MOTOR BEARING FLUTING
J. Alan Lawson
Southeast Paper Manufacturing Company
P.O. Box 1169
Dublin, Ga 31040
ABSTRACI'
Southeast Paper Manufacturing Company began operations in 1979
with one paper machine making recycled newsprint. A second paper
machine was added in 1989 along with a gas/oil fired turbine/generator
and a fluidized bed combustion boiler to supply steam to an extraction
turbine generator set. The mill is presently a 100% newsprint recycle
mill with sectional electric drivel on both paper machines. All the
electric power needs for the mill are generated by buming coal, natural
gas. and sludge.
Mill maintenance began a mechanalysis program in 1987. Motor
bearings were included on routine equipment checks. Prior to the
expansion in 1989, all bearing failures were inspected. There were no
recorded cases of motor bearing fluting until after the new machine start-
up in 1989. In 1991, 5 motors were positively identified as having motor
bearing fluting. In January 1992. 2 additional motor bearings were
replaced for fluting. Bearing fluting occurred on both paper machines
drives. Mill management decided in Febmary 1992 to identify the source
of these problems and solve them as quickly as possible. A Problem
Analysis group was formed to determine the true cause.
Electrical motor bearing fluting has been defined as damage due to
electrical current discharge through a motor bearing. Bearing race metal
is electroplated onto the bearing balls. Close inspection reveals
microscopic pits on bearihg ball and race surfaces.
The mill has experienced fluting on both dc and ac motors. There
is little or no published literature on the causes of ac motor bearing
fluting. AC motor bearing fluting may sometimes appear as a misaligned
bearing to the naked eye. Microscopic inspection shows electroplating
action taking place on the bearing balls and inner race load zone surface.
It is likely that many AC motor bearing failures have been incorrectly
appraised as misalignment instead of fluting. Without a good
mechanalysis program for early failure detection, many fluting failures go
undiagnosed or undetected, resulting in bearing catastrophic failure being
attributed as lubrication failure or something other than fluting.
Bearing current flow that causes fluting is the result of several
dynamic changes inside the motor. Unbalanced air gap magnetic flux
transient changes are the primary bearing current source. Rapid
unbalanced air gap flux changes are the primary facton affecting motor
bearing current flow. Bearing current flow increases with faster field pole
voltage transients. DC motor field pole voltage changes and armature
voltage flUCtuatiOnS alter the air gap magnetic flux wave that contributes
to the current wave through the bearing.
Test results should also explain why only 1 bearing per motor is
affected by fluting. Inboard or outboard bearing fluting is completely
random.
PROJECT DEFINITION
This project monitored a completely isolated dc motor with an isolated
ground wire equipptd with a shunt to determine if there were shon
duration current spikes going through the motor bearings. The test motor
was placed on a paper mchii drive known to have fluting problems in
the past and to have transient voltage spikes on the motor field supply
module. The test motor
CH3331-6/93/0000-0032$3.00 0 1993 IEEE 32
field and armature were paralleled across the existing motor. This
hypothesis was tested in a controlled environment.
A dc motor frame was Completely isolated from grwnd except by a
single g m d i n g conductor with applied m a t u r e and field voltage. No
motor shaft load was connected to the test motor. This confguration
eliminated parallel current paths so that bearing current flow is completely
directed down the monitored ground wire, through a dc shunt (a low
resistance current transducer). to ground. Motor bearing fluting ground
currents were measured and stored with a high speed oscilloscope
(5Omhertz bandwidth). Waveforms were recorded photographically.
With the motor running parallel with the I1 paper machine front drum
winder motor (lcnown to have a history of fluting problems), field voltage
transients on the field modules were also applied to the isolated test
motor. A Dranetz meter was applied to the dc field supply module to
verify the transient voltage magnitude and duration. An oscilloscope was
connected across the ground shunt. Motor bearing currents were recorded
with wave forms Jose to those expected under actual motor conditions.
These meters recorded the wave shape, level, and ground current pulse
duration that actually flowed through the motor bearings while rotating
at operating speed.
MOTOR AIR GAP DESIGN
D.C. motors air gap magnetic flux wave is developed between the
armature and field pole faces. Air gap flux density is affected by the
field poles and armature. As the annature begins to turn inside the field
pole flux, a resultant air gap flux is generated.
D.C. motor field coils are constructed and wound with the same type
of copper wire and insulation. Under normal steady state conditions, air
gap flux density between opposing field pole faces is nearly equal.
Ground current analysis under steady state conditions shows minimal
ground current flow. Ground current flow changes were found to be due
to motor speed changes, armature voltage fluctuations, field pole air gap
flux changes, and other unknown influences.
The m a
J
o
~ contributor to the air gap flux is from the field poles.
Affects of the field pole air gap flux density component are higher than
other sources and has the most affect on the motor air gap flux density.
Large amplitude, shon time constant, transient field pole voltages
contribute significantly to air gap flux imbalances.
Each manufactured field pole coil's transient reactance is different.
Field pole coil's are not an ideal resistance, capacitance, and inductance.
Therefore, their transient response will vary to rapidly chmging field
voltage.
POWER SYSTEM HARMONICS
Harmonic currents, a mult of non-linear loads, cause the current
waveform not to omform to the shape of the applied voltage waveform.
The most probable cause of harmonic distortion are ac and dc variable
speed drives.
Circuits containing both capacitive reauance and inductive reactance
are found in dc and ac adjustable speed drive systems. Such systems
have one or more natural frequencies capable of producing resonance.
Resonance causes amplification of the voltage or current. Non-linear
loads under resonance cause the current waveform to be further distorted,
increasing eddy current core losses in transformers, motors, lighting
ballasts, and solenoids.
 Wave shape distoltion under harmonics can shift the sine wave zero
with respect to the voltage zero intercept. This shift causes problems
with solid state device operating points and equipment operation.
Electrical component failures and inductive devices heating will increase,
thus making camected equipment less efficient.

