Fluid Film Bearings 050406S

Introduction May 2006June 2004
Outline
n Pioneer Motor Bearing Company
Introduction n Thursday: Journal / Sleeve Bearings
n Fundamentals
VIBRATION INSTITUTE n Operations impacts

FLUID-
FLUID-FILM BEARINGS n Installation / handling
n Friday: Thrust Bearings
Pioneer Motor Bearing n Extension of previous discussion
May 2006
(c) Pioneer Motor Bearing Company, 2006 (c) Pioneer Motor Bearing Company, 2006
Pioneer Motor Bearing Co.

n Established in 1920; family-
family-owned.
n Offers triad of engineering, new manufacture,
and repair services related to fluid-
fluid-film
bearings.
n Alliance partner with Michell Bearings
n Exclusive repair licensee of Siemens
(Westinghouse) and Alstom Power in North
America for large-
large-steam, babbitted products.
n Proprietary Fluid Pivot
Pivot tilting-
tilting-pad journal
bearing.
n Customized training courses available.
Locations
Philadelphia:
Technical
Services
California:
Administration
& Regional Sales North Carolina:
Engineering
Manufacturing
Service & Repair
(c) Pioneer Motor Bearing

CompanyIntroduction Sheet 1
Pioneer Motor Bearing
Engineering
Manufacturing Service & Repair

Full Spectrum of Services Full Spectrum of Services

n Engineering & Technical n Manufacturing Pioneer
Pioneers
Services Custom Designs
(Including Fluid Pivot
Pivot
Journal Bearings)
n Manufacturing to
Customers
Customers Designs
n Repair, Modifications &
Upgrades
Engineering Dr. Lyle A. Branagan

z Lyle A. Branagan n Engineering Manager
Engineering Manager n BSME / MSME Machinery dynamics
BSME, MS, Ph.D. n PhD Fluid-
Fluid-film bearing analysis
10 years with PG&E
Has substantial n University of Virginia ROMAC Lab
knowledge of rotor n Industrially-
Industrially-accepted design codes
dynamics of n Pacific Gas & Electric 10 years
turbomachinery
n Specialist in bearings and rotordynamics
Extensive experience
in the field n KnollsAtomic Power Lab
An expertise in fluid n Pioneer Motor Bearing 10 years
film bearings and seals

Fred C. Wiesinger
Frederick (Fred) C. Wiesinger
Technical Services Manager
Technical Services Manager
n Drexel University
Expertise in high speed gearboxes n BSME With Honors
Expertise in thrust bearings n Philadelphia Gear 7 Years
n Manager High Speed Gear Boxes
Expertise in bearing repair services
n Kingsbury, Inc. 14 Years
n Chief Engineer
Office in Lansdale, PA n Manager, Repair & Service Division
1-(215) 362-
362-4074 n Vice President, Manufacturing
n Turbo Research, Inc. 3 Years
Topics
Presentation Goals n Abbreviated from 8-
8-12 hour training
class
Understand operation of n Introduction
n Journal bearing overview
fluid-
fluid-film bearings n Lining overview
n Lubricant overview
Relate vibration changes n Wear overview
to potential bearing n Babbitted bearing damage

n Rotordynamics / journal bearings
changes n Predictive maintenance interface
n Installation and handling
n Questions and discussion
Topics Friday Demonstrations

Focus on Thrust (Axial) Bearings n Viscosity
n Thrust bearing overview n Hydrodynamic film
n Babbitted bearing damage
n Cavitation
n Rotordynamics / thrust bearings
n Slinger ring operation
n Predictive maintenance interface
n Installation and handling
n Questions and discussion

Perspectives on Bearings A small piece in the plant

n Pioneer Motor Bearing Company
n Power Plant or Manufacturing Plant
n Maintenance
n Machine Designer
n Lubricant Vendor
n Vibration Specialist
Machine Design Perspective

n Allow rotating equipment to operate
With the n Separate
rotating and stationary
potential components
n Support the rotating load
to cause:
n Control rotordynamics
n Requires
n Support
n Adequate cooling
GOAL: n Lubricant flow
Avoid Frustration, Extra Work, Late Nights, Lost Production
Lubricant Perspective Vibration Specialist Perspective

n Lubricant to satisfy requirements n Common point of measurement for
n Viscosity
vibration
n Potentialinteraction of sensors and sensor
n Proper additives mounting
n Adequate operational life n Defines the measured quantity
n Understand impact on oil analysis n May define allowable vibration

n Bearing clearance
n Allowable bearing loads, esp. dynamic
n Faultsmay affect vibration signature
n Excessive vibration may affect bearings

End
Introduction
(c) Pioneer Motor Bearing Company, 2006

May 2006
Fluid-Film Bearings
APPLICATIONS:
Babbitted Bearing Overview n Radial turbine, generator, fan,
pump, and motor bearings
n Turbine, generator, fan, pump, and
PIONEER FLUID-
FLUID-FILM BEARING WORKSHOP motor thrust bearings
n Generator hydrogen and other high
Pioneer Motor Bearing Company
August 2006
pressure seals
(c) Pioneer Motor Bearing Company, 2006. All rights reserved.

Outline Opening Up the Machine

n Radial bearings Bearing
bolted to
n Bore design machine or
mounted in
n Thrust bearings end bell.
n Profile designs
n Fluid-
Fluid-film bearing
analysis
n Reynolds equation
Bearing integral
with shell
(c) Pioneer Motor Bearing Company, 2006. All rights reserved. (c) Pioneer Motor Bearing Company, 2006. All rights reserved.
Opening Up the Bearing Load Orientations: radial/thrust
End bell and housing top removed
Upper half
and
lower half
showing ID
(c) Pioneer Motor Bearing CompanyBearing

