1

BEARINGS
1.

INTRODUCTION
A rotating shaft in any item of machinery has to be supported and held in position
(located) so that;

the mass (load) of the shaft and any attached components is supported,
axial or radial forces (thrust) generated by rotation are absorbed,
the shaft can rotate freely with minimum wear to the shaft or its supports,
the shaft is located (held) in the correct operating position relative to other
components and the supports and

the minimum of effort (power/ energy) is needed to overcome the frictional forces on
the shaft.
In most machines bearings of some type or other are used to meet these requirements.
The type of bearings selected for a particular application will mainly depend on the
following:
Forces (Dynamic, Static, Axial, and radial loading) acting on the bearing
Speed at which the shaft is revolving
Operating environment
Frictional forces involved
Bearings are subject to a certain degree to rolling or sliding friction. Lubricants are used
to reduce this friction to a minimum.

Lubrication however cannot reduce friction

completely because of the friction within the lubricating fluid itself. This fluid friction,
which directly relates to the viscosity, is substantially less than either rolling friction or
sliding friction. However, lubrication is an important factor in bearing operation,
particularly at high speeds and under heavy loads.
2.

PURPOSE OF BEARINGS
To effectively locate rotating shafts and machine components in both vertical and
horizontal positions during operation.

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3.

SAFETY
3.1

Personal safety
It is important to exercise particular caution when working in the vicinity of
rotating equipment and machinery. The following safety rules must be adhered to
at all times:
Do not wear loose hanging clothes
Do not climb over rotating machines
Horse playing is not allowed near rotating machinery
Always beware of hot surfaces which may cause severe burns
Always exercise surgical conditions when working with bearings (lubrication)
NEVER use rags, cotton waste or metal scrapers to remove excess oil or
grease from revolving shafts. This is a dangerous practice and can lead to
serious injuries.
It is also important to make sure that any personal protective equipment that is
required to perform certain duties, are always available when needed.

4.

FORCES ACTING ON A ROTATING SHAFT

4.1

Dynamic loading
The dynamic load rating of a bearing is defined as the constant radial (or centric
axial) load which the bearing can theoretically endure for a basic life rating of one
million revolutions.

This phenomenon is normally catered for in the

manufacturing process of all the different types of bearings that are available.
In single row angular contact bearings, the radial load relates directly to the radial
component of that load which causes only radial displacement of the bearing
rings.
4.2

Static loading
Static loading is the load acting on the bearing when the speed of rotation of its
rings in relation to each other is zero.

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All bearings are thus subjected to load under static conditions because they will
become stationary at some point during operational sequences. The safe static
load for each type of bearing is thus established during the manufacturing
process to ensure that the bearing does not sustain damage to the raceways and
rolling elements during static periods.

The damage incurred as a result of

excessive static loading is usually in the form of permanent indentations which

are sufficient to cause unsatisfactory operation (vibrations) of the bearing under
running conditions.
In general terms, the static load rating is the load on a non-rotating bearing
determined by the allowable amount of permanent damage or deformation at the
most heavily loaded point of contact between the raceways and rolling elements
and not by fatigue of the material.
4.3

Axial and Radial loading

Refer to Figure 1. A rotating shaft is subject to two principal forces, those that act
along the axis of the shaft (Axial) and those that act at right angles to the axis of
the shaft (Radial). This means that when the shaft rotates, forces act in a radial
direction away from the shaft at a point around its circumference. A horizontal
shaft always has the mass (weight) of the shaft acting downwards as it rotates
(i.e. radial force). The mass of a vertical shaft also acts downward in which case
this force is considered to be an axial force.
If not contained, radial forces will cause a shaft to wobble; particularly at low
speed.

At higher speeds, centrifugal forces will tend to absorb any minor

imbalance in the radial forces.

FIGURE 1: FORCES ON A ROTATING SHAFT

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Axial forces can cause the complete rotating mass (shaft + attachments) to move
and damage other components.

Typically, thrust bearings are used to both

contain axial forces (thrust) and locate the shaft in a fixed radial position.
5.