Several paper machine SCR (silicon controlled rectifier's) was found

to have low meggar resistance, thereby causing large variations in the
phase relationship between voltage and current. Phase shifting of voltage
and current on large alternating current variable speed controllers results
in high voltage resonant harmonic spikes. Voltage harmonic levels were
found to be directly related to motor load, As motor load increased,
voltage resonant peaks increosed in magnitude.
BEARING ROTATION DURING TRANSIENTS
FIELD POLE TRANSIENT REACTANCE

Transient reactance conditions occur for very short periods of time.
Field pole voltage transients were measured at 100 microseconds and less.
When the field voltage has a transient spike of several thousand volts for
100 microseconds, air gap flux density will be different due to the field
pole transient reactance for each pole.
This assumes that the field poles transient reactance is not perfectly
identical. It would not be econanically feasible to manufacture field
pole coils perfectly identical under transient conditions.
A magnetic motive flux wave imbalance cuts through the motor shaft
generating eddy currents for 1 microsecond or less. Eddy current flow
generates a shaft voltage by using ohms law; voltage equals the current
times the resistance of iron. (V=IR(iron)).
Figure 1 pictorially represents the shaft flux imbalance. The shaft
cross section shows the lines of flux in an unbalanced condition as the
result of a field pole transient voltage spike or drop. Flux wave
imbalance is a m s s the shaft center and is localized on the shaft. Voltage
equal potential lines are not equally distributed along the motor shaft,
with potential higher at only one motor bearing. Shaft voltage potential
is higher at one bearing, causing current flow to travel through the
bearing nearest the higher potential.
Bearing lubrication acts as a capacitor when placed between 2 parallel
metal plates (bearing race and ball). This is exactly the same as an oil
or grease filled capacitor. Film thickness will affect the capacitor rating
in microfarad's. Current flow through a capacitor is based on voltage
time rate of change and capacitor value, (I= C DVDT). Voltage time
rate of change affects cumnt flow more than voltage magnitude. A faster
voltage rate of change, increases current magnitude.
Field pole voltage transients exist in the altemating current side of
the dc field pole supply module. These transient voltages last from 70
to 100 microseconds and measure 1,750 volts ac to ground on a 138 volt
ac bus. Within a 2 second period, 15-20 oscillations were measured.
Field pole voltage transients induce eddy currents in the motor shaft. The
rate of transient voltage change with respect to time creates a transient
reactance in the pole coils.
Motor shaft/bearinginner race surface rotation during a 70 microsecond
or less current pulse is stationary, and generates an unbalanced motor
shaft current for 0.00007 seconds as per the following:
motor speed at 1,200 rpm.
motor shaft 3" diameter.
eddy current duration = O.ooOo7 seconds.
motor revolutions in O.ooOo7 seconds = 20/0.00007 = 0.0014 revolutions.
outer bearing race surface displacement = 3" X 3.14 = 9.42 X 0.0014
revolutions = 0.013 inches of rotation during a transient period.
Theoretically. the motor shaft is stationary during these short current
pulses. Bearing load m e marking will be from s h m duntion pulses
instead of long duration shaft discharges. The eddy current produces a
shaft voltage potential differential at the motor bearings.
BEARING FLUTING MARKS
Motor bearing lubrication acts as a capacitor and the rate of change of
shaft potential causes a current to flow through the bearing.
After the first initial marking by short term current flow, the bearing
load m e race is microscopically permanently marked. The marking
interval is evenly spaced according to the ball spaces. This indicates that
the first initial current flow was for a very short period of time. As the
bearing rotates, the race marking causes :light vibration, much lower than
what is normally detected by existing techniques.
Bearing balls fall into these microscopic pits in the race load zone and
extrude a small portim of lubricant out of the markings. Slight removal
of some of the lubricant lowers the capacitive value so that a voltage
transient will now cause a larger current to flow. This also desensitizes
the bearing by lowering the lower threshold for bearing current flow and
allowing lower level transienw to funher mark the.bearing. But marking
only occurs at the bottom of the original race marking. This is why
fluting marks always occur in the same place on the bearing race load
zone and all bearing fluting failurea appear exactly the same (see figure
2 and figure 3 on page 3).