Fundamentals Sheet 1
May 2006
Load Orientations: radial/thrust Radial Bearings

n Horizontal machine
n Radial bearing
n Gravity load
n Radial process / misalignment loads
n Thrust (axial) bearing
n Axial process loads
n Vertical machine
n Radial bearing
n Radial process / misalignment loads
n Thrust bearing
n Gravity load
n Axial process loads
Thrust Bearings Elements

n Function
n Purpose of a fluid-
fluid-film bearing
n Geometry
n Key features
n Hydrodynamic theory
n Materials
n Liner and support
n Lubricant supply
Function Separation
1. Separate rotating from non-
non-rotating n Maintain close clearances
components
n Motors / Generators windings
n Clearance
n Fan seals and blades
2. Transfer loads (static and dynamics)
from the rotating to the stationary n Turbine blades
structure
n Force transmission
3. Prevent undesirable vibrations
n Primary source of damping
4. Provide cooling

May 2006
Hydrodynamic versus Hydrostatic Hydrodynamic versus Hydrostatic

n Hydrodynamic pressure
induced by relative motion.
n Hydrostatic pressure
supplied by external
source.
Ref: Intelligent Mechanics Lab, Pukyong University, website
Sleeve Bearing Geometry General Clearance

Shell Rotating CLEARANCE
Babbitt Journal BABBITT CLEARANCE
36 40
35
30
CO
SHELL
NV
25
E
RG
hd( )
Clearance
IN
mil 20
G
GIN
15
CLEARANCE
END VIEW
ER
EXAGGERATED
X
DIV
10
BABBITT CLEARANCE ROTATING 4

JOURNAL 0
0 90 180 270 360
0 360
deg
SHELL Circumferential Position
CONVERGING
CLEARANCE
DIVERGING
CLEARANCE
ROTATING
JOURNAL
Clearance
Housin
g space is filled
by a lubricant.
CLEARANCE GREATLY EXAGGERATED
Clearance Clearance
n Assume 230 m (0.009
(0.009) radial
n Assume 0.009
0.009 radial clearance clearance on a centered 300 mm
on a centered 12
12 diameter (12
(12) diameter bearing
bearing
JOURNAL JOURNAL
BEARING BEARING
By comparison, the By comparison, the

minimum operating minimum operating
Human hair about clearance is only Human hair about clearance is only about
0.003
0.003 diameter 75 m (0.003
(0.003) diameter 50 m (0.002
(0.002).
about 0.002
0.002.

May 2006
Fluid-
Fluid-Film Bearing Reynolds Equation
Critical Geometry:
h3 P h3 P R h h
n Clearance space between the rotating + = + + Vthru
x 12 x z 12 z 2 x t
and stationary components Circumferential Axial Shear Squeeze Cross
n CONVERGING SPACES develop pressure Flow Flow Flow Flow Flow
n Circumferential grooves carry flow
n Axial grooves spread flow
n Determine hydrodynamic ( (>0) or
n Tilting pads reduce cross-
cross-coupled forces
hydrostatic pressures ( (=0).
n Corrections for turbulence (G (G and Gz)
n Sizeon the order of 0.001
0.001-0.050
0.050 (40-
(40-
2000 m) and cross-
cross-film viscosity variations
((y)).
Sleeve Bearing Geometry Bearing Pressures (Load Capacity)

Theoretical negative
pressures in the
diverging region are
cancelled by air flow
from the axial ends.
Pressures developed in
the lubricant due to
the converging wedge
provide the bearing
Converging load capacity
Film w/CCW
rotation
Reynolds Equation 2-D Profile Sleeve Bearing Flows

PRESSURE
Strong rotation with

shaft; average velocity Lower,
about shaft surface pressure
velocity. driven axial
velocity.

May 2006
Reynolds Equation - Cavitation Cavitation

Diverging Film ----
----> Converging Film ----
---->
Cavitation
Cavitation region,
present in the upper
half, generally
occurs by air
penetration, less
frequently by oil
vaporization.
Axial distribution:
Area at minimum film limits the flow available.
Downstream volume is only partially filled.
Bearing Cavitation Bearing Cavitation

Air intrusion
Axial Axial distribution

distribution:
Area at minimum
film limits the
flow available.
Downstream
increased volume
is only partially
filled.
Radial
distribution
Minimum
Air intrusion
Film
Cavitation - Experimental Cavitation Demonstration

n Manual
n Take (2) small plates
Plexiglass bearing
showing the formation n Spread thin layer of grease
of cavitation in the n Pressplates together with grease in
region of increasing film between
thickness.
n Open plates from one side
n Observe pattern of grease
n Demonstration rig
Ref. Cole and Hughes,
Proc.Inst.Mech.Engr.
Proc.Inst.Mech.Engr.,
170/17, 1956.

May 2006
Fluid-film Radial Bearing Hydrodynamic Demonstration

nSleeve around shaft controls Feel:
radial position. Reduction in friction

of dry versus
nMaximum load capacity
lubricated.
Observe:
nSimple sleeve bearing Film cavitation
nMaximum rotordynamic
stability
nTilting-
Tilting-pad bearing
Bore Designs Bore Designs

Define the
bore geometry
for the desired
operating
characteristics
Additional
effect of a
pressure dam
adds to the
Pressures in Pressures in pressures from
an elliptical an offset-
offset-half the cylindrical
bearing at light bearing. lower half.
loads.
Radial Bearing Components Radial Bearing Components

ANTI-
ANTI-ROTATION PIN HOLE
OUTER
DIAMETER
INSULATED
ON FIT
AREAS
SPLITLINE
OIL COLLECTION POCKETS DOWEL PINS BOLT HOLES
BOLT HOLES
BUMPER THRUST FACE
INSULATED RADIAL SLINGER RING GROOVE

BEARING WITH
BUMPER THRUST
SURFACES
SLINGER RING GROOVE
SIDEWELLS
LOWER HALF UPPER HALF (ROTATED)

LOWER HALF UPPER HALF (ROTATED)

May 2006
Joint Details Dowel Pins

Oil-
Oil-tight metal-
metal-to-
to-
metal joint between Used to control alignment:
the bearing halves. Bearing shell halves
Top half secured by
by (4) joint bolts. Seal retainers to shell
Alignment of top to
bottom half by (2) Unhardened allows
dowel pins. Pins deformation of the pin.
captured in the lower Hardened dowels may
half. damage shell under
excess loading.
Care required to separate
doweled pieces to avoid
upset to the pieces or the
dowel.
Damaged
Anti-Rotation Pins Bearings for Motors

Provides: Potential
Locates shell in housing damaging
Axial electrical
Circumferential ground
Prevent rotation of the shell current
in the housing. loops.
Insulation
required.
Ref: EPRI Manual.
Bearing Insulation Bearing Support

Motor /
generator end
bell
Potential damaging current loops.
Free-
Free-standing pedestal
Bearing
housing on
Double insulated liner
integral
for exciter bearing.
pedestal.
Insulation to prevent
electrical discharge across
OD insulation on a motor bearing bearing surface.