BEARING TYPES
Heavy industrial machines like those used in power stations use a wide variety of
bearings. All these however fall into one of two main categories, namely:
Fluid film bearings
Rolling contact bearings
5.1

Fluid Film Bearings

Fluid film bearings are classified according to the direction of the load they are
supporting. Plain journal bearings are cylindrical in shape and carry the mass
(weight) of the rotating shaft. Thrust bearings are typically disc shaped and are
used to prevent the shaft moving axially (lengthwise) by absorbing any force
caused by axial movement of the shaft. Both bearing types rely on the formation
of an oil film between the bearing surface and the shaft to reduce friction and to
support the load.
5.1.1 Pedestal mounted Plain Journal Bearing
Plain journal or sleeve bearing, illustrated in Figure 2 are commonly called
Plummer blocks or bushings.

They comprise a metal sleeve that fits

around the shaft and is enclosed and held by a bearing housing. The part
of the shaft that turns within the bearing is called the journal.
In some machines the bearing housing is no more than a hole bored
through the casing with a thin metal sleeve between the casing and shaft.
This arrangement is sometimes called a bushing or bearing bush.

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FIGURE 2 : HORIZONTALLY SPLIT JOURNAL BEARING

A basic plain journal bearing, comprising a solid sleeve and has the
disadvantage that it can only be removed from the shaft by sliding it from
an end.

With large machines this can be a time consuming, if not an

impossible task. Removal is made easier by splitting the bearing sleeve

horizontally along the axis of the shaft so allowing the shaft to be lifted out
when the upper half of the bearing is removed. A split journal bearing is
also easier to replace because the shaft does not have to be removed
completely.

With the upper half removed, the shaft only has to be raised

sufficiently to roll the lower bearing half into position below the shaft.
Large split steel shell journal bearings are normally found on jaw crushers,
large fans, turbines and generators. The bearing shell is a steel casting
that is split into an upper and lower half.

Each half is lined with a white

metal (tin/ antimony alloy) such a Babbitt metal. The shell is supported by

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a pedestal that stands on the machine bedplate or foundations.

The

bearing is oil lubricated using a pressure or ring/chain system.

5.1.2 Tilting-Pad Journal
This type of bearing, illustrated in Figure 3, has a segmented bearing
surface. The segments are supported on pivots so that they can move to
adjust to the best position for proper lubrication. The formation of a
lubricating oil film (wedge) between the pad and shaft journal is essential to
achieve radial stability and to prevent damage caused by metal to metal
contact when running.

FIGURE. 3 : TILTING PAD JOURNAL BEARING

NOTE:

Tilting pads are also used for thrust bearings.

Oil Wedge Formation

With tilting pad bearings, two conditions must be satisfied before the film
is established:
-

There must be relative motion between the two surfaces;

This is because the oil film breaks down when the shaft stops turning.
In practice the film will breakdown before the shaft stops during
rundown.

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There must be a continuous supply of oil to the bearing

surfaces.
One of the surfaces must be inclined at a small angle relative to the
other so that the oil is shaped like a thin wedge, tapering in the
direction of motion. In cylindrical bearings the wedge must be
imagined as being wrapped around part of the shaft.
Figure 4 illustrates how the oil film is developed as the shaft goes
from standstill up to running speed:

FIGURE 4 : JOURNAL BEARING OIL WEDGE FORMATION

Step 1 - When stopped, the shaft rests in the bottom of the bearing;
the mass of the shaft tends to squeeze the oil out of the bearing until
there is little or no oil adhering to the surfaces.
Step 2 - As rotation commences the shaft will tend to climb up the
bearing to a point where it begins to slip. At this stage there is a
sliding of metal on metal and some boundary lubrication from the oil
adhering to the metal.
Step 3 - As the speed of the shaft increases the lubricant is dragged
down until it forms a thin layer under the shaft and film lubrication is

