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<p>Centrifugal pumps in process industries often experience hydraulic instabilities that may accelerate component degradation. This case study presents a detailed root cause analysis of repeated failures of a QJ222-N2-MPA four-point contact thrust bearing in a horizontal centrifugal pump. Vibration monitoring and signal processing revealed that fluid pulsations under unstable operating conditions excited the vane pass frequency (VPF), which subsequently coupled with the bearing ball pass frequency outer ring (BPFO). This dynamic excitation initiated localized cracking at the impeller blade edges. The propagation of cracks altered the hydraulic balance, leading to abnormal axial thrust loads. These thrust forces were directly transmitted to the thrust bearing, resulting in progressive damage to the rolling elements and ultimately leading to premature failure. The results demonstrate the sequential interaction between process-induced pulsations, structural integrity loss, and mechanical degradation. The study emphasizes the importance of vibration-based diagnostics, advanced signal analysis, and proactive maintenance in preventing similar bearing failures in pumps subjected to fluctuating hydraulic conditions.</p>

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Failure Analysis of a QJ222-N2-MPA Thrust Bearing via Vibration Diagnostics and Signal Processing under Process Instabilities

  • 期刊论文

  • 发表日期：

    2026年2月25日

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  • Ali Hemati

摘要

Centrifugal pumps in process industries often experience hydraulic instabilities that may accelerate component degradation. This case study presents a detailed root cause analysis of repeated failures of a QJ222-N2-MPA four-point contact thrust bearing in a horizontal centrifugal pump. Vibration monitoring and signal processing revealed that fluid pulsations under unstable operating conditions excited the vane pass frequency (VPF), which subsequently coupled with the bearing ball pass frequency outer ring (BPFO). This dynamic excitation initiated localized cracking at the impeller blade edges. The propagation of cracks altered the hydraulic balance, leading to abnormal axial thrust loads. These thrust forces were directly transmitted to the thrust bearing, resulting in progressive damage to the rolling elements and ultimately leading to premature failure. The results demonstrate the sequential interaction between process-induced pulsations, structural integrity loss, and mechanical degradation. The study emphasizes the importance of vibration-based diagnostics, advanced signal analysis, and proactive maintenance in preventing similar bearing failures in pumps subjected to fluctuating hydraulic conditions.