of-round or lobular shaft X
Gasket (O-ring) failure or misapplication X
Corrosion X
Housing bore waviness X
Porous housing or closure X
False-brinelling or indentation of races X
Chips or scores under bearing seat X
Lubricator set at the wrong flow rate X
Electrical arcing X
Mixed rolling element diameters X
Out-of-square rolling paths in races X
Common Failure Modes of Blowers and
THE PROBLEM
Fluidizers

Insufficient Discharge Pressure

Elevated Air/Gas Temperature

Excessive Vibration and Noise

Elevated Motor Temperature

Excessive Power Demand
Insufficient Capacity
No Air/Gas Delivery

Excessive Wear
Excessive Heat

Motor Trips
THE CAUSES
Air Leakage into Suction Piping or Shaft Seal X X X
Coupling Misaligned X X X X X
Excessive Discharge Pressure X X X X X X
Excessive Inlet Temperature/Moisture X
Insufficient Suction Air/Gas Supply X X X X X
Internal Component Wear X X X
Motor or Driver Failure X
Pipe Strain on Blower Casing X X X X X
Relief Valve Stuck Open or Set Wrong X X
Rotating Element Binding X X X X X X
Solids or Dirt in Inlet Air/Gas Supply X
Speed Too Low X X X
Suction Filter or Strainer Clogged X X X X X
Wrong Direction of Rotation X X X
 Common Failure Modes of Bolted Joints THE PROBLEM

Fracture Under Static Load

Vibration Loosening
Fatigue Failure

Joint Leakage
Bolt Failure
THE CAUSES
Bolt/Joint Stiffness Ratio X X X
Damping in Joint X
Direction of Bolt Axis Relative to Vibration Axis X
Design And Manufacturing

Fillet Size and Shape X

Galling X
Improper Heat Treatment X
Nut Dilation X
Parts Finish X
Poor Fix X X
Radius of Thread Roots X
Relaxation Effects X X
Thread Run out X
Tool Marks X
Bolt-up Procedure X X
Condition of Gaskets X
Assembly
Practices

Condition of Joint Surfaces X

Improper Preload X X X
Thread Lubrication X X X
Type of Tool Used X
Corrosion X X X X
Operating

Magnitute of Load Excursions X X

Cond.

Temperature Cycling X
Common Failure Modes of Centrifugal Compressors THE PROBLEM

Excessive Bearing OII Drain Temp.

Units Do Not Stay in Alignment
Loss of Discharge Pressure
Low Lube Oil Pressure

Persistent Unloading
Compressor Surges
Excessive Vibration

Water in Lube Oil

Motor Trips
THE CAUSES
Bearing Lube Oil Orifice Missing or Plugged X
Bent Rotor (Caused by Uneven Heating and Cooling) X X
Build-up of Deposits on Diffuser X
Build-up of Deposits on Rotor X X
Change in System Resistance X X
Clogged Oil Strainer/Filter X
Compressor Not Up to Speed X
Condensate in Oil Reservoir X
Damaged Rotor X
Dry Gear Coupling X
Excessive Bearing Clearance X
Excessive Inlet Temperature X
Failure of Both Main and Auxiliary Oil Pumps X
Faulty Temperature Gauge or Switch X X X
Improperly Assembled Parts X X X
Incorrect Pressure Control Valve Setting X
Insufficient Flow X
Leak In Discharge Piping X
Leak In Lube Oil Cooler Tubes or Tube Sheet X
Leak in Oil Pump Suction Piping X
Liquid "Slugging" X X
Loose or Broken Bolting X
Loose Rotor Parts X
Oil Leakage X
Oil Pump Suction Plugged X
Oil Reservoir Low Level X
Operating at Low Speed w/o Auxiliary Oil Pump X
Operating in Critical Speed Range X
Operating in Surge Region X
Piping Strain X X X X X
Poor Oil Condition X
Relief Valve Improperly Set or Stuck Open X
Rotor Imbalance X X
Rough Rotor Shaft Journal Surface X X X
Shaft Misalignment X X
Sympathetic Vibration X X X
Vibration X
Warped Foundation or Baseplate X X
Wiped or Damaged Bearings X X
Worn or Damaged Coupling X
Common Failure Modes of Centrifugal Fans THE PROBLEM

