AA 0850126

CORPORATE STANDARD Rev No. 02

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NDT AND ACCEPTANCE STANDARD FOR WHITE METAL LINED BEARINGS

1.0 SCOPE :

This standard details the non-destructive tests and acceptance standard for white lined
Brass/Gun metal/Steel Journal bearing and thrust pads, guide pads used for Steam Turbines/
Turbo-Generators/ Hydro Turbines / Compressor Pumps and Suspension Bearing for
Traction Motors.
The quality of the bond is expressed in percentage of good bond area in terms of total bearing
area.

2.0 PERSONNEL REQUIREMENT :

Personnel performing non-destructive examination and evaluation shall be qualified to the

recommended practice SNT-TC-1A or any other recognized practice.

3.0 SURFACE PREPARATION :

The test area must be free of grease and other contaminants which impair the test. The
transducer / bearing surface for ultrasonic testing shall not have any unevenness and
gouges which impair the validity of the test.

4.0 VISUAL EXAMINATION :

4.1 On completion of finish machining, all bearings shall be subjected to a close visual
examination as detailed below and to the acceptance standards defined in Clause 4.2.
It shall take place under good lightning conditions and where necessary with a magnifying
glass. The white metal surface shall be examined for the presence of casting defects such as
inclusions, laps and porosity.

Where necessary to differentiate between real defects and superficial cavities formed by the
tearing out of tin-antimony cuboids during machining, the examination may be
supplemented with a liquid penetrant test (refer clause 5.0). Particular attention shall be given
to areas where ultrasonic testing has indicated the presence of sub-surface porosity.

A visible pore or inclusion in excess of 0 5 mm maximum site, if observed, at any location,

is liable for rejection.

All bearing which pass the Visual Examination shall be subjected to liquid penetrant
examination as detailed in Cl 5.0.
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4.2 Acceptance Standard :

Journal Bearing, Combined Journal & Thrust Bearing, Thrust pads and Guide Pads shall not
be accepted if:

i) There is any visible pore or inclusion in excess of 1 mm at any location.

ii) There are visible pores or inclusion in excess of 5 in number, in any area of 650 sq. mm.
or
iii) There is a total of visible pores or inclusions in excess of 8 for bearings up to 125 mm
diameter, 10 for bearing than 125 mm and up to 250 mm diameter, 20 for bearing greater than
250 mm and up to 510 diameters and 40 for bearings of larger diameter.
or
iv) In the thrust region, if there is any visible pores or inclusions in excess of one per 1300 sq. mm

Note : The above criteria shall not apply to superficial cavities formed by the tearing out of
tin- antimony cuboids during machining.

5.0 DYE PENETRANT EXAMINATION :

5.1 Procedure :

The procedure and interpretation of indications of dye penetrant examination shall be as

per corporate standard AA0850131.

5.2 Acceptance Standard :

5.2.1 Journal Bearing, Combined Journal & Thrust Bearing, Thrust pads and Guide Pads shall
not be accepted if :

(i) Cracks in the surface area of the bearing are not permissible. Any linear indication at any
location of bearing including edges is not acceptable.

(ii) Any isolated indication less than 1.5 mm shall be discarded when present on the sliding
surface. Such indications at the edges may be discarded only if they are not aligned and
close to each other (Separated by not more than 3 times the size of the larger indication).

(iii) If the flaws are in the form of a cluster comprising of 3 or more rounded indications
(when the distance between any two of three pin holes is less than 25 mm, it shall be
considered a cluster), shall not be acceptable.
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5.2.2 A two – lobe journal bearing shall be deemed unacceptable if :

a) any indication is found in the “ Defect Free Zone ” of the lower half of the bearing as
shown in Fig. 1.

Fig. 1 : Bearing Shell Lower Half

b) The number of individual rounded indication in place other than the ‘Defect free zone’
exceeds the following limits.

Bearing Diameter (mm)

Defect Position Upto 125 Over 125 Upto 254 Over 254 Upto 400
Max. No. of Bottom half 2 4 6
individual Top half 4 6 11
indications
Max. size indications (mm) 3.0 4.5 5.0

6.0 REPAIR :

6.1 Depending on the nature of defect, a decision has to be taken by Engineering / Quality
Control as to whether the bearing is to be repaired by local babbitting or the bearing is to be
rebabbited.

6.2 After repair / rebabbiting, the bearing shall be subjected visual and Dye penetrant
examination as above and the bearings passed in visual and DP examination shall be
subjected to ultrasonic examination to assess bondness of the Babbitt as detailed below :
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CORPORATE STANDARD Rev No. 02
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7.0 ULTRASONIC TESTING :

7.1 EQUIPMENTS:

7.1.1 Flaw Detector:

The equipment used for detection shall be of pulse echo type capable of generating
frequencies over the range of at least 1 MHZ to 5 MHZ. The ultrasonic flaw defector shall be
capable of resolving multiple reflections from white metal piece of the same thickness as that
of lining of bearing under test.

