ROTATING EQUIPMENT

ROTATING EQUIPMENT

• ~ moving part.
• Design and specification (head, types of fluid, capacity).
• Operating condition (pressure, noise, vibration, lubrication, mechanical seal, belting,
roller, alignment, cooling system).
• Efficiency of the equipment.
ELECTRIC MOTOR

• The principle function of an electric motor is to convert electric energy into mechanical
energy. The conversion is accomplished by two main component- the stator and rotor.
• Regardless of the type and application of an electric motor, all motors will be made up of
these two main components.
• The stator is the stationary component and the rotor is the rotating component.
• These components are separated by a small air-gap clearance to avoid mechanical
rubbing.
MAIN COMPONENTS

• The stator is generally made up of a winding, the frame, and the laminated steel punching
(core iron).

• The stator coils can be random wound (loops of wire) or form wound (pre-formed diamond
shape) coils of magnet wire.

• The rotor is usually made up of laminated steel punching (core iron), coils or rotor bars,
shorting rings and a shaft.
MAIN CATEGORIES

• AC Induction Motors: Squirrel-cage,

Wound rotor
• Synchronous Motors: Cylindrical rotor
or Salient pole
• DC Motors: Shunt wound, Series
wound, or Compound wound
APPLICATION
Institute of Electrical and Electronics Engineers
Electric Power Research Institute
CAUSES OF FAILURE
• Most conditions that cause electric motor failure will be cleared in
the form of vibration or excessive temperature.
• Vibration can be caused by conditions which are electrical as well as
mechanical.
• When an open bar develops in the rotor winding or a short happens
in the stator winding, the effect on motor operation may show up as
a slightly higher vibration reading.
• More often than not, the cause of vibration can be contributed to
misalignment or bearing wear/defect.
• Some times motors can be damaged in handling or have a
manufacturing defect which will appear as a vibration problem over a
period of time because of residual stress.
CAUSES OF FAILURE

• Major components - likely components of a motor to experience failure

• Symptoms - conditions that can be observed by inspections/tests
• Failure causes - most likely failure causes for the observed symptoms
• Failure mode - most likely failure mechanisms resulting from one or more of the failure
causes
SYMPTOMS/ CONDITIONS

• Overheated – the temperature increase over

normal or exceed the limit
• High vibration – abnormal condition due
to vibration
Causes of Failure

• Major components - likely components of a motor to experience failure

• Symptoms - conditions that can be observed by inspections/tests
• Failure causes - most likely failure causes for the observed symptoms
• Failure mode - most likely failure mechanisms resulting from one or more
of the failure causes
Failure causes
• Corrosion
• Excessive moisture
• High ambient temperature
• Inadequate lubricant
• Manufacturing defect
• Misalignment
Causes of Failure

• Major components - likely components of a motor to experience failure

• Symptoms - conditions that can be observed by inspections/tests
• Failure causes - most likely failure causes for the observed symptoms
• Failure mode - most likely failure mechanisms resulting from one or more
of the failure causes
Failure mode/ results
• Broken rotor bars
• Broken shaft/ parts
• Damage to bearing
• Reduce components life
Preventive Maintenance
• Scheduled routine inspection
• Document maintenance program
• Grease-Lubricated bearing only when scheduled
• Oil-Lubricated bearing every 2000 hours operation or at least
annually.
Predictive Maintenance
• Scheduled monitoring of vibration, temperatures, and/or oil
contamination (wear particles), with trend analysis to the potential
problems.
• The goal of predictive maintenance is to extended the life of
machinery by eliminating failures.
Benefit of predictive maintenance
• Repetitive problems are identified and eliminated
• Equipment installations is performed to precise standard
• Performance verification assures that new and rebuilt equipment is free
of defects.
Predictive Technologies
• Vibration spectrum analysis for rotating equipment
• Oil and wear analysis
• Thermography for all electrical equipment
Mobile Device detects vibration, temperature, and
balancing.
COUPLING
MAINTENANCE OF COUPLING
 Flexible Couplings for Power Transmission
• A flexible coupling is a mechanical device used to connect two
axially oriented shafts.
• Its purpose is to transmit torque or rotary motion without slip
• There are many supplementary functions, which include
providing for or restricting axial movement of the connected
shafts; minimizing or eliminating the conduction of heat,
electricity, or sound; torsional dampening; and torsional tuning
of a system.
• Basically, all flexible couplings can be categorized as either
mechanical flexing or material flexing.
Types of shaft coupling