Insufficient Discharge Pressure

Power Demand Excessive

Intermittent Operation

Overheated Bearings
Insufficient Capacity

Overload on Driver
Short Bearing Life

High Noise Levels

High Vibration
THE CAUSES
Abnormal End Thrust X X
Aerodynamic Instability X X X X X X
Air Leaks in System X X X
Bearings Improperly Lubricated X X X
Bent Shaft X X X X X
Broken or Loose Bolts or Setscrews X X
Damaged Motor X
Damaged Wheel X X X
Dampers or Variable-Inlet Not Properly Adjusted X X
Dirt in Bearings X X
Excessive Belt Tension X X
External Radiated Heat X
Fan Delivering More Than Rated Capacity X X
Fan Wheel or Driver Imbalanced X X
Foreign Material in Fan Causing Imbalance (Plate-Out) X X X
Incorrect Direction of Rotation X X X X
Insufficient Belt Tension X X
Loose Dampers or Variable-Inlet Vanes X
Misaligment of Bearings, Coupling, Wheel, or Belts X X X X X
Motor Improperly Wired X X X
Packing Too Tight or Defective Stuffing Box X X X
Poor Fan Inlet or Outlet Conditions X X
Specific Gravity or Density Above Design X X X
Speed Too High X X X X X
Speed Too Low X X X X
Too Much Grease in Ball Bearings X
Total System Head Greater Than Design X X X X X
Total System Head Less Than Design X X
Unstable Foundation X X X X
Vibration Transmitted to Fan from Outside Sources X X X
Wheel Binding on Fan Housing X X X X
Wheel Mounted Backward on Shaft X X
Worn Bearings X X
Worn Coupling X
120-Cycle Magnetic Hum X X
 M

X
X
X
X
X
X
X
X
Motor Trips
Common Failure Modes of Centrifugal Pumps THE PROBLEM

Insufficient Discharge Pressure

High Bearing Temperatures

Short Mechanical Seal Life

Intermittent Operation
Insufficient Capacity
No Liquid Delivery

Short Bearing Life

High Noise Levels

High Vibration
THE CAUSES
Bent Shaft X X X X
Casing Distorted from Excessive Pipe Strain X X X X
Cavitation X X X X X X X X
Clogged Impeller X X X X
Driver Imbalance X X X
Electrical Problems (Driver) X X X
Entrained Air (Suction or Seal Leaks) X X X X X
Hydraulic Instability X X X X X
Impeller Installed Backward (Double-Suction Only) X X
Improper Mechanical Seal X
Inlet Strainer Partially Clogged X X X X
Insufficient Flow through Pump
Insufficient Suction Pressure (NPSH) X X X X X X
Insufficient Suction Volume X X X X X X X
Internal Wear X X X
Leakage in Piping, Valves, Vessels X X X
Mechanical Defects, Worn, Rusted, Defective Bearings X X
Misalignment X X X X
Misalignment (Pump and Driver) X
Mismatched Pumps in Series X X X X
Noncondensables in Liquid X X X X X
Obstructions in Lines or Pump Housing X X X X
Rotor Imbalance X X X
Specific Gravity Too High X
Speed Too High
Speed Too Low X X X
Total System Head Higher Than Design X X X X X X
Total System Head Lower Than Design X X X X
Unsuitable Pumps in Parallel Operation X X X X X X
Viscosity Too High X X
Wrong Rotation X X
 OBLEM

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Power Demand Excessive

X
X
X
X
Motor Trips

X
X
X
X
X
X
X
X
X
X
X
Elevated Motor Temperature

X
X
X
X
X
X
X
X
X
Elevated Liquid Temperature

1
1
Common Failure Modes of CouplingsChain THE PROBL

Excessive temperature
Leaking lubricant
Vibration
Noise
THE CAUSES
Loose or damaged chain X X
Loose chain cover X
Loose key or damaged shaft keyway X
Misalignment, unbalance X X X
Worn chain sprockets X X
Lack of Lubricant X
Damaged chain cover X
Excessive loads or speeds X X
Improper or excessive lubricant X
Incorrect grease consistency or excessive lubricant X
THE PROBLEM
Common Failure Modes of CouplingsElastomeric THE PROBLEM

Distorted or deteriorated Elastomeric element

Fatigue of elastomeric element
Ruptured elastomeric element
Excessive Temperature
VIBRATION
NOISE
THE CAUSES
Loose bolts (components) X X
Ripped or torn rubber X
Loose key or damaged shaft keyway X
Misalignment, unbalance X X X
Excessive loads or speeds X X
Inappropriate guard (preventing air circulation) X
Torsinal shock X
Torsional vibration X
Excessive starts and stops X
High peak to peak Torsional overload X
Excessive heat X
THE PROBLEM
Common Failure Modes of FlexibleCouplings THE PROBLEM