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established. The shaft now assumes a central position but is raised

slightly in the bearing by the oil film.
Step 4 As the speed increases, the bringing oil to the wedge
increase the wedge/ film thickness. When this is completed the shaft
assumes the position illustrated with the ideal wedge-shaped oil film.
The tilting pad bearing is built to allow lubricant to reach the pad
surfaces and is slightly larger than the shaft. The clearance between
the bearing and shaft allows lubricant to circulate around the shaft
between the sliding surfaces. This clearance area varies, depending
on shaft size and speed, bearing load and the type of lubricant used.
Plain journal bearings often have oil grooves or channels cut into
them that help to distribute lubricant evenly over the bearing surface.
Where the load carried by the journal is large, such as in turbines or
large fans, it is possible that the oil film will become broken or
interrupted at low shaft speed or at a standstill. This will result in
metal-to-metal contact that will cause bearing and journal wear.
Where this may occur, the bearing is equipped with a lift or jacking
oil system that is used at low shaft speeds, during machine start up
and rundown. With a jacking oil system, the shaft is hydraulically
lifted by high-pressure oil that is pumped into the area between the
bottom of the journal and the shaft. The pressure and quantity of oil
used is sufficient to raise and support the shaft on an oil film
regardless of if the shaft is at standstill or rotating.

Jacking oil

systems are normally shutdown when the shaft is rotating at a speed

that is sufficient to maintain a stable oil film.
5.1.3 Thrust Bearings
There are many types of thrust bearings, the most common of which is the
tilting pad or Mitchell type bearing. This bearing holds the rotating shaft in
position in the casing and counteracts any axial forces tending to move the
shaft. The basic thrust bearing, illustrated in Figure 5, comprises a shaftmounted thrust collar that is sandwiched between segmented thrust and
surge pads. These pads are supported by a cast collar or housing that is

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filled with oil. Seals are fitted between the shaft and housing to prevent oil
leakage.

FIGURE 5 : BASIC THRUST BEARING

As with the tilting-pad bearings discussed previously, the bearing pads
comprise a gunmetal body that is faced with a white metal bearing surface.
The pads are also pivoted so that they can tilt to create the necessary
lubricating oil wedge.

Surge pads are fitted to absorb any momentary

reversal of thrust (e.g., during start up). The oil wedge also transmits the
axial forces imposed by the shaft journal, via the pads, to the housing. In
most installations the bearing housing is split so that it can be removed and
replaced without removing the shaft.
Tilting Thrust Pad Oil-wedge Formation
As with journal bearings, the tilting action of the pad is essential for the
formation of an oil wedge. As illustrated in Figure 6, the pressure in the
oil film reaches a peak approximately two thirds of the way across the
pad, and it is this pressure that enables the axial thrust forces to be
absorbed. As the pad is of a limited size, oil leaks from all the edges as

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illustrated. The effect of this is that the pressure distribution across the
pad varies from a maximum at the centre of the pad to a minimum at the
outside edge.

FIGURE 6: OIL WEDGE FORMATION

Oil Cooling
Because the bearing housing is flooded with oil there is considerable
churning and heat is generated. This effect may be reduced by baffles
inside the housing or by using an external oil cooler. With large Mitchell
bearings the thrust pads are fitted on a flat vertical plane so that they
take the thrust load equally. The pads are each supported by pistons
connected to a closed hydraulic system.
5.1.4 Tapered-land Bearing
The tapered land thrust bearing has two solid bearing elements that are
fitted either side of the shaft thrust collar. The bearing element surface is
segmented by radial grooves that are machined to create tapered lands.

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These lands promote oil wedge formation between the surfaces to provide
lubrication and thrust transmission to the stationary housing.
5.1.5 Bearing Lubrication
The choice of oil characteristics for the fluid film type bearings has to take
account of the operating conditions. Key among these is the oil viscosity at
start and normal operating temperatures.
Oil with a low viscosity would be squeezed out between the surfaces by the
load, causing the film to rupture and result in metal-to-metal contact. Oil
with an excessively high viscosity would cause additional fluid frictional
losses and consequent heating of the oil and bearing. Similarly the ability
of the oil to wet the surfaces is important so that there is always a thin film
of oil, even at standstill.
In practice a compromise is made; the viscosity must be high enough to
maintain the oil film, with a margin of safety, even at the highest working
temperature, but must not be so high as to overheat the bearing. In many
forced lubrication installations the oil in the tank is maintained above a set
temperature to ensure that the viscosity remains above an acceptable level
so that it flows and forms a wedge easily.
5.2

Rolling Contact Bearings

Rolling contact bearings are primarily designed to support and locate rotating
shafts or parts so that load can be transferred from the rotating to the stationary
members. They also are required to allow free rotation with the minimum of
friction. This type of bearing comprises several rolling elements (Figure 7) that
are held between an inner and outer ring. The rolling elements are either balls or
rollers (cylindrical, tapered or spherical). The essential differences of application
between ball bearings, roller bearings and needle bearings are:

Ball bearings : low load carrying capacity; higher speeds

Roller bearings: higher load carrying capacity, lower speeds

Needle bearings: low load carrying capacity, moderate speeds, high

accuracy

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FIGURE 7 : BEARING ROLLING ELEMENTS

FIGURE 8 : BALL AND ROLLER BEARINGS

Both types of rolling element are normally held in position, between the bearing
rings, by a cage or retainer. The cage also damps any vibrations of the rolling
elements.

