Bearing Maintenance
Bearing Maintenance
Bearing Maintenance
Maintenance
Bearing Assemblies
Summary
Journal Bearings
u Construction & features
u Maintenance
u Installation Tips
u Troubleshooting
Thrust Bearings
u Rotor Axial Thrust
u Thrust Bearing Assembly
u Lubrication
u Maintenance
u Troubleshooting
Journal Bearing – Principle
u On the bottom half
of the bearing, the oil
film thickness
decreases in the
direction of the shaft
rotation
u The shaft will attain equilibrium position in the bearing when the oil film
forces will balance in both horizontal and vertical direction
Dresser-Rand Journal Bearing
Conventional: Load on pad, 5 pads up to 12”
DATUM :
u Load on pad, 5 pads up to 9”
u Between pad, 4 pads from 10” to 14”
Type: Kingsbury LEG direct lube
Load: 200 psi breakaway & 500 psi rotating
Pad contact:
u Line contact for small & medium weight rotor
u Ball in socket for heavy rotor(high bearing stiffness)
Damper bearing:
bearing based on rotor stability analysis
Construction: Axial split
5
•© 2007 by Dresser-Rand
Dresser-Rand Tilt Pad Radial Bearing
Oil Control
Ring
Alignment
Dowel
Oil Supply
Hole
Oil Supply
Groove
Anti-Rotation
Dowel
6
•© 2007 by Dresser-Rand
Tilt Pad Radial Bearings
RTD
Wires
Bearing
Housing
7
•© 2007 by Dresser-Rand
Journal Bearing - Flooded Lubrication
u In the flooded design the bearing pads obtain their lubrication from the
surrounding oil bath
8
•© 2007 by Dresser-Rand
Journal Tilt Pad Spring
Spring
Sensor
Retainer
Steel Backing
Pad or Shoe
10
•© 2007 by Dresser-Rand
Orion Journal Bearing
u Journal shoe are positioned by cylindrical grooves in the retaining ring
11
•© 2007 by Dresser-Rand
Orion Style Journal Bearing
Babbitt
Pad Pivot
Sockets
Anti-
RTD’s Rotation
Dowel
12
•© 2007 by Dresser-Rand
Leading Edge Groove (LEG)
Oil Distribution
Grooves
13
•© 2004
2007 by Dresser-Rand
Journal Bearing -LEG
u The bearing pad incorporates
inlet spray bars for direct
lubrication, which increases the
effectiveness of cool inlet oil
14
•© 2007 by Dresser-Rand
Journal Bearing -
LEG Design
Leading Edge Groove
Trailing Edge
u Grooves located on both sides of the pad directly into the babbitted
surface are capturing and redirecting side leakage back into appropriate
areas of the shoe
u By reintroducing oil to the pad, the grooves recycled side leakage and
lowered the amount new oil needed to maintain the "critical oil level".
15
•© 2007 by Dresser-Rand
Journal Bearing – Pad Preload
u“Preload” describes the relationship between the pad
diameter, shaft diameter and bearing diameter
uCheck split lines surfaces for full contact. Stone / lap burrs or raised edges
18
•© 2007 by Dresser-Rand
Inspect Journal Bearing Oil Feed Tubes
21
•© 2007 by Dresser-Rand
Use Mandrel for Journal Bearing Clearance
u Measure and record the clearance within 0.0001” from the pivot
through the centerline of the bearing for each of the bearing shoes
uAverage the clearance readings found and multiply result by 0.894 to
obtain actual clearance of journal bearing
22
•© 2007 by Dresser-Rand
Record Journal Bearing Clearance
u As a "rule of thumb",
centrifugal compressor
bearings run about 1.5 mils of
diametral clearance per inch of
bearing diameter
25
•© 2007 by Dresser-Rand
Damper Bearing
Confined
Oil
Do Not
Remove
Spacers
The spring functions to support the cage in the middle of the clearance
between the cage and the housing when the half-weight of the rotor is
included
28
•© 2007 by Dresser-Rand
Damper
Bearing
29