Distorted or deteriorated Elastomeric element

Ruptured elastomeric flexible element

Swollen or cracked Flexible member

Fatigue of elastomeric element
Overheated Flexible element
Worn Flexible Element

Severe hub corrosion

Shaft Bearing Failure

Loose hubs on shaft

Sheared hub
THE CAUSES
Excessive shaft Misalignment X X
Torsional shock X X X
Overload X X X
Torsional vibration X X
Excessive starts and stops X X
High peak to peak Torsional overload X X
Chemical attack X X
Excessive heat X
Low Temperature
Loosen bolts
Improper hub size selection
Improper installation X
 X
Shattered Flexible Element

X
X
X
Elongated Bolt Holes

X
Key roll in seat
THE PROBLEM
Common Failure Modes of CouplingsFlexibleDiscs THE PROBLEM

Exessive temperature
Vibration
Noise
THE CAUSES
Loose, broken or missing bolts X X
Broken, cracked or loose discs X X
Loose key or damaged shaft keyway X X
Key of incorrect length or weight X
Misalignment, unbalance X X X
Excessive loads or speeds X
THE PROBLEM
Common Failure Modes of FluidCouplings

Installation runs unevenly

Rated speed not reached

Fusible safety plug melts

THE CAUSES
Drive motor defective or incorrectly connected X
Driven machine jammed X
Power consumption of driven machine too high X X
Too much oil in the coupling, motor does not reach rated speed X
Oil filling too low X X
Coupling leaking X X
Motor running to long in star mode X
Bad alignment X
Bearings damaged X
Foundation fittings loose X
THE PROBLEM
Common Failure Modes of CouplingsGear THE PROBLEM

Excessive temperature

Fretting corrosion
Leaking lubricant

Internal cracks
Tooth damage

Discoloration
Degradation
Vibration
Noise
THE CAUSES
Loose, broken or missing bolts X X X
Loose key or damaged shaft keyway X
Misalignment, unbalance X X X X X
Worn or broken gear teeth X X
Lack of Lubricant X
Damaged seal or gasket X
High temperature X
Excessive loads or speeds X
Insufficient, improper or excessive lubricant X
Sludge contamination reduces lubricant flow X
Sludge contamination reduces coupling flexibility X
Improper lubrication X X
Lubricant contamination X
THE PROBLEM
Common Failure Modes of CouplingsGrid

Excessive temperature
Leaking lubricant
Vibration
Noise
THE CAUSES
Loose, broken or missing bolts X X X
Loose key or damaged shaft keyway X
Misalignment, unbalance X X X X
Loose, broken or badly worn serpentine spring grid assembly X X
Lack of Lubricant X
Damaged seals X
High temperature X
Excessive loads or speeds X
Insufficient, improper or excessive lubricant X
THE PROBLEM
Common Failure Modes of ElectricalMotors

Motor seems too weak, runs slow

Motor will not start its load

Excessive brush wear

Faulty commutation
Motor runs too fast
Motor runs too hot
Motor fuses blown
THE CAUSES
No voltage at the motor terminals X
Low line voltage X X
Fuses blown X
Poor contacts or connections X X
Brushes not set properly X
Motor connected to the wrong power circuit X X X X
Motor terminals not properly connected to the power circuit X X
Service lines and/or transformer is too small X
Motor overloaded X X X X X
Shorted, grounded or open windings X
Worn bearings allowing the rotating part to dropdown on the X
stationary fields
Low voltage at motor terminals X
Motor improperly connected to circuit X X
Motor windings damaged X X X X X
High voltage X X
Frequency too high X
Motor overloaded during starting and running X
Misalignment X
Insufficient lubrication X
Faulty commutation X
One fuse blown in two or three-phase motor circuit allowing motor X
to operate on single phase
Fuse too small X
Protruding mica or rough commutator X X
Dirt or oil on commutator X
Brushes stuck in holders X
Wrong brush position X
Weak springs X
Excessive sparking or flashing at the brushes X
Wrong quality brush X
Copper dust
Dirt or oil on brush holder parts where oil enter the slots in the field
Defective Insulation
Mechanical damage to insulation in handling
Over-heating sufficient to char the insulation
Solder between commutator bars where armature leads are
connected
Broken wires
Defective soldering
Lead wires disconnected
Commutator leads loose
Dirt or foreign matter in brush holder
Rough spots on brushes
Brush tension spring inccorectly applied
Brush tension spring is weak
Brush spring not in proper position
Brushes are not sanded properly
 X
X
X
X
X
X
Grounded field or armature