• Rigid coupling
• Rigid couplings are used when precise shaft alignment is required; shaft
misalignment will affect the coupling's performance as well as its life.
Example
• Flange coupling
Types of shaft coupling

• Flexible coupling
• Flexible couplings are designed to transmit torque while permitting some radial and
axial and angular misalignment. Flexible couplings can accommodate angular
misalignment up to a few degrees and some parallel misalignment.
Flexible coupling

• Chain coupling
• compact units capable of transmitting proportionately
high torques at low speeds.
Flexible coupling

• Gear coupling
• They are capable of transmitting proportionately high torques at either
low or high speeds.
Flexible coupling

• Jaw coupling
• Compact units normally relegated to light or medium duty and moderate
speeds
Flexible coupling

• Elastomeric coupling
• These couplings are generally relegated to light- or
medium-duty service at moderate speeds.
Causes of coupling failure
• Most failures due to internal faults are the result of improper or poor machining.
• Defective materials and materials with inadequate strength and/or hardness.
• Improper product design-lack of a lubricating film
• Most common causes of failure due to external conditions have to do with improper
selection, improper assembly, and excessive misalignment.
Causes of coupling failure
• Coupling Selection
• Maintenance personnel are frequently faced with the problem of replacing a worn-out
or broken coupling.
• After the cause of failure has been determined, careful consideration should be given
to the type, size, and style of coupling that will be used as a replacement.
• Whenever possible, it should satisfy all the needs of the drive.
• Proper selection as to the type of coupling is the first step of good maintenance.
• A well-chosen coupling will operate with low cross-loading of the connected shafts,
have low power absorption, induce no harmful vibrations or resonances into the
system, and have negligible maintenance costs.
Causes of coupling failure
The primary considerations in selecting the correct type of flexible couplings, as
well as its size and style, are

• Type of driving and driven equipment

• Torsional characteristics
• Minimum and maximum torque
• Normal and maximum rotating speeds
• Shaft sizes
• Distance between shaft ends
• Changes in distance due to thermal growth, racking of the bases, or axial
movement of the connected
• shafts during operation
• Equipment position (horizontal, inclined, or vertical)
• Ambient conditions (dry, wet, corrosion, dust, or grit)
• Bearing locations
• Cost (initial coupling price, installation, maintenance, and replacement).
Alignment
• Remember that misalignment is the major cause of
coupling problems.
• Changes from the initial condition can occur through pipe
strain, bearing wear, settling of foundations, base
distortion due to torque, thermal changes, and vibrations
in the connected equipment.
• There are three conditions of misalignment that a flexible
coupling must accommodate.
• Angular misalignment, parallel misalignment, and axial
misalignment (end float).
3 conditions of misalignment
Shaft misalignment
Shaft misalignment (Dial indicator)
Shaft misalignment
Shaft misalignment (Laser)
General Periodic Inspections
• To maintain coupling reliability, mechanical-flexing couplings require
periodic inspections on a time- or condition-based frequency established
by the history of the equipment’s coupling life or a schedule established by
the predictive maintenance engineer.
General Periodic Inspections
• Inspect all components for cracks, breaks, and physical damage.
• Inspect lubricant for traces of metal
• Visually inspect coupling mechanical components for wear.
• Setscrews and retainers must be in place and tightened to manufacturer’s
specifications.
• Under operating conditions, perform thermographic scans to determine
temperature differences on the coupling
Mobile Device detects vibration, temperature, and
balancing.
PUMP &
COMPRESSORS
A gas compressor and pump is a mechanical device that increases the
pressure of a gas by reducing its volume.

