Monitoring slow-speed bearings under very heavy loads, especially with sudden shock applications, is always challenging. This becomes even more difficult when using grease lubrication, as the grease fully covers the bearings, making physical inspection nearly impossible.

We inspected the bearing and lubrication conditions using ultrasound technology. During this assessment, we identified issues with the current bearings and recommended immediate grease sample analysis along with ferrography to assess the extent of bearing damage and plan the next steps accordingly.

Ferrography confirmed that the bearing wear was on the higher side, requiring immediate grease flushing to remove metal debris already present in the system. This flushing will eliminate circulating contaminants and help prevent further damage. However, it’s important to note that flushing cannot recover the damage already done to the bearing.

The initial damage to a bearing cannot be recovered or repaired by any technology. But further damage can be delayed or minimized if you monitor the condition and understand the trends.

We now have a clear plan to keep this bearing running for a few more days until scheduled maintenance, thereby avoiding catastrophic failure.

I always recommend first studying the application, understanding your bearing and lubrication system, and then deciding on the right first step. This approach helps achieve the right results rather than blindly relying on whatever technology is available.