Large voltage resonant impulses create air gap flux transients on direct
current motor fields as described earlier. It is well known that voltage
harmonic resonance is the result of modem solid state devices and
inductive capacitance devices. Large solid state drives using SCR
commutation capacitors produce voltage harmonics.

Each direct current motor field pole coil is different. resulting in pole
face flux density changes for approximately 100 microseconds. The air
gap flux density is not balanced. This imbalance cuts the motor shaft
inducing a 70 microsecond (or less) shaft eddy current.

33

Figure 2
Inner Race Fluting
Figure 3
Outer Race Fluting
As bearing clearances continue to increase, fluting continues to
increase around the inner and outer race surface until the bearing is
replaced, or if left undetected, catastrophic failure occurs.
BEARING CURRENT LEVELS
During motor rotation, normal current flow in motor bearings is
usually 2 to 20 amperes. These current levels are not damaging. It can
not be fully determined how much shaft potential results in bearing
current without knowing the dynamic and transient circuit parameters for
the motor bearing.
There have been many papers written on shaft voltages to determine what
shaft voltage potential may damage the bearing. Methods to measure
shaft voltage are flawed due to brush voltage drop, shaft film resistance,
and determining the equivalent circuit parameters of a motor bearing
under transient conditions.
Monitoring an isolated motor connected to the paper machine variable
speed drive power supply is the only accurate method to determine how
much bearing current can flow through the bearing. Wave shape and
decay times indicate that bearing current is a capacitive discharge not
resistive. The bearing current waveform is shorter in duration than the
applied transient voltage at the field supply module, further indicating a
capacitive discharge (see figure 4).
Bearing current flow is a function of the field supply current. A motor
field pole rheostat set for maximum flux density will affect flux density
to a larger degree than a motor operating at a low field excitation.
Higher field currents will cause larger bearing currents.
Motor bearing damage due to current impulses are probably in the order
of several hundred amperes at very low voltages. The power to damage
a bearing (power = current squared X resistance of steel) is related to
current and conductivity of steel.
34
E
a
I FIQRE +
AC MOTOR BEARING FLUTING
There were 2 ac motor bearing fluting defects in the mill. Therefore.
depending on the voltage spikes present, every motor in the mill has the
potential to have bearing defects. Lost production and extra maintenance
charges cost the company many dollars.
The following explanation is how fluting occurs in an ac motor
bearing. Polyphase ac motors are constructed according to desired rpm
by setting the number of intemal poles. A 3,600 rpm motor will have
2 poles, a 1,800 rpm motor will have 4 poles etc. The resultant air gap
magnetic flux wave magnitude is dependant on poles, coil tums ratio, and
current per phase. If the current per phase were to change very quickly,
air gap flux wave magnitude will change proportionally.
Since stator windings per phase are distributed among several slots per
pole, the resultant space fundamental magnetic flux wave is obtained by
phaser mathematics. Each motor rotating field pole air gap flux wave
is equal in magnitude by design, and the resultant flux distribution
through the motor shaft is equal and balanced. Thus. under steady state
conditions, the motor shaft will not have eddy currents flowing along the
shaft.
If an imbalance in the flux distribution along the motor shaft were to
occur, flux imbalances generate shaft eddy currents and the result is the
same as documented in this report for dc motors.
The air gap magnetic flux wave will become unbalanced when a high
voltage transient spike occurs on an individual phase of a polyphase ac
motor. The voltage spike generates a current spike in the affected phase,
and unbalance the flux distribution inside the motor shaft. Resultant
current flow in the bearing is similar to that in a dc motor.
PROBLEM SOLUTION
The mill has followed the recommendations of the paper machine drive
manufacturer to meggar test all SCR power modules on a routine basis.
All power modules were retumed to the manufacturer, tested and repaired,
then retumed to the mill. SCR testing began in 1979 and continued until
1988. It was determined that meggar testing did not necessarily prove
that an SCR was defective.
Meggar testing increased maintenance costs. Because of part costs and
manufacturers recommendations of discontinuing the practice, meggar
testing power modules during paper machine shutdowns was discontinued.
SCR power modules were not tested on the paper machine drives from
1988 until 1992. Meggar testing for a lower threshold of 250,000 ohms
determines if the SCR is to be replaced. The lower limit was established
initially by the manufacturer. Meggar testing began as a preventative
