Bearing Types _ lorapai Applications.pptx

Bearing presentation

1. Dated: July 09, 2019 BEARING TYPES & APPLICATIONS

2. Introduction Training Introduction: This course is related to basic knowledge of different types of bearings along with their applications. The course will also cover bearing designation of Anti-friction bearing. Major causes of bearing failure also included in the course. Course Benefits: The course will be beneficial for participants in terms of basic knowledge of different types of bearings. It would also be helpful for participants to know about major problems occurred in bearings. Presenter: Hafiz M. Abdul Samad Ayoubi (Executive – Mechanical FPCL) Experience: 3.5 years experience in Mechanical Maintenance Experience Area: STGs, Boilers, BOP

3. Training Session Session-1: Introduction of Bearings and its Classification along with Designation System - Duration: 01 hour 30 minutes - Objective: The session will cover the fundamental attributes of Bearings and its types & classification and designation system. - Session-2: Major Causes of Bearing failure and Bearing problems at FPCL - Duration: 01 hour 30 minutes - Objective: The session will cover the details of major causes of bearing failure along with problems faced at FPCL. - Session-3: Wrap-up & Q/A Session - Duration: 30 minutes - Objective: The session will cover summary of important topics and detailed Q/A session. An assessment test will also be carried out.

4. Session-1: Introduction of Bearings and its Classification Topics Classification of Bearing Introduction of Bearing Designation of Anti-Friction Bearing Types of Anti-friction Bearing

5. Definition Bearings are used to support the shaft / load on the shaft with a minimum of friction and also permit the shaft to rotate freely, but they prevent axial or radial motion. Introduction of Bearings

6. 1. Depending upon the direction of load to be supported Radial Bearings – Load acts perpendicular to the direction of motion of the moving shaft Thrust Bearings – Load acts along the axis of rotation of the moving shaft 2. Depending upon the nature of contact Friction Bearings Anti-friction Bearings Classification of Bearings

7. Journal Bearing Bush Bearing Sleeve Bearing Insert Sleeve Bearing Elliptical Bearing Tilting pad Bearing Types of Friction Bearings

8. Tilting Pad Thrust Bearing 2. Thrust Bearing Combine Bearing (Thrust & Journal) Taper Land Thrust Bearing Types of Friction Bearings

9. Tilting Pad Thrust Bearing Kingsbury Thrust Bearing Pads Pads used in dual direction Michell Thrust Bearing Pads used in single direction Type of Tilting Leveling Key Pivot Shoe support Rocker pivot Types of Friction Bearings

10. Major parts of anti-friction bearing are: i . Inner ring ii. Outer ring iii. Rolling element iv. Cage (steel, brass, polyamide) Outer ring Inner ring Rolling Element Cage Parts of Anti-Friction Bearings

11. Designation System of Anti-Friction Bearings

12. Designation System of Anti-Friction Bearings 2. Bearing Number 0 Double row angular contact ball bearings 1 Self-aligning ball bearings 2 Spherical roller bearings, spherical roller thrust bearings 3 Tapered roller bearings 4 Double row deep groove ball bearings 5 Thrust ball bearings 6 Single row deep groove ball bearings 7 Single row angular contact ball bearings 8 Cylindrical roller thrust bearings

13. Designation System of Anti-Friction Bearings 2. Bearing Number The second digit of Bearing Number reflects the robustness of the bearing . As you go up the scale below from 9 to 4 the inner and outer race thickness will usually increase along with the ball size, this will be to help cope with extra load.

14. Designation System of Anti-Friction Bearings 2. Bearing Number The last two figures of bearing number give the size code of the bearing; when multiplied by 5, the bore diameter in millimeters is obtained. 00 = 10 mm 01 = 12 mm 02 = 15 mm 03 = 17 mm

15. Types of Anti-Friction Bearings

16. Types of Anti-Friction Bearings

17. Deep groove ball bearing (Single and Double Row) Accommodate radial and axial forces Suitable for high speeds Self aligning capability is limited Sealed deep groove ball bearings are maintenance free Types of Anti-Friction Bearings

18. Angular contact ball bearing (single row) Have one high and one low shoulder Accommodate axial forces in one direction only Suitable for high speeds Types of Anti-Friction Bearings

19. Tandem Arrangement Different arrangements of Angular contact ball bearings Face to Face Arrangement Back to Back Arrangement Types of Anti-Friction Bearings

20. Angular contact ball bearing (double row) Can accommodate high radial forces and, in both directions, axial forces Suitable for bearing arrangements which demand a rigid axial guidance Types of Anti-Friction Bearings

21. Self Aligning Ball Bearings Spherical raceway in the outer ring so it is self aligning Consist of double row Suitable for applications where considerable shaft deflections or misalignment and housing deformation are to be expected Can compensate for a misalignment of approximately 4 o out if the center position Types of Anti-Friction Bearings

22. Needle roller bearings Roller length is 2.5 times the roller diameter or more Act as floating bearing Consist of one or two bearing rings High radial load carrying capacity where space is sparse Light weight construction Can accommodate only radial loads Tapered roller bearings Carry axial load in one direction only Usually two such bearings are mounted in opposite configuration Higher radial and axial load carrying capacity Suitable for low speeds Types of Anti-Friction Bearings

23. Different arrangements of Tapered roller bearings Tandem Face to Face Back to Back Types of Anti-Friction Bearings

24. Spherical roller bearings Used for heavy duty applications having both radial and axial load carrying capacity Can compensate shaft deflections and misalignment up to 0.5 to 2 degree Available with cylindrical or tapered bore Types of Anti-Friction Bearings