Rolling bearings offer less friction compared to plain bearings,

especially on starting (Figure 8).

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Bearing friction is minimised by using as many rolling elements as is practical to

support the load. Lubrication is also used to reduce friction further by introducing
lubricant to the contact zones between the rolling elements, rings and cage.
Lubrication also:
Protects the bearing surfaces from dust, water and foreign matter
Protects the surfaces from corrosion
Absorbs and dissipates heat caused by friction between the contact surfaces.
5.2.1 Ball Bearings
Ball bearings work on a point contact so they are suited for high speed and
light loads applications; they are also less expensive than roller bearings. A
ball bearing assembly comprises of a number of steel balls that turn within
two rings or races (Figure 9).
The inner race has a groove on its outside surface in which the balls roll.
There is usually a similar groove on the inside surface of the outer race.
The balls are enclosed by a cage or retainer. The cage separates the balls
and prevents them from being forced out of the bearing. The balls must be
separated because friction would increase greatly if they came in contact
with each other while rolling.
Bearing lubrication is essential and seals may be used to retain lubricant
and prevent dirt or moisture entering the bearing races (Figure 10).

FIGURE 9 : BEARING AND CAGE

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FIGURE 10 : BEARING SEALS

Non-rubbing gap and labyrinth seals use lubricant (oil/ grease) to seal or
flush the gap between the bearing outer and inner rings. Rubbing felt,
radial or V-ring seals close the contact points between the moving parts.
There are several variations of the basic ball bearing design that are
intended for different applications. The most common types are:
Radial Ball Bearings
-

Deep Groove

Single and Double Row Angular Contact

Four point

Self-Aligning

Thrust Ball Bearings

-

Straight Thrust

Angular Contact

Radial Roller Bearings

- Cylindrical Roller
- Needle Roller

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- Tapered Roller
- Barrel Roller
- Spherical Roller
Thrust Roller
- Cylindrical Thrust
- Spherical Thrust
5.2.2 Roller Bearings
Roller bearings are constructed in much the same way as ball bearings.
They comprise a number of rollers that turn between two races or rings.
Roller bearings also have a cage or retainer that keeps the rollers equally
spaced around the bearing. This is to ensure that forces on the bearing are
equally distributed and that the proper shaft position is maintained.
As described previously, roller bearings are classified according to the
shape of the roller. The cheapest and most common is the cylindrical roller;
the races do not need a special shape to match the rollers.
Tapered Roller
The tapered roller bearing has rollers that are smaller at one end than at
the other. This design requires the race surface to be angled for it to
make full contact with the rollers (Figure 11). A tapered roller bearing will
carry some thrust force as well as radial force due to the tapered shape
of the race and cage.
Spherical Roller
Spherical roller bearings have rollers shaped like a barrel that is thick in
the middle and thin at the ends. The outer race is a segment of a
sphere, while the inner race is dished out so that it comes into contact
with the rollers. This construction allows for good force distribution even
when the bearing is slightly misaligned. Full contact can be maintained
even if the inner race is slightly twisted.

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FIGURE 11 : TYPICALTHRUST BEARINGS

5.2.3 Needle Roller Bearings
Again, Needle Roller bearings are constructed in much the same way as
roller bearings. They comprise a number of rollers that turn between two
races or rings (Figure 12). Needle Roller bearings also have a cage or
retainer that keeps the rollers equally spaced around the bearing. This is to
ensure that forces on the bearing are equally distributed and that the proper
shaft position is maintained.
A needle roller is one that has a length several times its diameter and is of
such a small size that roller guidance through rib faces is not achievable.
They therefore have a smaller radial section than conventional ball and
roller bearings thereby offering space saving, initial cost saving and weight
reduction.
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Needle roller bearings are designed only for radial load and can not be
applied for axial loads, consequently they are not used to provide axial
location.
Full complement types are suitable for low speeds whereas caged types
will operate at moderate speeds.
Misalignment of needle roller bearings has a greater effect on needle roller
skewing and bearing life than for conventional roller bearings.