May 2006
Conforming Bearing to Shell Distribution-

Distribution-Precision Halves
n Depends on the flexibility (stiffness) Common in
reciprocating
of the bearing: and gear box
n Thin-
Thin-shell bearings service.
n Liner type
n Insert type
n Medium wall bearings

n Thick wall bearings
Oil distribution
features
Circumferential groove sharply diminishes load capacity but allows

allows
for wider range of load angle.
Shell Wall Thickness Shell Wall Thickness

Thin wall Thick wall:
(liner
liner type): shell is
shell conforms supported by
to the housing and aligned in
geometry. the housing
but retains its
t < 0.03D
own shape.
t > 0.1D
Shell Wall Thickness Tilting Pad Radial Bearings

Medium wall: n Enhanced
shell is
supported by
rotordynamic
and aligned in stability
the housing
n Enhanced control
but
somewhat
somewhat of oil flows
conforms to the
housing n More components
geometry. n Higher cost

May 2006
Tilt-pad Radial Bearings Mechanical Pivot

n Tilt-
Tilt-pad radial bearings Shaft load
n Used to increase rotordynamic stability distributed as
n Avoid self-
self-excited vibrations oil pressure and
PRE RE concentrated in
n Segmented load bearing surface SSU SSU pad to the pivot
RE PRE
n Mechanical pivot load focused on a single (either a
contact point (Hertzian
(Hertzian contact stress) circular or
elliptical
n Line pivot
contact region).
n Spherical pivot (e.g. ball in socket)
Pressure will
n Fluid Pivot balance around
n No mechanical load concentration the pivot.
n Flooded or directed lubrication Pivot can be hardened material (e.g.
E52100 tool steel).
Tilt-pad Radial Bearings Preload

n Number of pads Rp pad curvature
n 3,4 or 5 typical Rb assembled bore
n Divides the load vector R journal
n Orientation C assembled
clearance
n Load between pads
C pad clearance
n Load on pad
M = 1 C/C
n Preload
n Difference
in pad curvature and
assembled bore size
Tilting Pad Bearings Tilting Pad Bearings

5-pad Segmented film
Load between pad Concentrated load
Flooded design
Mechanical pivot
Hydrostatic lift
Single point, or line

Contact support

May 2006
Specialty Journal Bearings Pivot Types

n Tilting pad bearings
Line
n Uses continuing to expand
Contact
n Alternative pivots
n Ball & socket designs
n Flexure Pivot
Pivot
n Fluid Pivot
Pivot
Conventional Pivot Types Quality of Pivot Contact
Contact
varies with
curvature,
load, and
temperature.
CYLINDRICAL SPHERICAL BALL-

BALL-IN-
IN-SOCKET
Ball-
Ball-in-
in-Socket Pivot Contact Flexure Pivot
Contact extent
varies with
curvature, load,
and
temperature.
Tilting action
Operation through
deformation.
requires sliding,
as well as Smaller bearings
benefit from the
rolling, motion lack of a 2nd
at the loaded tolerance for a
detached pad.
contact.
Ref: KMC Bearing web site.

May 2006
Pivot Designs Fluid Pivot - Tilt Pad Bearing

n Tilt Freedom as a Function of:
Hertzian contact area or web thickness
Stability Variation with Tilt
Restraint
1000
S tability (d im )
800 ideal
ideal tilt
pad 600
400
200
0
0 0.2 0.4 0.6 0.8 1 1.2
fixed
fixed pad
Hydrostatic pivot,
Restraint (dim) NOT a mechanical
pivot. Shell, pads, stop pins
JS Fluid Pivot
Fluid Pivot
Pivot
Gear box, style JC
Bearing includes
shell, pads, stop pins
Hydrostatic pivot, NOT a

mechanical pivot. On overload
pad OD sits on shell ID.3 pad ring
Flange-
Flange-mounted, style JC
Shown as Load-On-Pad Pedestal mounted, style JS
Fluid Pivot
Pivot Exciter Assembly
Fluid Pivot
Pivot
Pad supported on
self-
self-generated
hydrostatic film on
the OD of the pad.

May 2006
End
Bearing
Fundamentals I

August 2004
Oil System Design Options

n Lubricant selection and maintenance
Babbitted Bearing Overview n Viscosity grade and viscosity index
Part II n Cleanliness
n Supply options
n Pressure-
Pressure-fed
VIBRATION INSTITUTE SEMINAR
n Slinger ring
CHARLOTTE, NC
n Rotating disk
Pioneer Motor Bearing Company n Vertical sump
May 2006
n Hydrostatic lift systems

Oil Distribution Geometry Oil Groove Geometry

Straight Double
Single Figure Double Half
Bleeder & Figure Straight Circular
Loop Eight Circular Loop Eight
Axial groove Eight
ve
oo
re
ad
er
Gr
Double loop groove & double figure eight groove recommended
Sp
OIL INLET
for grease only.
HOLE
Radial groove Grease grooving often passes thru the loaded region
Bleeders which reduces the bearing load capacity.
Do not use grooving associated with grease (long
residence time) with oil lubrication (cooling flow).
Options Compared Sample Turbine Oil System

Want to have
100% cooling
efficiency and
Main oil pump is shaft driven Schematic of
100%
Turbine-
Turbine-
hydrodynamic
Generator
fluid-
fluid-film.
Lubrication
System
Best achieved
AC & DC pumps
with
pressurized oil
supply was
effective axial
distribution. Each bearing has a separate
pressurized supply (20 psig),
orifice-
orifice-metered, with a gravity
(or slight vacuum) drain back to
the reservoir.
Ref. Constantinescu,
Sliding Bearings,
Bearings,
Allerton,
Allerton, 1985, p.474.