7.1.2 Probe:

6-15 mm diameter, 2-4 MHz single or double crystal longitudinal wave probe shall be used.
The selection of the probe will be made according to the diameter of the bearing to achieve
proper contact.

7.1.3 Couplant:

Any suitable couplant such as oil, grease, Polycell or water may be used. The couplant
including additives shall not be detrimental to the material being examined. The couplant
used for testing shall be the same as used for calibration.

7.1.4 Test Block:

A stepped test block of the same composition of white metal shall be used for calibration.
Block containing eight steps of 1,2,3,4,5,7,9 and 12 mm thickness and a minimum of 25 mm
square area is recommended for test block.

7.1.5 Surface Finish:

The testing of the bearing may be done before or after machining, depending upon the surface
finish. If the bearing is to be tested before machining, the surface irregularities such as sharp
projections and depressions shall be removed to give uniformly good ultrasonic coupling.
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7.2 PROCEDURE :

7.2.1 Calibration (Time Base):

The base shall be calibrated using the test block detailed above, to cover at least two back
echoes from the backing member. Markers shall be placed or location of the interface echo
shall be noted.

7.2.2 Calibration (Amplification):

The sensitivity of the equipment shall be adjusted such that the first back wall echo /
reference echo is 80 % full screen height as obtained from the step of the test block
equivalent to the lining thickness.

7.2.3 Frequency Selection:

The criteria for frequency selection shall be the thickness of white metal lining. Thinner the
lining, higher should be the frequency required so that multiple reflections from the lining
can be easily resolved. Generally 4 MHz frequency is preferred.

7.2.4 Interface Echo:

In an area of good bond there will be an interface echo at the junction of white metal and its
backing. The amplitude of this echo depends upon the acoustic mismatch of materials. The
following values of reflectivity can be obtained for materials given below:

(i) White metal / Steel - 28%

(ii) White metal / Cast iron - 14%

(iii) White metal / Brass - 10%

(iv) White metal / Leaded Gunmetal - 25%

7.2.5 Scanning:

After application of the couplant, contact scanning shall be done from white metal surface.
The ultrasonic testing is done on the bearing metal in the test area with an overlap of
About 20% of successive scanning tracks to ensure 100% coverage of the babbited surface.
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7.3 INTERPRETATION:

7.3.1 Good Bond :

When the multiples of first back wall echo/ interface echo obtained is less than that
obtainable as per clause 7.2.4.
In case of babbitting of white metal with steel, the interface echo must be under 28 % FSH
as per clause 7.2.4. (i) to be considered as good bond and the same apply for Clause 7.2.4.
(ii), (iii) and (iv) also.

7.3.2 No bond :

When the multiples of first back wall echo/ interface echo obtained is more than that
obtainable as per clause 7.2.4.
In case of babbitting of white metal with steel, when the interface echo crosses 28 % FSH
as per clause 7.2.4. (i), it will be considered as no bond and the same apply for Clause
7.2.4. (ii), (iii) and (iv) also.

However, if an individual indication exceeds 50% of the reference echo by 5-10% and does
not have any multiple, then this does not have to be recorded as no bond.

7.4 ACCEPTANCE STANDARD :

7.4.1 Thrust, Guide pads & bearing for Hydro Turbines, Generators and Motors :

(i) Bearing with plane bonding surface :

No bond area up to 10% of the total bearing area shall be acceptable, provided the largest
individual defect does not exceed 625 sq. mm and they are separated from each other by 25
mm or a distance equivalent to the larger of the adjacent defects and situated 10 mm away
(minimum) from edge or any opening in the bearing

(ii) Bearing with dovetail bonding surface :

No bond area up to 20% of the total bearing area shall be allowed , provided the largest
individual defect does not exceed 1250 sq. mm and they are separated by a minimum
distance of 25 mm and situated 10 mm away (minimum) from edge or any opening in the
bearings.
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7.4.2 Traction Motor Suspension Bearing :

i) Main Bearing shell :

The limit of acceptance shall be as given in clause 7.4.1 (i).

ii) Flange :

(a) In the dovetail portion of the flange up to 50% no bond is allowed provided there is no
unbound area within 15 mm circumferential length near the horizontal joint and such area are
distributed and the largest individual unbond area does not exceed 50 mm in length.

