Discovering misalignment with infrared: The Damage is Done

James M. McLeod Technical Services Representative Mississippi Power Company

ABSTRACT
Infrared Thermography is one of the most useful predictive maintenance tools a technician can have in his or her toolbox. The correct use of infrared can mean huge savings to a company, but identifying a problem is only half the solution. Improper corrective actions and failure to understand the proper solution can cost money and more importantly reputation. While performing an electrical inspection at a local hospital, I noticed that a chiller system condensate pump had excessive heat radiating from the inboard bearing of the pump. It was suspected that this heat was due to misalignment of the shafts. The facilities manager was informed of the problem and suggested that the alignment be checked on this piece of equipment. The alignment was checked with a Rotalign laser alignment tool and the machine was grossly misaligned. The next logical step was to align the machine. The alignment was performed and the machine was placed back in service. A week later the machine wrecked and destroyed the inboard bearing of the pump. The next logical question was why? When the pump was disassembled and inspected it was noted that the actual pump housing had worn and the new bearings could not be pressed into the housing. This was due to the misalignment loading the bearings hard against the housing. The reason the machine crashed when it was aligned was due to the reloading of the bearings. The maintenance facility manager was notified of this condition before the pump was aligned. Had he not been notified of the preexisting problem the reputation of the thermographer could have been damaged. Keywords: Machine alignment, infrared thermography, bearings, load zone, shaft alignment, coupling alignment

1. INTRODUCTION
Misalignment of shafts on rotating equipment is the leading cause of premature bearing failure. Vibration analysis is the common technology for identifying misalignment, but infrared is an excellent tool for quickly identifying this problem. The question is what to do after identifying this problem and what is actually happening inside the piece of equipment being inspected?

2. CLASSIFICATION OF PROBLEM
Misalignment can be described by Vertical Offset, Horizontal Offset, Vertical Angularity, and Horizontal Angularity. These offsets between the two shafts are the reasons that heat builds up in the bearings. Common misconceptions are the importance of coupling alignment and coupling tolerances. The shafts are what need to be aligned not couplings. Coupling manufactures will give misalignment tolerances for there specific couplings. These tolerances vary from coupling to coupling and usually depend on flexibility of the coupling and speed of the machine. Essentially they are saying that some misalignment is ok, because the coupling can stand it. Bearings fail due to misalignment of shafts, not couplings. The diagram of figure 1shows the results of shaft misalignment.

Figure 1. The results of shaft misalignment Looking at the diagram the stationary machine (STAT) is usually the pump or fan. The opposite machine (MTBM) is the machine to be moved and this is usually the motor. Notice that the misalignment at the coupling is minimal compared to the misalignment at the rear motor feet. This is nothing more than rise/run. The further you get away from the coupling the more significant the misalignment is due to the length of the shaft. This is the reason shaft alignment should be performed, and not coupling alignment. Figure 2 is a vertical alignment reading of a misaligned pump. There is 52.1mils of angular misalignment at the coupling (I use the term coupling because it is at the end of the shaft, but this is shaft alignment). This is a substantial amount of misalignment even for a coupling. In the bottom right of the diagram are the shim corrections it takes to correct this misalignment. It takes 110mils to correct the rear foot and 67mils to correct the front foot. This is correcting both parallel and angular misalignment of the shafts, and as you can see the farther away from the coupling the more misalignment you have.

Figure 2. Vertical alignment reading of a misaligned pump

How does this look to a Thermographer? Figure 3 illustrates the result of misalignment

*>174.9F 150.0 100.0

Area3 Max 181.3

*<62.6F
Figure 3. Thermogram of an inboard pump bearing This is a thermogram of the inboard bearing of a condensate pump for a chiller system. The extremely high temperature is due to misalignment of the shafts. As you can see the motor bearing is not running as hot as the pump. This is due to the fact that the shaft from the motor is larger and is putting the pump under excessive strain, which causes the bearing to get hot. This is further illustrated in figure 4.

*>161.7F 150.0 100.0 *<84.0F

Area2 Max 151.6

Figure 4. Misalignment causes stress on bearings As you can see in the thermogram, the inboard bearing of the motor is hotter than the equipment it is driving. This is a prime example of what misalignment is actually doing to the machine. The coupling is showing no real temperature rise at all. The bearing is receiving the strain and the punishment that goes along with it. With proper alignment, temperatures return to normal, as shown in figure 5.

*>133.3F 120.0 100.0

*<82.0F
Figure 5. Properly aligned compressor This thermogram is of a compressor that has been precision aligned with a laser alignment tool. As you can see the coupling has a very small temperature rise as you get close to the inboard bearing. This is temperature rise is due to the fact that the compressor is sitting on an oil tank at a temperature of 156deg F. The actual temperature of the inboard bearing is 130deg F. Figure 6 is a thermogram of the inboard bearing of the motor of this same compressor. As you can see there is hardly any noticeable temperature rise at all. This is due to the fact that it is not sitting on an oil tank and more importantly there is a motor fan blowing across the bearing, and we know the effects of wind on infrared readings.

*>133.3F

120.0 100.0 *<98.2F

Figure 6. Inboard bearing of the same compressor as in figure 5

3. SUMMARY AND RECOMMENDATIONS

In conclusion it is important to realize that a machine that is running out of alignment may already have bearing damage. Bearings running in a machine have a load zone. This load zone should be on the bottom center of the bearing if the machine is aligned correctly. If this is not the case and the bearings are loaded in another direction due to misalignment there can be significant damage. Once misalignment is verified and corrected the load zone on the bearings will change. This change may be quiet drastic depending on the original alignment and how long the machine is running in this state. This drastic load change due to alignment corrections may cause bearings or the coupling to fail, and if the THERMOGRAPHER does not warn personnel that this may happen it can be detrimental to his or her reputation. The other side to this is that if the alignment corrections are not made more than likely

when the machinery fails it will take the housing of the pump or motor with it. This destruction due to wear of the housing will make it impossible to press new bearings into the equipment. If misalignment is the problem determine how long the machine has been running in this state. If it has run for a long period of time it may be a good idea to replace the bearings before you align it. Check the coupling for excessive wear. The coupling has been loaded in an awkward position due to misalignment and it may be necessary to change it also. Ensure that there is proper lubrication of the bearings.