Mischievous Magnetism in Rotating Machinery - Paul Nippes (MPS)

Safeguarding Machinery Worldwide
www.gaussbusters.com
Paul I. Nippes, P.E.
Beth Galano
Magnetic Products and Services, Inc.
Holmdel, NJ 07733
Copyright 2005
Mischievous Magnetism
In Rotating Machinery
Stray Magnetism denotes lost or misplaced
magnetism that may, or may not, cause trouble
Mischievous Magnetism (MM) is trouble-causing
Sources, paths and effects consist of:
asymmetry in magnetic patterns of electrical machines
residual magnetism
circular magnetism in ferrite components
Damaging effects to rotating machinery
Electrostatic current effects are not addressed
Paper Content
Magnetism is friendly when usefully-employed for energy
conversion or instrumentation
Mischievous magnetism is destructive, and/or impedes proper
performance of rotating machinery
character and strength of MM can vary considerably
direct measuring of MM is impossible when the machine is operating
Many rotating machinery problems, caused by MM, go un-detected
or un-corrected
This is a four-month bearing
Magnetism may also be blamed for mysterious occurrences
Proving or disproving effects of MM can be very challenging
Mischievous Magnetism (MM)
Sources and Effects of MM
Electromagnetic Sources and their Effects in
Electrical Machines
A1
Uneven Air Gap Axial Voltage Bearing Through-Currents
A2
A3
A4
A5
A6
A7
A8
Shorted Stator Laminations Axial Voltage Bearing Through-Currents
Shorted Rotor Winding Turns Axial Magnetism Homopolar Bearing Currents
Rotor Winding Ground Faults Axial Magnetism Homopolar Bearing Currents
Stator Winding Circuit Imbalance Axial Voltage Bearing Through- Currents
Shorted Stator Winding Turns Axial Voltage Bearing Through Currents
Electrical System Unbalance Axial Voltage Bearing Through Currents
Excitation Power Switching Capacitive Coupled Bearing Through Currents
Cross Reference Codes to Figures Aa and Ab
Figure Aa
Boiler Feed Pump from a large Generator Unit
Boiler Feed Pump from a large Generator Unit
Figure Ab
Example of Through Magnetism generating Eddy Currents
Example of Through Magnetism generating Eddy Currents
currents discharge at outside edges passing through the babbitt
Residual Magnetism in TG Components
B1 Axially Oriented Homopolar Bearing Currents
B2 Radially Oriented Axially at
Bearing
Homopolar Bearing Currents
B3 Circular Encircles the
Shaft centerline
internally
Homopolar Effects
B4 Localized/concentrated
in pole pairs
Random Local Currents in:
Journal Bearing
Journal
Thrust Bearing
Thrust Collar
Casing, frame or housing
Cross Reference Codes to Figure B
Figure B
Electric Current Erosion of Thrust Bearing Pads
from a Natural Gas Compressor
Spark Tracks
on the Active Pad Face
Pad Steel Backing Erosion
on Two Adjacent Pads
special case because it has complete invisibility
accidental direct through-current injection
generator rotor winding fault to ground, passing current axially through the
rotor shaft
intentional direct through-current injection
common practice called head shots - passing direct current axially
through the shaft, inducing circular magnetism adequate for magnetic
particle indication* of surface axial cracks.
*Admittedly, MPI is the most efficient and revealing method
for finding and evaluating such cracks, however magnetism remains,
unless completely removed following testing via Down-Cycle Demagnetizing.
What is Circular Magnetism?
Large Turbine-generator showing Strange Vibration
Indicated Are Responses On One Unit
when Shaft Grounding Brush was Lifted and then Restored
27/05/2005
7:29:09 AM
28/05/2005
7:29:09 AM
27/05/2005
7:29:09 PM
0.000
0.048
0.096
0.144
0.192
0.240
GENBRG6 VIBR(MyInSQL:U1GV005) GENBRG6 VIBR(MyInSQL:U1GV005) Cyclic Cyclic
(28/05/2005 7:06:52 AM) 0.028 mm (28/05/2005 7:06:52 AM) 0.028 mm
0.011 mm (0 days, 15:27:36) 0.011 mm (0 days, 15:27:36) (27/05/2005 3:39:17 PM) 0.039 mm (27/05/2005 3:39:17 PM) 0.039 mm 0.011 mm (0 days, 15:27:36) 0.011 mm (0 days, 15:27:36)
