COMPRESSOR TRAINING

BEARINGS*
*What bearing do they have on compressors?

Most Compressor Problems are traced to the

rotating elements or the rotor support system
and are first detected at the bearings by bearing
RTDs or vibration at the bearings.
The bearings are generally more compliant that other
machine elements and when there is a malfunction they
tend to give first.
Whatever the cause, modification of the bearing is
generally the most direct and economical means of
altering the behavior.

Bearing Family Tree

C O M P R E S S O R B E A R IN G S
R o llin g E le m e n t
(n o t A F )
S p h e r ic a l
E lip t ic a l
C y lin d r ic a l
T a p e r e d R o lle r

F L U ID F IL M

H Y D R O S T A T IC

M A G N E T IC

H Y D R O D Y N A M IC
( s e lf- g e n e r a t in g )

N o n - p r e lo a d
~ P la in J o u r n a l
~ A x ia l G r o o v e
~ P re s s u re D a m

P r e - lo a d e d
~ E lip t ic a l
~ Lobed
~ O ffs e t

T ilt in g P a d
~ fix e d p iv o t
~ s e lf- e q u a liz e d

A t t r a c t iv e

F ix e d L a n d
~ Taper
~ R a le ig h

R e p u ls iv e

Principal of Operation
Oil is drawn into the
converging wedge by the
moving bearing surface. A
pressure is generated in the
fluid which tends to separate
the two bearing surfaces.

Behavior of the oil in the Journal

bearing converging wedge is
defined by the Reynolds
equations:
Pressure ~ viscosity, rpm,
distribution function; and
(1/radial clearance)2

 = eccentricity ratio = e / radial clearance

Difference between the bearing set bore radius and the journal radius is the
bearing set clearance or running clearance. This is often specified as
clearance ratio: typical values are 1.5 to 2 mils per inch of shaft.

True partial arc and

floating bush bearings
are NEVER used with
Centrifugal compressors
for Process services
Plain journals are
SELDOM used.

Two-Axial Groove Journal Bearing

Grooves allow more oil flow and better

heat removal.

Pressure Dam abrupt endstep

causes a pressure differential
before and after the step which
creates a net down force which
further loads the bottom bearing
and increases stability.

BEARING PRELOAD
Rj = Journal
Radius
Rp = Radius of max shaft to fit in pad
bore
Rb = Machined pad bore radius
Cp = Rp - Rj
Cb = Rb - Rj
M = 1 - Cb/Cp = PRELOAD
Rp

Rj
Rb

PRELOAD forces the oil

to converge resulting in a
stronger oil wedge effect.

PRELOAD
In a two-lobe (lemon bore)
bearing.

Each of these
bearings has specific
advantages and
disadvantages

There is a broad selection of

available stiffness and damping
properties available. Therefore
some bearings will be better than
others for a particular
application.

Bearings Crush
CRUSH - dimensional
interference between the
bearing shell and the
support housing.

TOO MUCH - hot bearing!

TOO LITTLE - loose
bearing and synchronous or
subsynchronous vibration.
Need 0.002 in Crush on diameter!

Stiffness and Damping Relationships

In the flexible bearing region, the
shaft is stiff relative to the bearing so
bearing stiffness significantly affects
the critical speeds.

If the bearing is too stiff, the effectiveness of

the bearing damping will be limited.
The cross-coupled stiffness can create an outof-phase force. Under certain conditions the
bearing goes unstable and OIL WHIRL will
occur.

S = NLD/W (R/c)2

Tilting Pad Radial Bearings

The independent pivoting feature
significantly reduces or even effectively
eliminates the CROSS COUPLING
stiffness.
Each pad can pivot independently to
develop its own pressure profile

Tilting Pad Bearings - guidelines

Typically 4, 5, 7 or 9 pads are used.
Load On Pad increases stiffness. Load Between Pads increases
damping.
L/D (Slenderness Ratio) typically varies between 0.2 and 1.0.
Bearing UNIT LOADING (Load / Brg. Length x dia.) typically
between 150 and 250 psi.

A ROCKER is a line-contact
pivot with little axial
alignment compensation.

A SPHERICAL is a
semispherical surface-contact
pivot.

Types of Tilt-pad Shoe Contours

Tilting Pad Bearings - guidelines

LOAD ON PAD
increases stiffness
favors light rotors at
high speed
assymetry promotes
resistance to crosscoupling (stability)

LOAD BTWN PAD

increases damping
favors heavy rotors at
low speeds (low
Sommerfeld No.)

Comparison of Journal Bearing Types

What can cause bearing failures?

Design Deficiencies
film thickness too small
inadequate heat
dissipation
insufficient lubricant
unstable rotor/brg system
structural deflections
incompatible babbittjournal material (rub)

Mfg/assembly errors
not per design clearances
liners misaligned
non-cylindrical journals

Mfg/assy - contd

rough/scratched journal
excess runout thr-collar
dirt or debris from assy
poor bond of babbitt

Operator mistreatment

dirt/scale in oil
operation dry (no oil)
excess vibration
hot inlet oil
misalignment of driver

Under Running Conditions a

fluid film bearing can only
be damaged or fail from two
causes:
*. Film too thin which breaks
down the film and damages
bearing surfaces
*. Film too hot which
damages babbit surfaces
directly.