Compressors are similar to pumps: both increase the pressure on a

fluid and both can transport the fluid through a pipe. As gases are
compressible, the compressor also reduces the volume of a gas.

Liquids are relatively incompressible, so the main action of a pump is

to pressurize and transport liquids.
Pump
• Used to transfer liquid form one location to another.
• Centrifugal pumps basically consist of a stationary pump casing and an impeller mounted on a rotating
shaft.
• The pump casing provides a pressure boundary for the pump and contains channels to properly direct
the suction and discharge flow.
• The pump casing has suction and discharge penetrations for the main flow path of the pump and
normally has a small drain and vent fittings to remove gases trapped in the pump casing or to drain the
pump casing for maintenance.
Centrifugal Pumps
Pump Checklist
Compressors
• It runs tools and machinery, provides power for material handling systems, and
ensures clean, breathable air in contaminated environments.
• A plant’s expense for its compressed air is often thought of only in terms of the cost of
the equipment.
• Energy costs, however, represent as much as 70% of the total expense in producing
compressed air.
Centrifugal Type
Common Failure Modes of Centrifugal Compressors
• Excessive vibration
• Dry gear coupling
• Excessive bearing clearance
• Improperly assemble parts
• Loose or broken bolting
• Operating in critical speed range
• Shaft misalignment
• Worn or damaged coupling
Reciprocating Type
• A reciprocating compressor or piston compressor is a positive-
displacement compressor that uses pistons driven by a crankshaft
to deliver gases at high pressure.

• The intake gas enters the suction manifold, then flows into the
compression cylinder where it gets compressed by a piston driven
in a reciprocating motion via a crankshaft, and is then discharged.
We can categorize reciprocating compressors into many types and
for many applications. Primarily, it is used in a great many
industries, including oil refineries, gas pipelines, chemical plants,
natural gas processing plants and refrigeration plants.
Common Failure Modes of Reciprocating Type
• Lubrication System
• Poor maintenance of lubrication-system components, such as filters and
strainers, typically causes premature failure. Such maintenance is crucial
to reciprocating compressors because they rely on the lubrication
system to provide a uniform oil film between closely fitting parts
(e.g., piston rings and the cylinder wall). Partial or complete failure of the
lube system results in catastrophic failure of the compressor.
• Pulsation
• Reciprocating compressors generate pulses of compressed air or gas that
are discharged into the piping that transports the air or gas to its point(s)
of use. This pulsation often generates resonance in the piping system
and pulse impact (i.e. standing waves) can severely damage other
machinery connected to the compressed-air system.
• Imbalance
• Compressor inertial forces may have two effects on the operating
dynamics of a reciprocating compressor, affecting its balance
characteristics. The first is a force in the direction of the piston movement,
which is displayed as impacts in a vibration profile as the piston reaches
top and bottom dead center of its stroke. The second effect is a couple, or
moment, caused by an offset between the axes of two or more pistons on a
common crankshaft.
Common Failure Modes of Reciprocating Compressors