maintenance program. The cost of a power module is insignificant to the
cost of unscheduled paper machine downtime. Meggar testing SCR's is
an established practice with maintenance to determine what devices may
be performing poorly.
Power system transient magnitude was found to be affected by machine
drive load. Voltage transients began when the # l boiler ID fan variable
speed drive was in operation and stopped when the fan drive was shut B. High field pole voltage impulses can cause as much as 200 amps to
down. First indications were that a problem existed in the ID fan drive flow in the motor bearings. M o m bearing damage is also proportional
system. Close examination of the fan drive while running proved that the to field cvrrent settings.
problem was not there. Transient voltages were large enough to cross
over the two 56 mva 115 kv to 12.5 KV bus step down transfmers, and C. The bearing current waveform is in a capacitive chargeldischarge
across two additional step down transformers to the #2 paper machine shape. This finding indicates that bearing current is affected by the air
field supply modules. Transients measured on #2 paper machine were gap flux wave rate of change. Bearing current will increase with faster
lower than measurements on #l paper machine. The transients were rising harmonic impulses.
being transmitted through-out the entire distribution system and originated
on the #1 paper machine. It was also remmmended that both paper machines field supply module
voltages be monitored for impulse spikes above 400 volts (line to
Transient voltages were measured on the 240vac side of the field ground). The monitor should acknowledge when the spikes occur and
supply modules. The 3 channel Dranetz meter was connected phase to report this information as soon as possible to maintenanW. Accurate time
ground on both sides of the 240 volt power source. Channel A was and date reference information is essential to locating the source of the
connected to one side of the ac source to ground and channel B was problem inside the mill. Rapid location of the source and elimination of
connected to the other 240 volt leg to ground. Nominal voltage to voltage spikes will improve motor bearing life saving maintenance dollars.
ground is 138 volts ac. One Dranetz mefer channel reading phase to
ground recorded impulses of 1,750 volts to ground while channel B Recommendations include. conducting routine megger testing on paper
would remain at 138 volts. Figure 5 shows a sample Dranetz meter machine drive SCR's to quickly eliminate a source of voltage harmonics.
impulse read-out during transient conditions. Notice the large magnitude
short duration voltage spikes measured. Motor bearing fluting detection must be done by monitoring the power
system. Correcting the problem quickly means detecting and isolating the
problem for repairs. To accomplish this. it would be advisable to install
a continuous voltage transient monitoring device on dc motor field supply
transformers.
1729 V , 0002 CI s
1A IMP 16:59:39.05 The potential cost to Southeast Paper is replacing every dc motor
bearing failure due to fluting. There are 32 dc motors on #1 paper
machine and 26 dc motors on #2 paper machine. If the average cost for
1740 V , 0068 CIS a motor repair i s $5,000, this could affect the maintenance budget by 58
1A IMP 17:03:26.15 motors X $5.000 or $280,000 per event. It is equally likely that all 58
motors bearings are affected by the same power system voltage transient
conditions. Also, any variable speed drive in the mill has the capability
to induce the same voltage transients on the power distribution system,
1721 V , 0070 CI S damaging the dc motor bearings.
1A IMP 17:03:26.98
REFERENCE LITERATURE:
1746 V , 0065 (1 S
[ l ] E. Wallen and S . Andreson. "Passage Of Electric Current Through
1A IMP 17:05:30.13 Rolling Bearings." SKF.. Gothenurg, Sweden, 1968.
Publisher Aktiebolaget Svenska Kullagerfabriken.. June 1968.

DRANETZ IMPUSE VOLTAGE OUTPUT

FIGURE 5

The paper machine power modules were megged to determine if any

low resistance SCR power modules could be found on #1 paper machine
since testing stopped in 1988. Meggar testing on the wet end wire
tuming roll and pick-up roll were found to have low threshold resistance.
Both power modules were changed during a shut down. When the paper
machine restarted, no transient voltages were found on any paper machine
field supply modules. Measurements continued for another 2 months to
detea any reoccurrence of the voltage transients.
Dranetz readings were taken for a month with the # l boiler ID fan
running and not running, and there were no transients recorded.
condua improperly, increasing the magnitude of the harmonic value.
The magnitude of the harmonic is related to drive loading. Sample
transient voltage magnitude and pulse duration show how SCR loading
is directly proportional to transient voltage magnitude.

CONCLUSION
A. While the motor is d n g . normal bearing current flow without
transient spikes is between 2 and 20 amperes. No noticeable damage
occurs during this operation.

35