August 2004
Turbine Oil System Components Slinger Rings

Slinger rings
n Large capacity SETTLING TIME deliver oil from a
reservoir below
n Cooling
50-
50-micron silica particle: 12 minutes
50-
50-micron steel particle: 2.1 minutes the bearing to
50-
50-micron copper particle: 48 seconds the top of the
n Filtering 50-
50-micron chromium particle: 2.5 minutes rotating shaft,
driven by friction
n Often uses a loop filter between the
rotating shaft
n Settling and the ring.
n Contaminants water & dirt

n Contamination control
n Breather same or better filter than
the direct oil filter
Oil Grooving and Distribution Slinger Rings

Ring driven by
A ring, rotating by means of friction
between the ring and the journal, Shaft shaft rotation.
lifts oil from the reservoir where it is
sprayed into the top half of the Bearing
bearing and directed to the loaded Babbitt
half.
Circumferential Slinger ring ID
Slinger generally about
collection groove ring
twice the journal
OD.
Axial
distribution
Oil level Oil level depth
(normal) above slinger
ring ID roughly
10% of ID.
Ref. Elwell and Booser,
Booser,
Mechanical Design,
Machine Design, Ref: Mike King, Palisades
12/7/69, pp.111-
pp.111-115. Nuclear Station report
oil feed
Slinger Rings Split Slinger Rings

n Important to be
n In-
In-plane
n Concentric
n Circular
n Ring speed is a fraction of the shaft

running speed Trapezoidal
n Oil depth is important cross-
cross-section
n Balance oil lift (submergence of the ID)

with ring drag

August 2004
Slinger Ring Guides Cast Slinger Ring Guide

Seek to
maintain rings
Cast aluminum guide
perpendicular
with oil scraper
to shaft arrangement. Single
without screw bolts guide upward
introducing into upper shell. Guide
metal-
metal-to-
to-metal or screw should be
friction. Made staked to avoid looseness
of bronze, or rotation.
steel, or This guide showed
aluminum. rubbing wear on the
upper part of the guide.
Subject to wear or
damage, particularly if
misapplied.
Slinger Ring Observation Slinger Ring Observation

Bulls eye
eye
for viewing
the rotation
of the slinger
ring.
Level indicator
should show
change from
static to
operating oil
level in
reservoir.
Ref: Mike King,

Palisades Nuclear
Station report
Hybrid System Slinger Ring Demonstration

n Combination of slinger ring and n Threeslinger ring
pressurized system. designs
n T-shape: common,
n Forced sump cooling
inexpensive
n Shaft driven main oil supply n Trapezoidal:
heavier, high-
high-
speed
n Trapezoidal with
grooves:
n Best oil flow

August 2004
Rotating Disk Lubrication Vertical Sump

Rotating sleeve pumps oil into a
circumferential groove on the
bearing. Bearing partially flooded.
Rotating disk, attached to
the shaft, lifts oil from the
reservoir. A fixed scraper at
the top directs the oil to slots
or holes at the top of the
bearing.
Bearing
Ref. Booser,
Booser, Handbook
of Lubrication III,
III, 1994,
pp521. Exploded
View
Issues: Oil height, reservoir pressure, oil temperature, hole alignment
alignment
Vertical Sump Vertical Sump
Upper guide bearing runs above

nominal oil level, supplied by
longer rotating holes. Includes
inactive
inactive thrust bearing on the
lower surface.
Partially-
Partially-flooded with pressure-
pressure-driven grooves to lift the oil
for rotation in either direction.
Issues: Oil height, reservoir pressure, oil temperature
Oil Level Indication Incorrect Oil Level Indication

n Sight glass Angled oil line allowed
residual oil to be mistaken
n Mark normal elevation of oil in sump for the actual oil level
resulting in operation with
n Elevation will change during operation minimal, if any, circulating
n Measurement is at a specific point on oil. Bearing Housing
the reservoir Shaft
n Sight glass must be vented Oil level (As Bearing Babbitt

found in level Oil fill line
indicator) Slinger ring
Target oil level Oil level (As

found)
Ref: Mike King,
Palisades Nuclear
Station report

August 2004
Automatic Oiler Automatic Oiler

Proper venting,
alignment, and filling
beneficial to correct
operation.
Ref: Malinowski, Trico Corporation Ref: Malinowski, Trico Corporation
Oil Flow Observation Oil Flow Observation

Inlet or drain
flow;
Full-
Full-flow or by-
by- Quick
Quick indication as to
pass;
the operation of the
Ease of access; bearing through the
May be drain line (temperature
combined with and flow), nonetheless
drain reveals little of the
temperature health of the bearing.
measurement.
General Bearing Start Bearing Start/Shutdown
Metal-
Metal-to-
to-metal Contact
Boundary Lubrication
H < 0.0005
0.0005
Hydrodynamic
Lubrication
H > 0.0005
0.0005 Ref. Basics,
Basics,
Noria,
Noria, Johnson,
2001

August 2004
Hydrostatic Lift Systems Hydrostatic Lift Systems

n Installed to provide hydrostatic oil n Injecthigh pressure oil (typically >
films where hydrodynamic oil films 1000 psi)
psi) at the location of the
may not otherwise be present highest loading
n Startup operation
n Hydrostatic film is developed
n Turning gear operation
through pressure, film thickness is
n Some emergency conditions
n Per DIN 31652 part 3 consider
controlled by flow
hydrostatic lift where startup loads n Quite often, many bearings are fed
exceed 2.5-
2.5-3.0 MPa (363-
(363-435 psi)
psi) by a common high pressure header
n May be required for lower loads
Hydrostatic Lift System Hydrostatic Lift System

n Introduce externally-
externally-pressurized oil
into bearing cavity for operation at
low surface speeds and high loads
n Forms hydrostatic bearing on lower half
Hydrostatic lift in tilting pad thrust shoes.
Sample Hydrostatic Lift Oil System Bearing Design

n Physical / mathematical model
Main oil pump is shaft driven Schematic of
Turbine-
Turbine-
used to define the characteristics of
Generator
Hydrostatic the fluid-
fluid-film (possibly with
Lift System
supporting components) in the
AC & DC pumps
bearing geometry.
n General evaluation based on key
Each radial bearing #3-
#3-8 has a
separate pressurized hydrostatic-
hydrostatic- design parameters
lift supply (1500 psig), separate
supply pump with a gravity (or
slight vacuum) drain back to the
reservoir.