• Valves
• Valve failure is the dominant failure mode for reciprocating compressors. Because
of their high cyclic rate, which exceeds 80 million cycles per year, inlet and discharge
valves tend to work harden and crack.
ROUTINE MAINTENANCE
• LUBRICATION
• The most important check for any compressor is the lubrication system
• Keep the compressor well lubricated; check the oil level at least once
every 8 hr of operation.
• Use only oil and greases as recommended by the compressor
manufacturer.
• VALVES
• Reciprocating compressor valves must be kept in first-class operating condition,
as leaking or broken valves cause excessive operating temperatures and loss of air
delivered.
• PISTON RINGS
• Piston-ring wear usually is very slow when the rings are properly lubricated, but
operating time will eventually wear
• BEARINGS
• Check bearings for heat and noise after starting
• CLEANING
• An important item for proper compressor maintenance is keeping
the compressor clean on the outside surfaces.
• Dirt and oil will make an insulation which obstruct heat dissipation
to atmosphere.
Compressor Checklist
Turbine
• Equipment that used to move other equipment such as blower, pump,
compressors.
• Divided: steam and gas turbine.
Turbine Maintenance
• Scheduled maintenance inspections are necessary for safe and efficient turbine
operation.
• Actual intervals between inspections cannot be specified rigorously because
maintenance scheduling is dependent on factors best known by those directly involved
with the turbine and its particular application.
• The actual frequency of required maintenance inspections can only be determined
after carefully considering turbine performance records, maintenance history,
corrosion, erosion rates, tests, observations and anticipated service demands.
• The established inspection schedule will usually be consistent with the availability of
the turbine, necessary manpower and an adequate supply of repair parts.
• At the same time, scheduled inspections must be frequent enough to avoid unsafe
operating conditions.
BEARING
• Bearing is defined by Webster’s to be “a support or supporting part”
• – In machine design, a bearing is a component that allows for relative motion between two bodies
• Bearings are for:
-reduce friction
-carry load
-guide of moving parts
 APPLICATIONS

Motor vehicles
Electric motor
 General Engineering (e.g. centrifugal pump)
Machine tool
BEARING COMPONENT

Rolling elements
Inner ring

Seal Cage
Outer Ring
BEARING TYPES

• Sliding Bearings (Journal Bearing)

• Rolling Element Bearings
• Ball bearings
• Roller bearings
• Needle Bearings
INSPECTION OF BEARINGS

Inspection of a machine’s bearings during operation is important to prevent unnecessary

bearing failure. The following methods are generally adopted to inspect the bearing:
• Check of bearings in operation
• Included are the check of bearing temperature, noise, and vibration, and the examination of the
properties of lubricant to determine when lubricant should be replenished or exchanged.
• Inspection of bearings after operation
BEARING FAILURES

• Flaking
• Condition
• Very rough surface
• Cause
• Excessive load
BEARING FAILURES

• Stepped wear
• Condition
– Surface is worn
– Dimensions are reduced
• Cause
– Poor lubrication
– Dirt and other foreign object in lubricant
BEARING FAILURES

• Chipping
• Condition
• Partial chipping of inner ring, outer ring or rolling element
• Cause
• Trapping of large solid foreign objects
• Impact or excessive load
BEARING FAILURES

• Rust and Corrosion

• Condition
• Rusting or corrosion of bearing ring and rolling element surfaces
• Cause
• Ingress of water or corrosive material
• Condensation of moisture contained in the air.
• Poor packaging and storing conditions.
PREVENTIVE MAINTENANCE

• Lubrication Supply
Proper bearing design and material are necessary to achieve long service life but are not by
themselves sufficient. The lubricant is the key component of the system which determines
bearing life.
• Cleanliness
Sleeve bearings simply cannot survive without adequate lubrication. Once this is assured, the
next most important consideration is the cleanliness of the lubricant. Since minimum film
thickness is so small, the presence of oil-borne debris can greatly accelerate the wear process.
If foreign materials such as metal chips and abrasives are large and numerous, bearing failure
can occur rapidly.
The most common lubricants have
traditionally been grease and oil.
PREDICTIVE MAINTENANCE

This is the fan inboard bearing starting to show some heat. This could be a dry
bearing or it could be that the belts are too tight pulling the shaft therefore placing
stress on the bearing.

We checked this bearing with ULTRASOUND and it was found to be a dry bearing. We
greased it just enough to make it quiet and it cooled right down
Mobile Device detects vibration,
temperature, and balancing.