•© 2007 by Dresser-Rand
Journal Bearing – Damper Bearing
u Pressurized lube oil is supplied into this annular gap through a feed
groove at the midpoint between the o-rings
u The oil functions in the gap between the cage and housing much the
33
•© 2007 by Dresser-Rand
Bearing Split Line Sealant
This entire surface was found to be
covered with sealant upon disassembly
Correct application of
bearing split line sealant
34
•© 2007 by Dresser-Rand
Damper Bearing – Centering Verification
35
•© 2007 by Dresser-Rand
Damper
Bearing
Test
36
•©
© 2007
2000 by Dresser-Rand
Damper Bearing Test
37
•© 2007 by Dresser-Rand
Journal Bearing Installation Layout
Coupling Guard
to Bearing
Housing Adapter
& Labyrinth Seal
38
•© 2007 by Dresser-Rand
Journal Bearing Adapter Installation
39
•© 2007 by Dresser-Rand
Journal Bearing – Condition Monitoring
u If the length of diameter ratio (LD) is greater than 0.5, two sensors shall
be installed, each located at a distance of 0.25L from the end of the
bearing running face
u If the length of diameter ratio (LD) is less or equal to 0.5, a single
sensor shall be axially located in the center of the bearing
42
•© 2007 by Dresser-Rand
Journal Bearing – Condition Monitoring
The transducer system provides the following signal components:
u AC signal (negatively fluctuating) - provides shaft dynamic motion
relative to the probe mounting
u DC signal – provides the average radial shaft position relative to the
probe mounting
Note : the radial proximity probe shall be used to measure radial shift
position within the bearing (similar to axial position probe)
“Shaft Centerline Position” – determined by compiling of X&Y
signals and the known radial bearing clearance. An initial “zero gap” is
required to obtain accurate data (rotor at rest/ turning gear)
Shaft Centerline Position, provides valuable information:
u Coupling and bearing alignment
u Rotor preload
u Oil film thickness
u Bearing wear
u Attitude angle
43
•© 2007 by Dresser-Rand
Journal Bearing – Condition Monitoring
44
•© 2007 by Dresser-Rand
Journal Bearing – Condition Monitoring
45
•© 2007 by Dresser-Rand
Thrust Bearings
46
•© 2007 by Dresser-Rand
Thrust Bearings
u Lubrication
u Maintenance
u Troubleshooting
47
•© 2007 by Dresser-Rand
Thrust Bearings
u Axial thrust is generated in a centrifugal compressor by
the pressure rise through the impellers
u The major portion of the thrust load is compensated by
either :
§ balancing drum ( straight through compressors)
§ placing the impeller in back to back configuration
Diaphragm Bulb
Diffuser Cover Area
Return Channel
DIMPELLER EYE
PIMP ≈ P1 + .75∆ P
≈ PIMP
≈ PIMP
P1 ≈ PIMP
F
50
•© 2007 by Dresser-Rand
Impeller Pressure Loading & Forces
P3
Diffuser
Diaphragm Diaphragm P4
P2
Impeller Eye
Labyrinth Impeller Eye
Seal Labyrinth
Seal
Spacer Labyrinth
Seal
Spacer Labyrinth P1 P3
Seal
Impeller Impeller
Spacer Spacer
51
•© 2007 by Dresser-Rand
Balance Piston Function
P5
P3
Balance Piston
P2 P4
P1
P3
P1
52
•© 2007 by Dresser-Rand
Balance Piston Labyrinth Seal
Balance Piston
Labyrinth Seal
53
•© 2007 by Dresser-Rand
Straight Through Configuration
Balance
Inlet
Connector
Impellers Disch
Balance
Piston
Thrust Bearing Seal
Active Inactive
F1 F2 FC
F3
FBP
Ps
Last Stg. Ps
FBP = BP
Compensating DBAL PISTON
Force DINTERSTAGE
FBP = Area x ∆P 55
•© 2007 by Dresser-Rand
Balance Piston
56
•© 2007 by Dresser-Rand
Effect of Balance Piston Laby Wear
Last Stg. Ps Pressure drop increases in
balance connector line.