August 2004
Specific Load
Specific Load
n Radial bearing loads
n Gives a measure of the load on the n Maximum load capacity
bearing n 300 psi radial (American)
n Based on Nominal Load (psi
(psi).
). n 5 MPa (725 psi)
psi) radial (European)
Thrust, W n 500 - 700 psi thrust
P =
OD 2 ID 2 n Minimum load for stability with some

4 bore designs (10 psi 50 psi)
psi)
W
Radial,
P=
L D
n Not the same as the peak pressure (psi
(psi))
Nominal versus Actual Pressure

Surface Speed
Actual peak n Measure of heat generation
pressure will n Basedon peripheral speed (ft/min).
exceed the nominal
pressure.
Thrust, (OD + ID)
U= N
Radial, 12 2
D
U= N
12
Limits due to turbulent heat generation.
Surface Speed Clearance Ratio

n Increasing speed allowed for n Expresses the radial bore clearance
different bore designs as a ratio of the journal diameter
n Sleeve: 30 m/s ( 98 ft/s)
Cd
n Elliptical: 75 m/s (240 ft/s)
n Horizontal machines
=
n 4-Lobed: 125 m/s (410 ft/s) D
n Tilting pad: 150 m/s (492 ft/s) n Pressurized: 1.5 2.0 mils/in
n Motors, fans, compressors, turbines n Slinger rings: 2.0 2.5 mils/in
n Vertical machines
n 0.5 1.0 mils/in
Ref: Renk Slide Bearing design guide

August 2004
Minimum Design Clearance Sommerfeld Number

n American Standard - Radial.
2 W
N D L D P=
S= LD
W C

Cd
d =
D
1 2 U
S= viscosity
D P 2 N rotating speed (Hz)

Ref. Neale,
Neale, Bearings,
Bearings,
Butterworth Heineman,
Heineman,
U surface speed
1998, pg. 39.
Bearing Design Heat Transfer

n Main Considerations: Ratio of conduction to convection is
proportional to:
n Peak temperature
K 2 B
Losses include oil ratio 2
Losses shear, churning, oil
Cp Uh
Toil = pumping, and process
J cv Qtotal
heating Where,
K-thermal conductivity
-density
n Minimum film thickness Cp-
Cp-specific heat
=K/
=K/Cp thermal diffusivity
n On the order of 0.001
0.001
0.5**D
B-0.5*
n Designby Empiricism and Detailed U-surface velocity

H-average film thickness
Analysis.
Ref: Cameron, Basic Lubrication,
Lubrication, pg 127.
Design Space Limits Summary

A load limit n Radial bearings
B B temperature limit n Bore design
C material burst n Optimum load sleeve
speed
n Optimum stability tilt pad
n Thrust bearings
A n Profile designs
n Optimum load tilt pad
n Fluid-
Fluid-film bearing analysis
C n Reynolds equation
Ref. Neale,
Neale, Bearings,
Bearings,
Butterworth Heineman,
1998, pg. 38.
Heineman, n Cavitation

August 2004
End
Bearing
Fundamentals II

May 2006
Outline
n Vibrationmonitoring
Interface with Predictive
n Lubricant monitoring
Maintenance Programs n Temperature monitoring
n Thermography
PIONEER FLUID-
FLUID-FILM BEARING WORKSHOP
n Balancing
Pioneer Motor Bearing Company

May 2006
(c) Pioneer Motor Bearing Company, 2006. (c) Pioneer Motor Bearing Company, 2006.
Types of Alarms Monitoring Purposes

n Protection / Aging n Avoidabsolute
absolute levels at which
n Statistical damage is expected
n Example: Prevent high temperature at
n Goal based
which bearing material can no longer
support the applied load.
n Detectchanges in the machine
based on trending
n Example: Identify step increase in
vibration level over time.
Machine Monitoring Vibration Monitoring

Vibration
Vibration is the
monitoring
at or near product
the
bearings
of the
excitation
(force)
(force)
with the
machine
system
(transfer
function).
Must
know two
out of
three.
Ref. Ehrich,
Ehrich, Handbook of
Ref: Mitchell, Machiner Monitoring Rotordynamics,
Rotordynamics, p.4.54.
p.4.54.
Interface with Predictive Maintenance

Programs Sheet 1
May 2006
Vibration Monitoring Vibration Monitoring

Non-
Non-linear
vibration
responses.
Common vibration
frequency content
with malfunctions.
Ref. Ehrich,
Ehrich, Handbook of Ref. Ehrich,
Ehrich, Handbook of
Rotordynamics,
Rotordynamics, p.4.55-
p.4.55-4.56.
4.56. Rotordynamics,
Rotordynamics, p.4.60.
p.4.60.
Shaft Relative to Casing Measurement Mounting Considerations

Mounting external to the bearing
Mounting internal
to the bearing Impact on vibration limits?
Impact on
bearing
Useful for monitoring where the primary shaft motion is within the the load
bearing (consider the relative stiffness of the oil film and the bearing capacity?
support). Also, can compare motion to the expected bearing Ref: SKF web site, 04/06.
clearance.
Flexibility Effect on Monitoring Include Casing Measurement