FIGURE 12 : MACHINED TYPE NEEDLE ROLLER BEARING

Needle Roller bearings are lubricated with a newly developed thermosetting
solid-type lubricant. A large amount of lubricating oil and fine particles of
ultra high molecular weight polyolefin resin are solidified by heat treatment
to fill the inner space of the bearing. As the bearing rotates, the lubricating
oil is squeezed out onto the raceway in proper quantity, keeping the
lubrication performance for a long period of time. These bearings are
referred to as Capilube Bearings and are available in all Needle Bearing
series with outer diameter not exceeding 80 mm.

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5.3

Bearing Installation
Bearings are installed in a variety of ways depending on their duty, location within
the machine and any lubrication or cooling requirements. Typically, where a shaft
is to be supported, the outer bearing race is located within a bore in the machine
casing or held in a pedestal housing (Figure 13). The shaft passes through the
bearings inner race and may be a sliding or interference fit.

If a shaft is

supported by two in-line bearings, such as a fan shaft, the shaft is only fixed
(located) to one bearing leaving the other floating. This is done to accommodate
thermal expansion of the shaft. In many machines the fixed bearing is at the
drive-end of the shaft (Figure 13 a).

FIGURE 13a : SHAFT / BEARING ARRANGEMENT

5.4

Bearing Lubrication
The bearing may be oil or grease lubricated. Pedestal bearing housings lend
them to oil filling, oil circulation (external cooling) or grease packing.
5.4.1 Greasing
Greased packed housings normally have a grease nipple and a grease
vent hole. Grease is then expelled from the vent during greasing. Where
the bearings are exposed to moisture, dirt or dust (e.g., conveyor tail shaft)
the housing/ shaft seal is arranged so that grease is expelled via the seal
such that greasing flushes the bearing housing.

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FIGURE 13 : PEDESTAL BEARING (Fixed Type)

5.4.2 Oil Filling
Oil filled housings are normally equipped with a sight level glass that shows
the level of oil in the housing (Figure 14). Oil filling and drain plugs may be
incorporated with the level indicator located on the housing.

FIGURE 14 : TYPICAL BEARING OIL LEVEL SIGHT GLASS

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6.

TYPICAL APPLICATION OF BEARINGS

Bearings have to be carefully selected for different applications.

As mentioned in

paragraph 1 the type of bearings selected for a particular application will mainly depend
on the following:
Forces (Dynamic, Static, Axial, and radial loading) acting on the bearing
Speed at which the shaft is revolving
Operating environment
Frictional forces involved
The following are typical examples of machines on which the various types of bearings
are used:
6.1

Journal bearings
Horizontally split journal bearings are widely used on machines which operate
under heavy loads such as Turbines, Induced Draught fans.

On Circulating

Water (CW) pumps where the bearings are mounted vertically, it is usually
combined with a thrust bearing to accommodate the vertical thrust exerted by the
weight of the shaft.
6.2

Thrust Bearings
During normal operation, Steam Turbine shafts are subjected to continuous axial
thrust due to the effect of the high pressure steam on the turbine blades. This
thrust must be limited to prevent contact between the moving Turbine blades and
the stationary diaphragms.

FIGURE 14a : POSITION OF THRUST BEARING ON A TYPICAL

TURBINE
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All modern Turbines are therefore designed with their blading arranged in such a
way to largely counter-act the thrust (Figure 14a). This is however not sufficient
and it is thus also necessary to fit a thrust bearings to reduce axial movement to
an absolute minimum.
6.3

Rolling Contact bearings

Rolling contact bearings are suited for operation on machines where dust and
sludge is handled. The reason for this is that these bearings are pre-lubricated
and sealed.
Typical applications are:
Gearboxes
Slurry pumps
Electric motors
Conveyor idlers

7.

CARE OF BEARINGS
There are very few machines on a power plant that do not have bearings in one form or
another. The failure of only one bearing can cause extensive damage and put a
complete generating unit out of service for several weeks.

