Split Bearing Inspections: A Four-step Bearing Health Check If You Don’t Have Condition Monitoring

Did you know that only 10% of industrial equipment can physically “wear out”, meaning over 90% of mechanical failures are potentially avoidable?

The best way to avoid failures is through predictive rather than reactive maintenance. In other words, identifying and resolving problems before they become significant. Condition monitoring sensors are the most effective way to achieve this, allowing issues to be detected long before they become noticeable to the human senses.

While condition monitoring is a worthwhile investment, it isn’t always practical for every business. In the absence of sensor-based monitoring, a regular split bearing inspection programme provides an effective condition monitoring alternative that can help reduce unplanned downtime.

Here’s a simple four-step bearing health check process for businesses that don’t yet have condition monitoring.

Step One: Conduct a Visual Inspection

If your process allows for a brief planned shutdown, carry out a visual split bearing inspection. In the main, you are looking for wear characteristics on the raceways and rolling elements, including fretting (discolouration) and spalling (peeling metal). Both may indicate poor lubrication, misalignment, incorrect fitting practices, or fatigue.

While the shaft is running, check for any visible movement of the housing, which may indicate looseness within the bearing caused by one of the issues above.

Don’t forget to inspect the seal faces for unusual or excessive wear, along with the shaft surface itself. Is the shaft still the same diameter where it contacts the seal?

Take photographs of your findings each time you inspect the bearing. Comparing images over time can help identify subtle deterioration that might otherwise be missed.

Step Two: Listen for Noises and Monitor Vibration

Listening to the bearing during operation, it is often possible to detect early signs of damage or deterioration. A healthy bearing will usually produce a soft humming sound, whereas squeaking, grinding or other irregular noises may indicate a developing fault.

Monitoring vibration is equally important. While manual listening has its limitations, digital vibration monitoring remains the preferred solution where possible. Even so, paying close attention during routine split bearing maintenance can provide valuable early warning signs.

The onset of mechanical issues is almost always accompanied by increased vibration, and the characteristics of the vibration often provide clues about the underlying fault.

Step Three: Pay Special Attention to the Grease

Incorrect lubrication, or the absence of grease altogether, remains one of the most common causes of bearing failure.

During your bearing health check, inspect whether the bearing is running dry or whether the grease has discoloured or separated due to excessive heat or vibration. Both may indicate too much or too little lubrication.

Equally, excessive grease can also cause problems, particularly in high-speed applications. Always use the manufacturer’s recommended grease quantity and compare your findings with previous bearing inspection steps.

Grease that resembles Marmite or carries a burnt carbon smell may indicate overheating.

Also inspect surrounding areas for lubricant leaks and ensure the labyrinth seals remain properly filled with grease to provide maximum protection.

As with the visual inspection, photograph the grease condition each time to make future comparisons easier.

Step Four: Monitor Temperature During Operation

Provided operating conditions remain unchanged; bearing temperatures should stay relatively consistent.

An increase in operating temperature may indicate bearing damage and the potential for imminent failure. Handheld infrared thermometers are inexpensive, widely available, and ideal for routine spot checks.

Remember, however, that a temporary temperature increase is perfectly normal immediately after machine start-up or following fresh grease application. These elevated temperatures may persist for several hours before stabilising.

Bonus Step: Ask for Support and Guidance

Industry continues to evolve rapidly as manufacturers strive to improve productivity while reducing costs. As machinery operates under increasingly demanding conditions, effective split roller bearing care becomes even more important.

If you see, hear, smell, or detect anything unusual during your inspections, seek advice from your bearing supplier. Early technical support can often prevent unnecessary repairs, extend bearing life, and help avoid costly unplanned downtime.