Programs Sheet 2
May 2006
Frequency Content Allowable Vibration Levels

Primary frequency content associated
with fluid-
fluid-film bearings is n Absolute limits
synchronous (1X). Other frequencies n Generally based on experience
may occur due to different causes.
Ground Currents n Limit to a fraction of the bearing
clearance (e.g. 50%)
Subsynchronous whirl
n Bearing limits generally not controlling
Looseness: Subsynchronous whip
n Contact at seals
n Excessive loads
Misalignment
Bearing Loads Affected Bearing Loads Affected

n Conditions determined by vibration Imbalance dynamic loads on bearings
analysis which have an impact on
bearing loads
n Static
n Dynamic
Misalignment - static load
variation
Soft Foot dynamic load variation
Lubricant Monitoring Lubricant Monitoring

n Viscosity Monitoring n Requires careful sampling
n Note that baseline oil will vary within n Representative of the bulk oil
the standard n Sampling point
n Look for changes around +/- +/- 10% from n Maintain cleanliness
baseline
n Consistent handling
n Oil Degradation
n Auxiliary bearing oil reservoirs may
n Wear Materials be small
n Sampling assumes reservoir is much
larger than the sample

Programs Sheet 3
May 2006
Lubricant Degradation Metals in Oil

n Various metals included in additives
Shows n Boron (B)
scatter of
RBOT testing n Calcium (Ca)
for a single
oil and effect
n Magnesium (Mg)
of operation n Barium (Ba
(Ba))
of 18 years
and 21 years n Molybdenum (Mo)
on two
particular n Phosphorus (P)
oils.
n Concern w/catalytic converter (may change by 04/04)
n Potassium (K)
n Zinc(Zn)
n Antimony (Sb
(Sb))
Metals in Oil Metals from Bearing

n Metals from bearing n Babbitt wiping
n Babbitt (tin based) n Large platelets may not be detected
Wide range of
n Tin possible babbitt n Babbitt fatigue
wear particle
n Antimony n Large pieces may not be detected
sizes. Many
n Copper detection
methods in oil n Electrolysis
n Slinger rings (bronze) analysis are size n Smaller particles more likely to be detected
n Copper dependent.
n Tin / Zinc n Slinger ring abrasive/adhesive wear
n One plant takes action around 30-
30-100 ppm
n Journal / Shell (steel)
of copper (Cu)
n Iron
Particle Detection Lubricant Cleanliness

n Detection
by many spectroscopic n Measured by particle counting
techniques n Representative
Representativesample
n Particles smaller than 5 microns n Reported based on particle size and
concentration
n Current standard: R4/R6/R14
n Older standard: R5/R15
n Limits set by critical component
n Control surface or valves, bearing
n OEM limits: 16/12, 16/13, 15/12

Programs Sheet 4
May 2006
Contamination from Oil System Grease Contamination

n Contamination of oil from adjacent
grease lubricated system
n Increase in particle count
n Without increase in wear particles
n Reduction in viscosity is possible
n Due to the gelling agent
n Not the base oil which is typically more
viscous
Ref. Noria presentation material
Lubricant Degradation Temperature Monitoring

n Baseoil has finite life due to on-
on-going n Limits
oxidation
Oil degradation n Journal bearings
n Catalyzed in copper piping
rate doubles
n Catalyzed by water in the oil with every 18
18F
n Thrust bearings
rise in bulk oil
n Additive depletion temperature.
n Reduction of anti-
anti-oxidant
n Base oil burned at hot spots
n Base oil changes
n Increasing viscosity
n Sludge and varnish
Temperature Limits Absolute / Relative

n ISSUES n Absolute limits
n Require knowledge of design details, loads,
n Measurement location and speeds
n How close to the hottest metal location? n Generally a predictive effort
n Possibly relating a peak temperature to a measured
n Load point
n Babbitt strength is dependent on n Relative limits
temperature n Requires historical temperature information
n Heavy load regions will move first
n Looking for deviation from a norm
n Can be complicated by normal operating variations
n Thermal distortion n Rules of thumb
thumb
n Changes in film thickness distribution that n Guidelinesto initiate relative monitoring in
reduce load capacity the absence of predictive information

Programs Sheet 5
May 2006
Temperature Limits Lubricant Temperature Limits

n Considering Babbitt (not Lubricant) n Loss of Viscosity.
n Nominal bearing loading. n Due to temperature or oxidation.
n Requires accurate measure of peak n Material Degradation.
temperature. n Oxidation.
n Alloy #2.
n Varnishing.
APPLICATION ALARM TRIP Reference
Steam / gas turbine 225F (107C) 250F (121C) Glacier n Loss of additives.
Tilt pads 230F 250F (121C) Nicholas
KEPCO (95-100C) (120C) n Activated by corrosion.
No load 300F (149C) Glacier
Trident sub gear bearing 300F
n Actual temperature also controlled by Support Material, Oil
Flow Path, and Oil Volume.
Temperature Profiles Journal Bearing Measurement

n Thermocouple or RTD (100
(100F-
Case 2: 250
250F).
Peak
Temperatur n Location.
e
n Circumferential - 75% offset from
leading edge.
SAME Drain
n Axial - centered or symmetric pair.
Temperature
n Radial - retain support for babbitt
Case 1: Peak above sensor.
Temperature
n Wiring.
Angular Location from Start of n Avoid impeding pad tilt or oil flow.
Film (c) Pioneer Motor Bearing Company, 2006. (c) Pioneer Motor Bearing Company, 2006.
Temperature Measurement Mounting Locations

Options for thermocouples
or RTD
RTDs.