25. Thrust ball bearings Used when loads are only axial Suitable for medium speeds Angular contact thrust ball bearings Accommodate high axial loads in only one direction Suitable for higher speeds and also take up low radial loads Low friction bearings, so little drive energy is required Types of Anti-Friction Bearings

26. Cylindrical Roller Thrust Bearings High axial load carrying capacity in one direction No radial load carrying capacity Spherical Roller Thrust Bearings Accommodate heavy axial loads Can accommodate medium radial loads Raceways are inclined relative to the bearing axis Has self aligning properties Can accommodate misalignment and shaft deflections Suitable for high speeds Types of Anti-Friction Bearings

27. Point Contact Line Contact Difference in Contact b/w Ball & Roller Roller bearings have higher load carrying capacity due to line contact

28. Session-2: Bearing Failure and Countermeasures Topics Application of Bearing Bearing Failure & Countermeasure Problems related to Bearings at FPCL Bearing Lubrication and Manufacturers

29. Bearing Failures Bearing failures are major cause of machinery shutdowns. Never Ignore Them Two third of all bearing failures are premature which could be prevented.

30. Bearing Failures

31. Causes Observations ● Rough and worn surfaces. ● Ingress of solid foreign objects. ● Lack of cleanliness before and during mounting operations. ● Do not unpack bearing until just before it is mounted. ● Filtration of lubricating oil ● Keep workshop clean and use clean tools ● Use fresh clean lubricant. 1. WEAR ( due to abrasive particles) Countermeasure Wear on full circumference of raceways Wear found on cage Primary Damage

32. Primary Damage Causes Observations ● Dent marks on surface. 2. INDENTATIONS Dent marks can be seen. Indentation probably by dust. ● Ingress of solid foreign objects. ● Lack of cleanliness before and during mounting operations. ● Do not unpack bearing until just before it is mounted. ● Improvement in sealing ● Filtration of lubricating oil Countermeasure

33. ● Ingress of water or corrosive material (such as acid) ● Condensation of moisture contained in the air. ● Improvement in sealing Rusting on raceway surface due to presence of moisture in lubricant . Rust on rolling contact surface due to ingress of water Observations ● Greyish black streaks ● Pitting on raceways. Primary Damage 3. CORROSION Causes Countermeasure

34. Causes Observations ● Surface is roughened and tiny particles adhere . ● Rolling elements slip in rolling motion and characteristics of lubricant are too poor to prevent slippage. ● Select optimum lubricant and lubrication system capable of forming sound oil film Smearing on roller Smearing Smearing caused by heavy axial loading and improper lubrication Primary Damage Countermeasure 4. SMEARING

35. Countermeasure Causes Observations ● Breaking of retainer. ● High speed spinning or large fluctuation of speed ● Poor lubrication ● Trapping of foreign objects ● Heavy vibration ● Improvement in load conditions ● Improvement in lubrication system ● Selection of optimum retainer Secondary Damage 1. CAGE DAMAGE

36. Causes Observations ● Cracks (sometimes accompanying smearing) ● Poor mounting practice ● Smearing ● Always use a soft drift or mounting sleeve. Never subject the bearing to direct hits. ● Prevent smearing Crack caused by smearing Countermeasure Secondary Damage 2. CRACKS Crack in race way caused by faulty mountings

37. Causes Observations ● Surface is flaked. (Surface after flaking is very rough) ● Flaking may be caused by over-load, preloading etc. ● Rust, Smearing, Indentations. ● Examine operating conditions and adopt bearings with larger capacity as per requirement ● Increase viscosity of oil and improve lubrication system to form an adequate lubricating oil film ● Eliminate installation errors. Flaking Flaking Countermeasure Secondary Damage 3. FLACKING

38. Bearing Failure Chart

39. Bearing Applications General Applications Steam turbines Industrial and Automotive gearboxes Electric motors and generators Pumps Fans Compressors

40. Bearing Applications Bearing Applications at FPCL Steam turbines 10MW - Tilting pad type Thrust & Journal bearing 24MW - Tilting pad type Thrust & Journal bearing 60MW - Tilting pad type Thrust & Journal bearing Industrial Gearboxes Sleeve bearing Electric Generators Elliptical bearing Pumps 24MW Condensate Pump (DE) - 6309 Z C3 24MW Condensate Pump (NDE) - 7309 BECBJ 60MW Condensate Pump (DE) - 6311 60MW Condensate Pump (NDE) - 7311 BECBP

41. 24MW Condensate Pump (DE) 6 3 09 Z C3 Bearing Type (6 = Single Row Deep Groove Ball Bearing) Bearing Series (3 = Medium robustness) Bore Dia (9 x 5 = 45mm) Suffix (Z = Metal seal) Suffix C3 = Internal Clearance Decoding of Bearing

42. Problems related to Bearings at FPCL Bearing Installation Problem at STG#04

43. Problems related to Bearings at FPCL Rubbing Marks found on STG#01 Generator DE Bearing

44. Functions of Lubricants in Bearings Avoid or reduce metal to metal contact between the rolling and sliding contact surfaces Protection against corrosion Heat dissipation from the bearings Discharge of wear particles and contaminants from the bearing Bearing Lubrication

45. WAUKESHA KINGSBURY SKF FAG TIMKEN NSK etc. Bearing Manufacturer

46. Session-3: Summary and Assessment Topics Assessment Brief Summary and Q/A Session

47. THANK YOU