(b) In the remaining area of the flange, maximum of 20% no bond is allowed provided there is
no unbond within the 25 mm circumferential length near the horizontal joint and the largest
individual unbond area does not exceed 50 mm in length.

7.4.3 Steam Turbine Bearings :

i) This specification applies only to bearing having a generally uniform white metal thickness
not greater than 6 mm bonded to a backing metal with an inter face surface roughness not in
excess of 3.2 pm Ra (125 CLA).

ii) Dense areas of sub-surface porosity which prevent effective ultrasonic testing of the bend
shall be regarded as unbond areas and included with the ultrasonically detected unbond areas
for assessment in accordance with the acceptance criteria.

7.4.3.1 Acceptance Standard :

7.4.3.1.1 Lack of Bond :

The half bearing is unacceptable if :

(i) There is any lack of bond within a radius of 25 mm from the centres of the oil jacking hole
or
(ii) There is any lack of bond within 12 mm from the edges of the white metal on bearings
up to 254 mm diameter or within 25 mm on bearings of larger diameter.
or
(iii) There is any lack of bond within 12 mm from the oil inlets on bearings up to 254 mm
diameter or within 25 mm on bearings of larger diameter.

(iv) There is, in areas not covered by (i) (ii) and (iii) lack of bond in excess of the limits shown
in Table 1.
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7.4.3.1.2 Sub-surface Porosity:

The half bearing is unacceptable if:

(i) There are measurable areas of porosity (i.e. in excess of 40 sq. mm) with/h a radius of
25 mm from the centre of the oil jacking holes.
or
(ii) There are measurable areas of porosity within 12 mm of the edges of the white metal on
bearings up to 254 mm and within 25 mm on bearings of larger diameter.
or
(iii) There are measurable areas of porosity within 12 mm of the oil inlets on bearings up to 254
mm and within 25 mm on bearings of larger diameter.
or
(iv) There are, in areas not covered by (i) (ii) > and (iii) areas of porosity in excess of the limits
shown in Table 1 for total allowable percentage (%) porosity and maximum area of single
defects.

Table 1 (Cl 7.4.3.1.1 (iv) & (Cl 7.4.3.1.2 (iv)

Sl Bearing Diameter (mm)

No. Defect Position
Up to Over 125 Over 254 Over 510
125 Up to 254 Up to 510 up to 760
1. Total allowable lack of bond Bottom half 5 5 10 15
%
Top half 10 10 15 20
2. Total allowable porosity % Top and 20 10 15 20
Bottom half
3. Maximum area of isolated Bottom half 160 320 650 1300
single defect (Bonding or
porosity) sq. mm Top half 160 650 1300 2000

4. Minimum separation between Top and

defects for consideration in Bottom half 6 12 25 25
isolation mm
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7.4.4 Combined Journal & Thrust Bearings :

7.4.4.1 Journal Region :

The acceptance standard shall be as detailed in clause 7.4.3.1.

7.4.4.2 Thrust Region :

7.4.4.2.1 Lack of bond :

The half bearing is unacceptable if :

i) There is any continuous of lack of bond greater 6mm at the inner or outer edges on
bearing up to 180 mm outside diameter and greater than 12 mm on bearings of large
diameter or an aggregate lack of edge bond greater than 10% of the total peripheral length.
or
ii) There is any single area of lack of bond greater 125sq.mm on bearing up to 180 mm
outside diameter of greater than 250 sq. mm on bearing of larger diameter.
or
iii) There is an aggregate lack of bond exceeding 5% of the total thrust area.

7.4.4.2.2 Sub-surface Porosity :

Measurable areas of sub-surface porosity shall be regarded as unbond areas and

included with ultrasonically detected lack of bond for assessment in accordance with the
acceptance standard given above for “Lack of Bond”.

7.4.4.3 Thrust Pads :

7.4.4.3.1 Lack of Bond (Refer Fig. 2) :

The thrust shall not be accepted if :

i) There is any lack of bond which breaks into edges (1).

or
ii) There is any continuous length of lack of bond greater 6mm on edge (2).
or
iii) There is a total of lack of bond on edge (2) exceeding 10 % of the length of edge (2).
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iv) There is any single area of lack of bond greater than 125 sq. mm.

v) The total areas of the lack of bond exceed 5% of the total pad area.

Fig. 2 : Thrust pad - Lack of bond

7.4.4.3.2 Sub-surface porosity :

Measurable area of sub-surface porosity shall be regarded as unbond areas and included
with ultrasonically detected lack of bond for assessment in accordance with the acceptance
criteria of clause 7.4.4.2.1 (Thrust region – lack of bond)

8.0 REPAIR :

Repaired bearing shall be subjected to all requirement of this standard.