Programs Sheet 6
May 2006
Tilting Pad Journal Bearings Thrust Bearing Temperatures
Flooded design: sump (drain)

temperature is an average of the Directed lubrication (Fluid
circulating oil temperature and Pivot
Pivot) with direct
can be directly lowered by measurement of bearing
increasing flow. metal temperature.
Thrust Bearing Measurement Thrust Bearing Measurement

n Thermocouple or RTD (100
(100F-
250
250F).
n Location.
n 75%/75% Tilt pad.
n 70%/70% Circumferential/Radial.
n 50%/50% Circumferential/Radial. *
* Standard
n Axial - retain support for babbitt above monitoring
sensor. location for one
OEM
n Wiring.
n Avoid impeding pad tilt or oil flow. Ref: Mitchell, Machinery
Mounting Locations Thermography

n Gives an overview of the
temperature over accessible
portions of the housing, shaft, and
bearing.
n Need to understand the relationship
between the measured locations
and the hottest operating parts of
the bearing

Programs Sheet 7
May 2006
Thermography Balancing
n Balancing
calculation is generally
Consider the likely
temperature gradient determined by the
from the peak bearing n Current vibration level at the bearings
babbitt temperature
to the motor casing n Influence of a weight at each balance plane
temperature. Note n Vibration level changes
circumferential and
axial spreading of the n Bearingchanges or
hot spot
spot. n Imbalance changes?
n Influence of balance weights

n Based on the dynamics of the rotor support
n Based on the bearing geometry and condition
Outline
n Consider effect of bearing design and
operation on the tools in your Predictive End
Maintenance program
n Vibration monitoring
n Lubricant monitoring
Preventative Maintenance
n Temperature monitoring Interface
n Thermography
Rotor change or
bearing change or
?
Section
n Balancing

Programs Sheet 8
August 2004
Outline
n Abbreviated presentation with emphasis on
Installing and Handling potential impact on machine vibrations:
n Visual Inspection
of Babbitted Bearings n Measurements
n Alignment Considerations
(partial) n Pedestal Measurements
n Scraping
n Shaft Roughness
n Cleanliness Requirements
Pioneer Motor Bearing Company n Material Handling Requirements
NDE Requirements
May 2006 n
n Insulation
n Final Assembly Tips
Copyright 2006, Pioneer Motor Bearing Company Copyright 2006, Pioneer Motor Bearing Company
Visual Inspection Journal Diameter

n Visually inspect bearings and n Measure for diameter, taper, and
associated hardware for damage ellipticity
n Measure within 0.0002
0.0002
n Refer to the bearing damage section
n Should be round within 0.0005
0.0005
of this presentation for assistance n Taper less than 0.0005
0.0005/inch of length
with root cause analysis n Uniform taper less critical with dynamically
aligning radial bearing
n It is never a great idea to re-
re-assemble
n Be aware that any eccentricity from the
any machinery with bearings that are journal to the rest of the rotor can
visibly damaged appear as higher dynamic forces
Bore diameter Outer diameter

Measure 5 C Repeat
diameters.
B D measure-
measure-
C
Circular bore ments
=
A+ B +C + D + E near front
B D 5
and back
E
E axial
Elliptical bore
A
Vertical = C
A faces to
check for
A+ E taper.
Horizontal
2 A
B=D E
D B
Repeat measurements near front and back C
axial faces to check for taper. Copyright 2006, Pioneer Motor Bearing Company Copyright 2006, Pioneer Motor Bearing Company
Installation and Handling Sheet 1

August 2004
Pad thickness Tapered Thrust Plate

Measure wall CCW rotation
thickness near
E both axial faces
D Measure drop
(check taper) and with respect to
C on each pad flat land region
B
(check at 15 circled
circled
consistency). points, as
A CROSS-
CROSS-SECTION
indicated.
Preloaded pad
has thicker
crown (C) than
ends (A,E).
Thrust Bearing Clearances Thrust Bearing Clearances

n Axial range of motion of the shaft n Usually Adjusted through the use of a
between active
active and inactive
inactive thrust shim or filler plate
surfaces.
n Avoid the use of numerous stacked shims
n Field checked by bump test
n Calculate the required shim thickness
n Must overcome residual oil films
using measurements of available space
n Clearance
can increase due to
component compression n Thickness of tilting pad thrust bearings
n Leveling links must be measured as an assembly
n Shim packs or supports n Confirm final clearance by bump checking
n Clearance can decrease due to shaft rotor with upper housing half in place
expansion
Alignment Considerations Bearing Elevation

n Review historical operational data n Multiple bearings (>2) for a continuous
shaft
n Review OEM recommendations
n Typical power generation shafts
n Measure and document as found n Goal: even
even loading by setting proper
conditions elevation and alignment of each bearing
n Typical elevation follows catenary curve
n Avoids adding additional shaft moment
n Installation may need to preload
preload
bearing to set at the proper elevation

August 2004
Catenary Curve Catenary Curve

Applies to Bearing
hanging installation
chain, seeks to
power line, place all
rope, etc. bearings on
a caternary
curve.
y ( t ) = amp cosh t
amp
Catenary Curve Catenary curve Catenary Curve

Catenary Curve: Designed vs As-Built minimizes bearing
n Raise bearing from shaft sag
1.35 1.5
loads and moments.
position to desired point on the

catenary curve.
1
cat
Gravity Sag (in)
in
catFound 0.5 >1.2

>1.2 Setting elevation of
in end bearing (e.g.
exciter)
Operating catenary curve
0 Preload
Preload
Sag
0.121
0.5
0 20 40 60 80 100 120 140 160 Ref. Bearing
0 axial 152 Misalignment
Misalignment500MW
TurboGenerator
TurboGenerator, Ettles, et
ft
Axial Position from #1 Bearing (in) al, 1974. Main Bearing Overhung Bearing
500 MW turbine generator, 150 ft long, 14 bearings
Elevation Preload Bearing Adjustment

n Raise bearing from shaft sag position n Quite often, when installing new or
above desired point on the catenary rebuilt bearings will require
curve to improve stability of sleeve alignment of the machinery
bearing.
Setting elevation of end n Many large turbine and generator
bearing (e.g. exciter)
Additional bearing elevation
bearings have alignment Keys
Keys
Operating catenary curve Preload
installed
Sag n Many smaller machines require
adjustment of the bearing housing
Main Bearing Overhung Bearing or pedestal

August 2004
Bearing Adjustment Bearing Adjustment
Typical Tilting Pad Journal Bearing with external