Modes of Bearing Failure

MODE
Abrasion
Bond failure
Cavitation erosion
Corrosion
Electrical Pitting
Erosion
Fatigue
Fretting
High chromium damage
Non-homogeneity
Overheating
Seisure
Structural damage
Surface wear
Tin oxide damage
Wiping

OTHER NAMES
Gouging, scoring, scratches
Spalling
Cavitation
Chemical attack
Frosting
Worm tracks
Fretting corrosion
Wire-wool; black scab
Blistering; porosity
Mottling; anisotropy;
ratcheting; sweating
Black scale
Wear
Smearing; polishing

REF:
McCloskey, T.,
Trouble shooting
Bearing and Lube Oil
System Problems.
Proceedings of the
24th Turbomachinery
Symposium.

Zeidan/Herbage, Fluid
Film Bearing
Fundamentals and
Failure Analysis.
Proceedings of the
20the Turbomachinery
Symposium

OIL TEMPERATURE AND PRESSURE

API 617 limitations:
180 F (82 C) Oil Temp Out
50 F (28 C) Temp Rise
200 F (93 C) Brg. Temp.

Increasing oil flow /

pressure seldom cures
the problem
Change to oil grade or
bearing geometry is more
beneficial

98 - 99% Copper alloyed with

chromium can be backed pads
(as a retrofit) and are effective in
dissipating heat and lowering
bearing temperature.

Bearing Babbitt
Traditional babbitt material
is lead-based or tin-based.
Presently favored material
is white metal - which has
broad definition.
Broad use of 60 Sn - 40 Al.
Tri-metal: lead-tin-copper
which is a thin (<.004)
overlay of a stronger
aluminum or copper alloy
backing

Tin-based:
Excellent antiseizure
corrosion resistant except HCl &
H2S (seal oil)
good embedability
good conformability
Poor Fatigue properties

Lead-based:
excellent embedibility
excellent conformability
sensitive to corrosion from organic
acids

Bearing Babbitt
Embedability implies
thickness (20 to 50 mils)
but thickness reduces
fatigue strength (resistance
to fracture from vibration
loads)

Improvements in oil
filtration have reduced the
concern for particulates.

Typical of Compressor Bearings

FMCL Air Compressor Train Bearing

This is a picture of the FAILED FMCL

NH3 Plant bearing.

Final determination was a

electrical discharge problem

Misalignment

Fixed Land type Thrust Bearings

Typical design
load < 200 psi

(Plain grooved thrust bearings are never used on process compressors)

Tilt-pad Thrust Bearing

Unit DESIGN
loads for a tiltingpad thrust
bearing are
typically 250 to
500 psi.
Check experience
for designs using
higher loads.

Center pivot - most

common and good for
reverse rotation and
avoids missinstallation.
Offset pivot can lower
bearing temperature.

Typical No. of pads vs speed & load

Self-aligning Thrust Bearings*

*This compensates
for mis-alignment of
shaft or housing or
dirt behind the
carrier ring.

EQUALIZING LEVER

This is NOT a cure

for a cocked thrust
collar!

SPRING EQUALIZER

SPHERICAL SEAT

Directed Flow Bearings

Most of the oil is needed to remove
heat rather than develop a hydraulic
film.
Too much oil assures turbulent flow
which promotes higher fluid friction
losses.

Injection Nozzle
Groove / Slotted Edge
Pocket
Spray Bar

One way of beating the horsepower

loses of tilting-pad bearings is by
minimizing the oil used to assure
laminar hydraulics. The risk is
inadequate heat removal.
Directing it to the proper point
(bearing hot spots) allows an
economy of oil flow.

Ref: Stewart, C., Influence of Oil Injection Method on Thrust Bearig Performance. Proceedings
of 28th Turbomachinery Symposium

Directed flow bearing

BN ServoFluid Control Bearing

BN ServoFluid Bearings
Supply pressure
is typically 600
to 1000 psi.

Self
compensating

Electromagnets

Electromagnetic
forces

Rotor
laminations

F
Radial bearing

Clearance
= 0.5 mm

Position Sensors

Electromagnet

0.5 mm
Auxiliary Bearings

Rotor
Rotor
F
0.2 mm

Laminations

Radial bearing

Control loop
Amplifiers

Electromagnets
Sensors

Signal treatment
Setpoint
Center

Controller
PID,...

+/Position information

Rotor

Typical compressor w/ magnetic bearings

SABIC Unit

Radial mag-bearing & thrust bearing assembly

Requires extensive
interface and
coordination with
CSE and Electrical
team members.

ADVANTAGES

NO MECHANICAL CONTACT ~ No wear

No lube oil system~ No process pollution by lubricating oil
Wide operating range (1 to 500K, 0 to 100% speed)

Higher rotation speed

Lower energy consumption => Best operating costs

Maintenance free concept => Best availability

PERMANENT ACTIVE CONTROL

Unbalance control => low vibration level

Built-in diagnostic and monitoring
Optimal rotor dynamic performances

LIMITATIONS

Technical limitations
High temperatures over 250C without cooling
Max. axial load / speed (ex.: 20 tons at 6,900 rpm)
Rotor dynamic : requires careful engineering
E-ex environment : requires careful design
Current saturation leading to poor restoring forces
Considerable heat removal
Load carrying capacity
Human limitations
Training on a new technology (maintenance...)
Resistance to innovation
Higher costs