X
X
Short circuited field or armature

X
Open circuited field or armature
Sticking brushes
Brushes not making contact
THE PROBLEM
X
X
X
X
X
X
X
X
X
X
Common Failure Modes of Gearboxes and Gear Sets THE PROBLEM

Variations in Torsional Power

Insufficient Power Output
Overheated Bearings

Overload on Driver
Short Bearing Life

High Noise Levels

High Vibration
Gear Failures

Motor Trips
THE CAUSES
Bent Shaft X X X X
Broken or Loose Bolts or Setscrews X X
Damaged Motor X X X
Eliptical Gears X X X X
Exceeds Motor's Brake Horsepower Rating X X
Excessive or Too Little Backlash X X
Excessive Torsional Loading X X X X X X X
Foreign Object in Gearbox X X X X
Gear Set Not Suitable for Application X X X X
Gears Mounted Backward on Shafts X X X
Incorrect Center-to-Center Distance Between Shafts X X
Incorrect Direction of Rotation X X X
Lack of or Improper Lubrication X X X X X X X
Misalignment of Gears or Gearbox X X X X X X
Overload X X X X X
Process Induced Misalignment X X X X
Unstable Foundation X X X X
Water or Chemicals in Gearbox X
Worn Bearings X X
Worn Coupling X
Common Failure Modes of Inverters THE PROBLEM

Control Circuit Undervoltage

Frequent Speed Deviations

Main Circuit Undervoltage

Motor/Inverter Overload
Momentary Power Loss

Heat-Sink Overheat
Load Short-Clrcuit
Ground Fault
Overcurrent

Overvoltage
THE CAUSES
Accel/Decel Time Too Short X X
Acceleration Rate Too High X X
Ambient Temperature Too High X
Control Power Source Too Low X
Cooling Fan Failure or Improper Operation X
Deceleration Time Too Short X X
Excessive Braking Required X
Improper or Damaged Power Supply Wiring X X
Improper or Damaged Wiring in Inverter-Motor X
Incorrect Line Voltage X X X
Main Circuit DC Voltage Too Low X
Motor Coil Resistance Too Low X X
Motor Insulation Damage X X
Pre-Charge Contactor Open X
Process Load Exceeds Motor Rating X X
Process Load Variations Exceed System Capabilities X
Common Failure Modes of Pneumatic Conveyors THE PROBLEM

Frequent Fan/Blower Motor Trips

Output Exceeds Rated Capacity
Fails to Deliver Rated Capacity

Fan/Blower Bearing Failures

Frequent System Blockage
Product Contamination

Fan/Blower Failures
THE CAUSES
Aerodynamic Imbalance X X X
Blockage Caused By Compaction of Product X X X
Contamination in Incoming Product X
Excessive Moisture in Product/Piping X X X X X
Fan/Blower Too Small X X X
Foreign Object Blocking Piping X X X
Improper Lubrication X X
Mechanical Imbalance X X
Misalignment X X
Piping Configuration Unsuitable X X X
Piping Leakage X X
Product Compaction During Downtime/Stoppage X X X
Product Density Too Great X X X
Product Density Too Low X
Rotor Binding or Contacting X X X
Startup Torque Too Great X
Common Failure Modes of Rotary-Type, Positive-
THE PROBLEM
Displacement Compressors

Insufficient Discharge Pressure

Elevated Air/Gas Temperature

Excessive Vibration and Noise

Elevated Motor Temperature

Excessive Power Demand
Insufficient Capacity
No Air/Gas Delivery

Excessive Wear
Excessive Heat

Motor Trips
THE CAUSES
Air Leakage Into Suction Piping or Shaft Seal X X X
Coupling Misaligned X X X X X
Excessive Discharge Pressure X X X X X X
Excessive Inlet Temperature/Moisture X
Insufficient Suction Air/Gas Supply X X X X X
Internal Component Wear X X X
Motor or Driver Failure X
Pipe Strain on Compressor Casing X X X X X
Relief Valve Stuck Open or Set Wrong X X
Rotating Element Binding X X X X X X
Solids or Dirt in Inlet Air/Gas Supply X
Speed Too Low X X X
Suction Filter or Strainer Clogged X X X X X
Wrong Direction of Rotation X X X
Common Failure Modes of Rotary-Type, Positive-
THE PROBLEM
Displacement Pumps