No. Server TagName Minimum Maximum Units Description:
1 MyInSQL U1GV005 0.00000 0.24000 mm GENBRG6 VIBR
3 MyInSQL U1TE003 -35.00000 15.00000 mm LP TURB DIFF EXPN
4 MyInSQL U1DT059 0.000 50.000 C AMBIENT TEMP (BOILERBASEMENT)
5 MyInSQL U1GK002 0.000 100.000 C GENBRG6 DRNOIL TEMP
6 MyInSQL U1TP011 0.000 20.000 kPa CONDABS PRES (MEASURED)
7 MyInSQL U1BT608 100.000 600.000 C RHOUT AVGTEMP
8 MyInSQL U1GC012 -100.000 400.000 MW 1 UNIT MW
9 MyInSQL U1TZ001 2.00000 2.10000 mm TURB ROTORPOSN
10 MyInSQL U1GL609 0.000 140.000 kPa SEAL OIL/H2 DIFFERNTIAL PRES
11 MyInSQL U1TS001 0.000 3500.000 RPM TURB SPEED
12 MyInSQL U1GT006 0.000 100.000 C CH2 CLRH2 INTEMP
Brush
Up Down
27/05/2005
7:33:20 AM
28/05/2005
7:33:20 AM
27/05/2005
7:33:20 PM
0.000
0.060
0.120
0.180
0.240
0.300
GENBRG5 VIBR(MyInSQL:U1GV004) GENBRG5 VIBR(MyInSQL:U1GV004) Cyclic Cyclic
(27/05/2005 8:40:10 AM) 0.082 mm (27/05/2005 8:40:10 AM) 0.082 mm
-0.054 mm (0 days, 22:38:59) -0.054 mm (0 days, 22:38:59) (28/05/2005 7:19:10 AM) 0.028 mm (28/05/2005 7:19:10 AM) 0.028 mm -0.054 mm (0 days, 22:38:59) -0.054 mm (0 days, 22:38:59)
No. Server TagName Minimum Maximum Units Description:
3 MyInSQL U1TV001 0.00000 0.30000 mm TURB BRG1 VIBR
7 MyInSQL U1TP011 0.000 20.000 kPa CONDABS PRES (MEASURED)
Brush
Up Down
HIGH VIBRATION IN DUAL SHAFT GROUNDING BRUSHES.
NORMAL VIBRATION WHEN ONE GROUNDING BRUSH IS LIFTED
A
TEST
FOR
CIRCULAR
MAGNETISM
Magnetism Fundamentals
1. Shut down unit (or, at least, partially disassemble) to get
access for magnetizing coils and measuring instruments
2. Auto-Down-cycle a component in the primary, or possibly
all three axes, to determine the presence and orientation of
residual magnetism that it may possess.
The programmed sequence of auto-down-cyclingis
the key to evaluating residual magnetism.
MPS REMOVAL OF ANY MAGNETISM
Effective Down-cycling
If Auto-Down Cycling :
a) Reduces MM; Repeat down-cycling to minimize.
b) Makes small change in MM; Repeat down-cycling
with repositioned coil and at reduced power levels.
c) Increases axial magnetism notably; Indicates
reorientation of magnetism from cross-wise or circular
mode to an axial mode. Continue down-cycling as
axial magnetism increases and then drops to the lowest
value possible. Reduce further according to item a)
above.
Unusual Effects Related to MM
1) Vibration and Position Probes
Inaccurate physical vibration indications:
due to saturation of the shaft probe track by
magnetism saturated
steel has the appearance as air gap to the probe
Magnetic bases placed onto a probe track
show as sharp pulses on the vibration orbit.
2) Efficiency
Circulating eddy currents
consume considerable energy that goes into
the product as heat
primarily in turbines and compressors
Evidence of this shows as melted steel
puddles at contact faces and partings
may never be indicated by unit monitors or
instruments
3) Damage often requiring shutdown
Journal, anti-friction and thrust bearings
suffer from pitting, sparking and arcing
Melted steel voids and puddles requiring
component replacement or machining
bearing
housing
3 pad
backsides
face of bottom pad
Turbine Bearing Housing and Pads Following
a Severe Crash Due to Residual Magnetism
FLUTING OF TAPERED ROLLER BEARING
CAUSED BY ELECTRICAL CURRENTS
Shaft Current Effects
THRUST COLLAR BEARING
FAILED
EROSION
FLUTING
Stray current melting at flange parting indicating high losses and reduced unit
efficiency from high residual magnetism
Mischievous Magnetism can cause:
considerable damage
reduced efficiency
unit down time
To prevent:
investigative and establish a prevention program and follow it.
Trend with Shaft Condition Monitors in addition to traditional unit
monitors
confirm early warning and indications
Summary and Conclusions

Mischievous Magnetism in Rotating Machinery - Paul Nippes (MPS)

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