+ (0.75 x Last Stg. ∆P)
Balance Piston
Laby Leakage
Increases
Division
Shaft Wall Shaft
Shoulder Stg.1 Stg.2 Stg.4 Stg.3 Shoulder
Area Area
(SSA) (SSA)
60
•© 2007 by Dresser-Rand
Thrust
Clearance
Thrust Bearing
(Float) Assembly
Active Inactive
Thrust Thrust Thrust
Bearing Bearing Journal Bearing
Disc
Lock
Nut Shaft
Shoulder
Hydraulic Fit 61
•© 2007 by Dresser-Rand
Michel Thrust Bearing Construction
Inboard
Thrust
Outboard Bearing
Thrust
Bearing
Compressor
Rotor Shaft
Thrust
Bearing
Cover
Thrust
Thrust Bearing
Rotor Pad/Shoe
Thrust
Housing
Base Ring
Oil Pad
Thrust Disc
Babbitt
Rotation
Oil Pad
Base Ring
Thrust Cover
Machined
Recess 63
•© 2007 by Dresser-Rand
Michel Trust Bearing Features
u The shoes are steel with babbit face
u The line of contact with the base ring is past the centerline
of the shoe in the direction of the rotation
uThe “offset” causes a lower pressure at the leading edge
and a higher pressure at the trailing edge – optimum oil
wedge
u The shoe support with the base ring is a line contact
(instead of point contact) which reduces the specific load on
the back of the shoe
u The base ring is made of alloy steel:
§ The thickness of the span allows it to deflect at a
predetermined load
§ This provides more uniform load distribution on the
bearing 64
•© 2007 by Dresser-Rand
Kingsbury Load Equalizing Mechanism
Lower
Leveling Plate
Babbitt on
Thrust Pads Shim Area
Upper
Leveling Plate
Thrust
Housing 66
Base Ring
•© 2007 by Dresser-Rand
Kingsbury
Thrust Bearing
1 – CW base ring
2 – Leveling plate dowel
3 – Lower leveling plate
4 – Upper leveling plate
5 – Leveling plate set screw
6 – CW LEG shoe
7 – Shoe support
8 – Oil feed tube
9 – O-ring
10 – Anti-rotation key
11 – Key screw
12 – Collar
13 – CCW bearing assembly
67
•© 2007 by Dresser-Rand
Self-Leveling Bearing Pads
Inboard
Bearing
Thrust Disc
Outboard
Bearing
Lower Bearing
Housing
68
•© 2007 by Dresser-Rand
Directed Lubrication, Self-Leveling
Thrust Bearing
Oil Inlet
Pad Spacing Channels A
Stop
View A-A
Oil
70
•© 2007 by Dresser-Rand
Trust Bearing Pad LEG Design
Set Screw
Split Ring
A thin sleeve is
mounted to the shaft
Shaft with a loose fit
73
•© 2007 by Dresser-Rand
Polygon Fit
u Three- lobe shaft polygons and mating bores
are produced by precision grinding techniques to
close tolerances
uThe thrust disc is mounted by hand
onto the shaft in the assigned position
without use of heat or force
u The thrust disc polygon bore shall
be aligned to the polygon journal of
the shaft
u Once the disc is in position, it is hand torque onto the shaft producing
a three line contact to lock the impeller
u The locking force is sufficient enough to withstand main drive torque
as well as transient forces
uAll polygon fit rotor assemblies are match marked for proper
positioning allowing field assy / disassembly without re-balancing
74
•© 2007 by Dresser-Rand
Thrust Disc Polygon Fit
u The thrust disc is pressed up against the shaft shoulder by axial set
crews contained within a locknut
u Removal of thrust disc from the shaft is accomplished by merely
reversing the self looking feature of the lobe contour
75
•© 2007 by Dresser-Rand
Thrust Bearing Maintenance
There are seven wear points in the bearing. All these points shall be
checked for wear:
§ Soft babbited shoe face
§ The hardened steel shoe insert face ( 30-35 Rockwell hardness)
§ The face of hardened steel upper leveling plate (47-50 Rockwell )
§ The outer edge of the upper leveling plate
§ The upper edge of lower leveling plate (47-50 Rockwell)
§ The pivot point of the lower leveling plate
§ The inner face of the base ring (25-27 Rockwell)
76
•© 2007 by Dresser-Rand
Thrust Bearing Inspection
u The base ring is the softer
component, it is likely to show
the most wear