Depending on the

circumstances this can cost the station millions of Rand for repair and loss revenue.
Bearing failure can often be prevented by ensuring that proper checks, inspections and
maintenance is done before a plant is started and while it is in operation. Depending
on the system typical running checks that MUST be done at least once a shift are:
Check the bearing oil pressures (pressure oil system). Any observed pressure that
is outside the specified limits must be reported immediately. A high pressure is also
cause for concern as it may be the result of a blocked filter or oil way.
Check bearing temperatures; they should be within the specified limits; particularly
below the maximum specified. Bearing temperature will rise quickly after the plant
has been started, and then reach its steady normal running value.

Where the

temperature continues to rise rapidly, report it immediately and have the plant shut
down.

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Check that the oil levels, both 'standing' and 'running' (where this is indicated) are
correct. The level may be visible on a dipstick, or in sight-glass type level gauge. It
must be remembered that an excessively oil level may overheat the machine and
bearing and will slow down or stop an oil ring lubricator.
Check for abnormal oil level rise or fall particularly where oil-cooling systems are
used. A rise in level could be caused by cooling water entering the system or
reservoir. Such water will cause the oil to emulsify (creamy appearance) and reduce
its lubricating properties. A fall in level may indicate oil entering the cooling water
With oil ring lubricated bearings, check the ring to see that it is in its correct position
and free to move or turn. When the plant is running, the ring must turn with the
shaft. If the ring has stopped turning contact your supervisor or the Maintenance
department. DO NOT attempt to get it moving using metal rods or fingers.
Oil flow must also be monitored on a continuous basis. If the oil flow to a bearing is
insufficient, make sure that the in line filters and strainers are clean. Where duplex
strainers are provided, change them over and defect the clogged strainer end follow
up to ensure that it gets cleaned as soon as possible.
Always be on the look out for emulsified oil. Emulsification will cause the oil to
become a milky white colour and foaming will occur. This usually occurs when
water is leaking into the oil in oil coolers. Inspect oil coolers for leaks.
Keep level gauge glass and breather clean. See that the small hole on the level
gauge glass is not blocked as it may give a false high oil level indication.
Check for and report any oil leaks immediately. If necessary, maintain the oil level
(top up) until the plant can be shut down. If the oil leak is severe shut down the
equipment immediately.
Check automatic bearing lubricating devices for correct operation; see that the
discharge rate of lubricant is adequate.

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DO NOT over grease bearings; too much grease will increase fluid friction and
generate excessive heat causing bearing overheating and subsequent failure.
Check that oil filler caps are fitted and secure, this is essential to prevent dirt
entering.
The Four Rs (Always keep them in mind!)
Always exercise caution when oiling a bearing. Always use the Right amount of the
Right oil in the Right place at the Right time.
8.

POTENTIAL OUT-OF-NORMAL BEARING CONDITIONS

During plant inspections it is possible to detect possible faults and other abnormal
operating conditions on bearings. This can be achieved by using out natural senses of
smelling, hearing, feeling and seeing.

The following abnormal conditions can be

observed in these ways:

8.1

Noise
Damage to bearings normally manifests in a humming noise. Thus, by simply
listening to the sound of a running bearing, its physical condition can be
diagnosed. Should any abnormal sound be emitted from the bearing housing the
following must be checked:
Sufficient lubricating oil available
If it is ring lubricated, check that the ring is rotating
If the lubrication is in order, the bearing must be reported as defective without
delay.

8.2

Heat
A damaged bearing will run hot. By simply placing the palm of your hand on the
bearing housing can tell whether it is running abnormally hot. If the temperature
is such that a burning sensation is experienced within 4 to 5 seconds, it can be
accepted that it is running hot. Once again, the lubrication of the bearing can be
checked for satisfactory operation. If the lubrication is in order, and the bearing is
still running hot, report it immediately.

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NOTE:

Special care must be taken not to sustain burns when inspecting

bearings that are suspected of running hot.

8.3

Vibration
Although varying levels of slight vibration is very difficult to recognise it is a skill
that can be practiced and developed. Simply by placing a hand on the bearing
housing which is vibrating, a continuous shivering feeling will be felt. To develop
this skill, it is good practice to compare different bearings on the same machine.
Should any bearing be diagnosed as vibrating excessively, it must be reported
immediately.