Insufficient Discharge Pressure

Excessive Vibration and Noise

Elevated Motor Temperature

Elevated Liquid Temperature
Excessive Power Demand
Starts, But Loses Prime
Insufficient Capacity
No Liquid Delivery

Excessive Wear
Excessive Heat

Motor Trips
THE CAUSES
Air Leakage into Suction Piping or Shaft Seal X X X X
Excessive Discharge Pressure X X X X X X
Excessive Suction Liquid Temperatures X X
Insufficient Liquid Supply X X X X X X
Internal Component Wear X X X X
Liquid More Viscous Than Design X X X X
Liquid Vaporizing in Suction Line X X X X X
Misaligned Coupling, Belt Drive, Chain Drive X X X X X
Motor or Driver Failure X
Pipe Strain on Pump Casing X X X X X
Pump Running Dry X X X X X
Relief Valve Stuck Open or Set Wrong X X
Rotating Element Binding X X X X X X
Solids or Dirt in Liquid X
Speed Too Low X X X
Suction Filter or Strainer Clogged X X X X X
Suction Piping Not Immersed in Liquid X X X
Wrong Direction of Rotation X X X
Common Failure Modes of SurfaceAerator THE PROBLEM

Bearing Failure
THE CAUSES
Write the List of Causes on this Column
THE PROBLEM
Common Failure Modes THE PROBL

Excessive belt edge wear or cracking

Premature tooth wear

Tensile break
Belt cracking

Tooth shear
THE CAUSES
Flange damage X
Belt too wide X
Misaligned drive X
Rough flange surface X
Improper tracking X
Belt hitting drive guard or bracketry X
Excessive shock loads X
Subminimal diameter X
Improper handling or storage prior to installation X
Extreme sprocket run-out X
Misaligned drive X
Subminimal diameter X
Backside idler X
Extreme low temperature at start-up X
Extended chemical exposure X
Too low or high belt tension X
Belt running off unflanged sprocket X
Incorrect belt profile for sprocket (i.e., HTD,GT, etc.) X
Worn sprocket X
Excessive shock loads X
Less than 6 teeth-in-mesh X
Worn sprocket X
Incorrect belt profile for sprocket X
Misaligned drive X
Belt undertensioned X
THE PROBLEM
Common Failure Modes THE PROBLEM

Bottom and sides burned

Bottom of belt cracking
Worn side patterns

Belt pulled apart

Belt turnover
THE CAUSES
Constant slip X
Misaligned sheaves X X
Worn sheave X X X
Incorrect belt X
Belt slipping, causing heat buildup and gradual
X
hardening of undercord
Idler installed on wrong side of belt X
Improper storage X
Belt slipping under starting or stalling load X
Foreign material in grooves X
Tensile member broken through improper installation X
Incorrectly aligned idler pulley X
Extreme shock load X
Belt came off drive X
THE PROBLEM
 Common Failure Modes of Wear Part Surfaces Surface Appearance and Component Failure M

Abrasive Wear

Scratching
Cavitation

Polishing
Staining

Scuffing
Fretting
Spalling

Erosion
Pitting
Desciption of Worn Surface
Melted (Bubbles Wavy)
Micro-Smooth

Progressive loss and reformation of surface films by fine

abrasion and/or tractive stresses, mutually imposed by X X X
adhesive or viscous interaction
Very fine abrasion with loss of substrate in addition to loss
X X
of surface film
Abrasion by medium-coarse particles X X
Micro-
Rough

Due to tractive stresses resulting from adhesion

Micro-pitting by fatigue X X
Smooth
Macro-

Caused by abrasive heid on or between solid backing X X X

Advanced stages of micro-roughening, where little

X X
unaffacted surface remains between pits
Abrasion by coarse particles, including carbide and other
Macro-rough

hard inclusions in the sliding materials

Abrasion by fine particles in turbulent fluid, producing
X
scallops, waves etc.
Local fatigie failure resulting in pits or depressions caused
by repeated rolling-contact stress and high-friction sliding X X X X
or impact by hard particles, as in erosion
Severe adhesion X
Thick films resulting from aggressive environments,
Shiny Dull

X X
including high temperature due to corrosion
Very thin, or no, surface film of oxide, hydroxide, sulfide,
chloride or other X X X
 X
X
Gauging

X
Scoring

X
X
X
Grooving

X
X
d Component Failure Mode

Galling

X
X
X Exfoliation
Melting