u By experience, a wear of 6
mils will cause a” lock up” of
the leveling plate
Base ring
79
•© 2007 by Dresser-Rand
Measure & Record Thrust Shoe Thickness
Kingsbury thrust shoes
u0.002" tolerance variation up through and including the 10.5" thrust
bearing size;
u 0.004" tolerance variation above 10.5 “ thrust bearing size;
u Shoes with RTD's may have up to 50% greater variation (i.e., .003" or
.006") than above (the shoes are pulled form stock, then drilled and the
pad surfaces re-lapped after machining which can reduce the height
slightly)
Note: Kingsbury bearings accept higher tolerances as they use links and
leveling plates to achieve load sharing between pads and not tight
manufacturing tolerances as Michel
80
•© 2007 by Dresser-Rand
Inspect Thrust Shoe Surface
u Discoloration - Tin Oxide damage
• Tin oxide damage is recognized by hard, dark brown / black
film that forms on the babbit surface
• Tin oxide forms in the presence of tin based babbit, oil and salt
water, beginning in areas of high temperature and pressure
• Once formed, can’t be dissolved and it’s hardness will prevent
foreign particles from embedding in the babbit
Recommendations:
• Eliminate some or all contributing
elements
• Replace the lubricating oil
• Reduce the oil temperature
•The lube oil system shall be flushed and
cleaned (bearings, pipes, reservoir) with
mineral spirits
81
•© 2007 by Dresser-Rand
Kingsbury Thrust Bearing Shims Adjustment
Add shims
82
•© 2007 by Dresser-Rand
Michel Thrust Bearing
83
•© 2007 by Dresser-Rand
Michel Thrust Bearing
84
•© 2007 by Dresser-Rand
Michel Thrust Bearing Installation Cross-section
85
•© 2007 by Dresser-Rand
Kingsbury Bearing
86
•© 2007 by Dresser-Rand
Kingsbury Thrust Bearing Installation
87
•© 2007 by Dresser-Rand
Thrust Bearing End Play Adjustment
u End play is the axial clearance between thrust collar and
thrust subassemblies
u Clearance is required to allow the oil film formation and
rotor thermal growth expansion
88
•© 2007 by Dresser-Rand
Lubrication ISO 32 vs. ISO 46
89
•© 2007 by Dresser-Rand
Lubrication
ISO 32
90
•© 2007 by Dresser-Rand
Lubrication
ISO 46
91
•© 2007 by Dresser-Rand
Thrust Bearing Failure
u Fluid Slugging – passing a slug of fluid through the
machine can increase the thrust to many times its normal
level
u Surge Events
92
•© 2007 by Dresser-Rand
Thrust Bearing – Temperature Measurement
u A temperature
sensor shall be
located in each of two
shoes in the normally
active thrust bearing
u The sensors shall be located in the lower half of the thrust bearing
assembly to identify the maximum pad temperature
u The temperature sensors shall be placed at 75% of the pad width
radially out from the inside bearing bore and at 75% of the pad length
from the leading edge
93
•© 2007 by Dresser-Rand
Thrust Bearing Axial Displacement
94
•© 2007 by Dresser-Rand
Axial Displacement Limits
Alarm = (Axial Thrust) / 2 + 5 mils; S/D = (Axial Thrust) / 2 + 10 mils
uThe thrust bearing typically runs either on one side of the thrust
bearing or the other (Rarely does it float in the middle)
u The 5 mils past that point to alarm allows for babbitt wear on the pads
(they have typically 60 mils of babbitt) and for deflection of the base ring
under load
u The Michel bearing deflects only one mil+ for 500 psi loading
whereas a Kingsbury style, with it's pins and linkage bars, deflects 10+
mils under 500 psi loading
Note: DR have recently opened up those AL and S/D values to even
greater numbers than what were the standards at the time these units
were built (the client was experiencing nuisance alarms and trips due to
axial position AND nothing was wrong with the thrust bearings)
95
•© 2007 by Dresser-Rand
www.dresser-rand.com
[email protected]
96
•© 2007 by Dresser-Rand