Keys
Keys for adjusting the radial position of the bearing
Lower Bearing half with adjustment keys centered
Bearing Adjustment Misalignment

n Radial: journal axial centerline is
not parallel to the bearing
centerline.
n Thrust: runner surface is not
parallel to the bearing surface.
Adjustment of keys for horizontal offset showing improper contact

contact
with the housing bore
Misalignment Accommodation Misalignment Accommodation

n Goal: Prevent un-
un-even loading of bearing
n Especially edge-
edge-loading
n Radial
n Spherical,ball fit
fit on OD (outer diameter)
n Spherical(e.g. ball in socket
socket) surface for
pad OD in tilt-
tilt-pad bearing
n Other means of aligning: scraping, pins,
shims
n Thrust
n Leveling
links
n Sphericalfit on thrust plate back
n Other means: pins, shims Blue Check of Turbine Journal Bearing

August 2004
Alignment Issues Bearing Support Fits

n Generally installed under cold n Housings
conditions n Clearance fits / Tight fits
n Alignment varies with temperature n Depends on housing design and bearing
wall thickness
n Affected by casing distortions
n Pedestal
n Mechanical fits can lock up
up under
n Avoid soft
soft foot
operating bearing (radial or thrust)
n No deflection > 0.001
0.001
loads
n Prevents further adjustment n Consequence of looseness
n Problem installations require non-
non- n Reduced stiffness and damping
mechanical accommodation n Increased vibration
Thrust Collar Runout Material Handling

n Want the collar square
square to the axis of rotation
Requirements
n Avoid collar wobble
wobble
n Avoid excessive force
n Can be difficult to measure if shaft is floating on
the radial bearings n Use secure jacking systems to
n Dial indicators 180
180 apart
n A and B indicators
support shaft during and after
n Record the measurements as the shaft is turned at bearing removal
both indicators
n Sign of the reading (+ or -) must be recorded n If using an overhead crane, roll the
Insure that both indicators return to zero
zero
n
n Subtract readings at B from A
bearing using chainfalls,
chainfalls, not the
n Gives twice the TIR of the collar main or auxiliary hook
Material Handling Bearing Insulation

Requirements n Insulation serves as a electrical
Bearings will gall and pick up metal boundary
from the pedestal bore if excessive
n Humidity will degrade insulation
force is used for installation or
removal. n Insulation resistance lowers with
Caution must be exercised while temperature
installing or removing bearings. n Oily dirt and debris will degrade
Fingers should never be inserted in insulation
barring holes or between lifting
eyes and the pedestal joint. It is n Insulation serves as a
quite a common occurrence that a mechanical boundary
bearing that seems tightly wedged
in position will quickly roll to n Prevent dirt from bridging
bridging the
bottom dead center with great insulation
force. n Avoid damaging due to impact or
peeling.

August 2004
Bearing Installation Assembly Tips

n Thin wall shells n Keep area clean, so as not to
n Precisionhalves conform to housing drop any foreign material into
n Bearing geometry depends on housing the bearing during reassembly
geometry
n Clean joint faces
n Shell must conform to housing geometry
n Joint faces should be tight
n Thick wall shells
n Bearing defines geometry
within 0.001
0.001
n Housing supports bearing n Avoid striking or scratching
n Distortion from housing is undesirable babbitt surface
n Avoid overuse of gasket cement
around the pedestal cap joints
End
Installing and Handling

Bearings (partial)
Copyright 2006, Pioneer Motor Bearing Company

Fluid Film Bearings 050406S

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Introduction May 2006June 2004

VIBRATION INSTITUTE n Operations impacts

Pioneer Motor Bearing Co.

(c) Pioneer Motor Bearing

Pioneer Motor Bearing

Manufacturing Service & Repair

Full Spectrum of Services Full Spectrum of Services

Engineering Dr. Lyle A. Branagan

(c) Pioneer Motor Bearing

n Turbo Research, Inc. 3 Years

to potential bearing n Babbitted bearing damage

Topics Friday Demonstrations

(c) Pioneer Motor Bearing

Perspectives on Bearings A small piece in the plant

Machine Design Perspective

Lubricant Perspective Vibration Specialist Perspective

n Understand impact on oil analysis n May define allowable vibration

(c) Pioneer Motor Bearing

(c) Pioneer Motor Bearing Company, 2006

(c) Pioneer Motor Bearing

(c) Pioneer Motor Bearing Company, 2006. All rights reserved.

Outline Opening Up the Machine

Opening Up the Bearing Load Orientations: radial/thrust

End bell and housing top removed

(c) Pioneer Motor Bearing CompanyBearing

Load Orientations: radial/thrust Radial Bearings

Thrust Bearings Elements

(c) Pioneer Motor Bearing CompanyBearing

Hydrodynamic versus Hydrostatic Hydrodynamic versus Hydrostatic

Sleeve Bearing Geometry General Clearance

BABBITT CLEARANCE ROTATING 4

By comparison, the By comparison, the

(c) Pioneer Motor Bearing CompanyBearing

Sleeve Bearing Geometry Bearing Pressures (Load Capacity)

Reynolds Equation 2-D Profile Sleeve Bearing Flows

Strong rotation with

(c) Pioneer Motor Bearing CompanyBearing

Reynolds Equation - Cavitation Cavitation

Bearing Cavitation Bearing Cavitation

Axial Axial distribution

Cavitation - Experimental Cavitation Demonstration

(c) Pioneer Motor Bearing CompanyBearing

Fluid-film Radial Bearing Hydrodynamic Demonstration

radial position. Reduction in friction

Bore Designs Bore Designs

Radial Bearing Components Radial Bearing Components

OIL COLLECTION POCKETS DOWEL PINS BOLT HOLES

BUMPER THRUST FACE

INSULATED RADIAL SLINGER RING GROOVE

LOWER HALF UPPER HALF (ROTATED)

(c) Pioneer Motor Bearing CompanyBearing

Joint Details Dowel Pins

Anti-Rotation Pins Bearings for Motors

Ref: EPRI Manual.

Bearing Insulation Bearing Support

Potential damaging current loops.

(c) Pioneer Motor Bearing CompanyBearing

Conforming Bearing to Shell Distribution-

n Medium wall bearings

Circumferential groove sharply diminishes load capacity but allows

Shell Wall Thickness Shell Wall Thickness

Shell Wall Thickness Tilting Pad Radial Bearings

(c) Pioneer Motor Bearing CompanyBearing

Tilt-pad Radial Bearings Mechanical Pivot