Machinery and Components

Machine/Component Failures
• Major source of production downtime in most
industrial plants
• Cost of production downtime is often higher than the
expense involved with the repair or replacement
• Many machine/component failures can be averted,
or at least the useful life can be extended
• An important part of this process is knowing the
cause of the failure.
 Machines
• Pumps
• Motors
• Compressors
• Fans
• Conveyor belts
• Crushers
• Gearboxes
• Rollers
 Components
• Shafts
• Bearings
• Gears
• Couplings
• Pulleys + Belts
• Sprockets + Chains
• Impeller/Vanes
• Electrical (Rotor and Stator)
Large Engines
Large Engines
Small Engines
Why? Understand failures
 Shafts
• Rotating bars which transmit force, power, and motion
• Usually circular cross section
• Torque is twisting force resisted by shaft

• Stresses on shafts
– Torque
– Tension TENSION COMPRESSION

– Compression
– Bending
– Combinations
TORSION BENDING
 Types of Loads

Tension Torsion

Compression Bending
 Bearings
► A device that supports, guides, and reduces the friction of motion
between fixed and moving machine parts.

Ball Bearing Roller Bearing

 Journal Bearings
• Shaft rotates inside a bearing • At rest, there is metal-to-metal
bore slightly larger than the contact between the journal
shaft diameter and the bearing, along the line
• Lubricant is supplied to the of contact
annular gap • Once rotation begins, a
• Portion of the shaft within the lubricant film develops
bearing is called the journal. between the journal and the
bearing
• As speed increases, a wedge of
lubricant forms, supporting the
shaft away from the bearing,
and preventing wear.
 Bearing Faults
• Revolution around outer race • Causes
• Non-uniform radial tension of – Handling/Transportation
bearing – Defects of
• Misalignment of outer race installation/maintenance
– High dynamic loads from shaft
• Wear of the outer race
• imbalance, coupling
• Cavities on the outer race misalignment, and self-
• Wear of the inner race excited rotor oscillations
– Bearing distortion
• Cavities on the inner race
– Lubrication
• Wear of balls, rollers or cage • Lack of
• Cavities, spallings of • Excess
balls/rollers • Impurities
• Complex defect • Degradation
• Slip of race
• Defects of lubrication
 Bearing Faults
• Defects can lead to
– seizure of the bearing
– breakage of cage
– Rapid or slow wear of bearing
– Pitting
– Cavities
– Cracks
– Increase in the friction coefficient
 Gears
• Gears • Types of gears
– Wheel, disk or bar with – Gear train
teeth on periphery – Bevel gears
– Teeth mesh with teeth on – Internal and external gears
other gears – Worm gear drive
– Simple gears transmit
power directly from one
shaft to another
– Internal or external teeth
– As two engaged gears
rotate together, the same
number of teeth on each
gear pass the line between
the centres
Couplings
 Couplings
• Couplings are used to make co-axial connections between two shafts
• They serve two main purposes:
– To allows first shaft (driver) to drive the second shaft (driven) at the same
speed
i.e. transmission of power
– To compensate for minor amounts of misalignment and random movement
between the two shafts.
• Couplings are either rigid or flexible
– Rigid couplings require very close alignment of the shafts
• Sleeve coupling
• Flange coupling
– Flexible couplings generally ‘sandwich’ something flexible in between, or
connected to, rigid flanges attached to each shaft
• Toroidal coupling
 Pulleys and Belts
• V belts • Toothed belts
– create greater friction by – don’t slip (synchronous)
wedging into the groove on
the pulley – hence transmit torque at a
constant ratio
– hence greater torque capacity
– Between 70-96% efficiency – good for applications requiring
precise timing
– very efficient
• Flat and round belts
– work very well – more costly than other types
– require higher tension than V
belts to transmit the same
torque
– require more rigid shafts,
larger bearings, etc.
– Up to 98% efficiency
 Sprockets and Chains
• Compared to belts, chains can transmit more power for a
given size, and can maintain more precise speed ratios.
• Like belts, chains may suffer from a shorter life than a gear
drive.

• Flexibility is limited by the link-length, which can cause a

non-uniform output at high speeds.
• Can be very efficient – around 98%.
• User controls the length (with master links)
• Sprockets wear out much more frequently than pulleys
Motors
 Motor Faults
Neglect Misapplication
– Dirt – Under-sizing
• Surface dirt causes • Service factor is not for
overheating
normal use
• Internal dirt degrades
insulation – ASD Stresses
and bearings • Low speed + high torque =
– Bad Lubrication overheating
• Too much or too frequent • Induced bearing currents
• Too infrequent • Standing wave phenomena
• Mixing incompatible – Poor Ventilation
lubricants
– Poor Power Quality • Causes overheating
• Over/under voltage – Coupling & Belts
(especially under) • Misaligned couplings or
• Unbalanced voltage sheaves = Bearing Failures
• Single-phasing • “Soft Foot”, ie. bad shimming
 Motor Faults
Severe Environment Normal Wear
– Hot Ambient – Without unusual stresses,
• Requires de-rating motors sometimes last for tens
– High Altitude of thousands of operating
• Causes overheating - requires
hours, but will eventually
de-rating succumb to...
• Bearing wear
– Humidity
• Insulation failure
• Motors in storage
• Motors with significant off
time
• Requires internal or ambient
heating
– Airborne Contaminants
• Damages insulation or
bearings
• Kills by abrasion or chemical
deterioration
Faults modes for monitoring
Mechanical Electrical
– Unbalance – Rotor
– Misalignment – Stator
– Bearing
– Looseness
– Lubrication
– Cavitation
 Unbalance
Balanced Unbalanced
Centreline
of mass

Centreline
of rotation

► Unbalance is the force exerted on a rotor due to the difference between

the centre of rotation and the centre of mass
 Misalignment

Offset
Misalignment

Angular
Misalignment
Monitoring/Diagnostic Techniques
• Many predictive maintenance technologies
• Examples include
– Vibration analysis
– Oil analysis
– Ultrasound
– Thermography
– Motor Current Signature Analysis
Condition Monitoring
Tools
 Typical Installation
Motor Driven Pump

A: Non drive end

B: Motor
C: Drive end shaft
D: Coupling:
E: Drive end and
shaft
F: Pump
G:Roller Bearing C D E F G
A
B
 Activity
• In small groups (3-4)
• Discuss the components and sub-components
(pieces of equipment) which are needed to
move a large ship from port to port
• Create a list of components and possible
problems which could occur
• Include how they might fail and have an affect
on the ship