8.4

Leaks
Lubricating oil leaks on bearings is not only a threat to the reliable operation of
the machine but it is also a safety threat and fire hazard. Leaking bearings must
be reported and repaired immediately. The oil that has leaked out of the bearing
must be cleaned immediately.
The bearing lubrication must be checked and maintained at its normal working
level until the machine can be taken off load for repairs.

9.

BEARING PROTECTION SYSTEMS

To ensure continuous and reliable operation of bearings, they are in many cases
equipped with condition monitoring and protection devices. These devices include the
following:
9.1

Bearing vibration monitoring and protection

Bearing vibration pick-ups are installed on large machine bearings such as those
on Steam Turbines which are rotating at high speeds. The reason for providing
protection against vibration is that it could result in disaster if it is not noticed and
the necessary corrective actions taken in time. Severe vibrations may result in
serious damage to bearings, machine foundations and in the case of precision
machines such as steam turbines, cause internal rotating components to rub
against each other.

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Bearing vibrations are measured in Micro-Siemens (s).

In many cases,

recording instruments are provided in the control room where the vibrations of
each bearing on the machine are continuously recorded.

Any abnormal

increases are thus immediately visible.

For large turbines the normal vibration level for any bearing is typically in the
region of 0, 02 to 0, 04s. Should the vibration severity increase and reach a
typical value of 0.1 to 0, 12s an audible and visual alarm will be raised to warn
the operator about deteriorating conditions. Should the vibration levels increase
in excess of 0, 15 to 0, 2s an automatic tripping device will trip the machine to
avoid any further damage to the bearings, machine or other components.
Normally, a simultaneous rise in bearing metal temperature and lubricating oil
return flow together with abnormal bearing vibrations is a sure indication that
bearing damage has occurred.
9.2

Metal temperature monitoring and protection

Metal temperature monitoring and protection devices are also provided for each
bearing on large machines. The purpose of these instruments is to monitor the
operational condition of each bearing individually. Higher than normal bearing
metal temperatures is a sure indication that the bearing is not in a healthy state.
In cases where a bearing is damaged to such a degree that the metal
temperatures are increasing to values above its normal operating temperature,
the rate of deterioration usually becomes worse. For this reason, tripping devices
are also normally provided to trip the machine if the bearing metal temperatures
reach temperatures of typically 80C to 85C.
Monitoring of bearing metal temperatures is accomplished by thermocouples
which are fitted to the bearing housing. The electrodes of the thermocouple are
usually positioned as close as possible to the inner core of the bearing housing to
minimise the delay of heat conduction through the bearing metals.

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9.3

Lubricating oil pressure monitoring and protection

The single most important factor upon which efficient bearing operation is
dependant is adequate lubricating oil supply. The only reliable assurance that a
bearing is adequately lubricated is indicated by the lubricating oil pressure and
associated bearing oil flow.
To accomplish this, oil pressure measuring devices and local pressure gauges
are provided to enable the operator to monitor lubrication parameters.
A pressure measuring device comprises of tapping points and impulse lines on
the lubricating oil supply line to the bearing. The impulse lines are connected to a
pressure transmitter which transmits an electronic pressure signal to the remote
control panel.
The value of the lubricating oil supply pressure differs from application to
application.

9.4

Lubricating oil flow measuring devices

The most common method to measure lubricating oil flow is with a differential
flow meter. This technique requires the oil pressure to be measured on both
sides of an imposed restriction (orifice plate) in the path of normal flow. The flow
rate is then calculated based on the change in pressure across the restriction.
A pressure transmitter is used to transmit the differential pressure signal to
electronic devices where the signal is processed to provide a signal
corresponding to the actual pressure in the lubricating oil supply pipe.

ESKOM 2004

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10.

SELF ASSESSMENT
After having studied all the material, you can now request the Self Assessment from
your Facilitator. Make sure that you have mastered all the information contained in this
manual and attempt not to look for the correct answers in the text.
If you do not master the Self Assessment at the first attempt, re-study the material,
make notes of the topics that are not absolutely clear to you and approach your
Facilitator to explain these issues again.
When you feel confident that you have mastered this manual, you can then request to
write the Criterion Test.
GOOD LUCK!

ESKOM 2004