Magnetism in Machinery

There have been many documented cases of failed bearings, seals, couplings
and journals due to electrostatic and electromagnetic discharge in machinery.
This phenomenon can occur in electrical equipment (electric motors) and non-
electrical equipment (turbine, compressors, pumps, gearboxes etc.).

An electrical generator converts mechanical power to electrical power by rotating

a magnet inside of a wire coil. This causes electrons to flow in the wire coil,
hence the flow of electrical current. The same process takes place if residual
magnetism is left on a rotor or case. If the frame of a machine or the rotor is
magnetized, when relative motion occurs between the rotating and stationary
parts the generation of and build-up of current can take place. When the charge
reaches sufficient amperage it seeks a path to ground, which is typically through
the journal bearing but can be any close tolerance interface that presents a path
to ground. The discharge often produces sparking with frosting, spark tracks,
and, in extreme cases, welding.

The residual magnetism in turbomachinery occurs from manufacturing

processes, testing, and environmental causes. They have been measured at the
surface and in gaps of disassembled parts of a machine at levels from 2 gauss to
thousands of gauss.

Some specific examples of causes are:

 Machines that have experienced rubs from a wreck or process fouling.

 The use of electrical welders and heaters on pipes and other parts.
 Items that have been subjected to magnetic particle inspection often retain
residual magnetism because of insufficient or improper demagnetizing
following the test.
 The use of magnetic chucks and magnetic bases during manufacturing.

Measurement Techniques

Magnetic fields are measured with devices called gauss meters using a Hall
effect probe. The transverse hall effect probe is the easiest to use. The typical
units of measure are gauss or tesla. Magnetic fields are directional and polar,
with "North" at one end and "South" at the other

Small, hand-held compass-type gaussmeters can be used for rough checking of

a part or an assembly. Experience has demonstrated that these devices can be
very inaccurate. They also do not indicate the polarity of the magnetism.

On assembled machines only the external surfaces can be measured. On

disassembled machines the most desirable areas to measure are those involving
close clearances between rotating and stationary parts. Measurements should be
taken around bearings, seals, shaft ends, coupling hubs, gear teeth, foot
mountings, probe areas and pipe flanges.

Set the gauss meter in the DC mode, and in the real-time and peak display
modes. Gauss level readings can change as parts are removed because the
magnetic fields are altered. For instance, when a coupling is removed, the
adjacent bearing magnetic field levels may increase or decrease. Take readings
during the disassembly so that the measured levels are representative of the
operating conditions prior to the shutdown.

Gauss readings should also be taken on fully disassembled parts, recording

readings taken before and after degaussing. As assembly takes place,
magnetism should be measured on new and reworked parts as they are
assembled, and of the assemblies themselves.

Move the transverse hall effect probe slowly over the surface of the part to be
measured. Make a drawing of the part and map out the average and peak
readings and their polarities.

The higher magnetism values will be found on the edge of parts. These “edge
effects” generally represent levels that are higher than the overall value found on
the part.

Parts that exhibit north (+) and south (-) poles alternately across the surface of
the part are most undesirable. When rotated, alternating poles will cause a
generator effect and currents will be generated.

First conduct a cursory survey to learn if levels exceed the maximum acceptable
magnetism values. If not, then degaussing and a tabulation of magnetic readings
are not necessary.

A table of magnetism limits that has been developed based upon 15 years
experience with approximately 200 turbomachinery installations by Magnetic
Products Inc., is shown below.

Maximum Allowable Residual Magnetic Field Levels (As

Measured in Open Air)
Bearing components, including pads and retainers,
2 gauss:
journals, thrust disc, seals, gears and coupling teeth.
3 gauss: Bearing housings and stationary parts.

Demagnetizing Rotors or Parts

Demagnetization is accomplished by subjecting the part to a magnetic field equal

to or greater than the magnetic field used to magnetize the part, in the opposite
direction, then continually reversing the field direction while gradually reducing it
to zero gauss.

Degaussing of machinery is an art. There are no techniques which work in every

situation.

The hardware used for degaussing consists of a power supply and electrical coils
that are used to generate magnetic fields. The power supply should have the
capability of producing AC or DC output. In the DC mode, a reversing means is
necessary to facilitate the downcycling operation.

Output capacities should range up to 15,000 ampere-turns. The coils must be

properly sized for the output current, to avoid overheating the insulation, use
heavy 2/0 or 4/0 cable.

Strong fields can be obtained with a few turns carrying high currents, or many
turns carrying low current. The field of the coils is directly proportional to the
product of the number of turns and the current.

Commercial auto degauss units have automatic downcycling capability and can
use AC or DC current.

For small parts or parts with thin walls, a standard magnetic tape eraser may be
effective if used in a sweeping motion across the part

As a rule AC current works best for thin walled parts and DC current is needed
for deep penetration into large parts.

Magnetic particle inspection power supplies, direct current welding machines and
DC generators can be used can be used as current sources for demagnitizing.

The magnetic field in a rotor may be reversed by:

1. Reversing the rotor in the magnetic field.

2. Reversing the current through the coil.
3. Turning the coil 180 degrees.

The magnetic field may be reduced by:

1. Reducing the magnetizing current.

 2. Moving the rotor away from the coil.
3. Moving the coil away from the rotor.

Specialized degaussing equipment using DC current and capable of alternately

reversing the direction of the field and reducing the strength of the field
simultaneously is the most effective means of removing magnetism.

An alternative method using an AC welding machine can be effective on thin

walled parts. This can be accomplished by passing the part through a high
intensity AC current coil and slowly draw the part through the field coil. A coil of
5000 to 10000 ampere turns is recommended. The part should enter the coil
from 12 inches away and move slowly and steadily through it until the part is 36
inches beyond the coil. The current to the coil should not be turned off until the
part is clear of the coil. It may require several passes through the coil to reduce
the magnetism to acceptable levels. Each successive pass should be at reduced
field strength. Parts that can be rotated while passing through the coil will
demagnetize quicker and to lower levels.

Some parts are very difficult to remove the residual magnetism even after
repeated auto-down cycling with a fixed coil wrap and require continued cycling
of the field called "massaging" to reduce the magnetism.

Two notes of caution should be observed:

1. Never disconnect the demagnetizing coils while they are energized. The
magnetic energy can be substantial, and may produce arcing if the circuit is
interrupted. Possible damage to the coil insulation can cause personal electrical
shock. The correct procedure is to reduce the current, open the controller power
switch, and then make disconnections.

2. Loose parts should be suitably clamped or braced prior to applying fields.

Strong magnetic forces can snap parts together pinching hands and fingers.

Experience has shown that the best results are obtained when the field is
reversed at a frequency of about once per second. Direct current controlled at a
1 reversal per second rate is the best method for demagnetization. With easily
magnetized metals, the demagnetizing force can be reduced in larger steps,
metals that are hard to magnitize take more steps. A rule of thumb is at least 10
reversals are required but not more than 30.

Sometimes rapping the end of the rotor (Face of shaft end – not the shaft
diameter) with a hammer while it is in the magnetic field will demagnetize the
rotor. Do not hit the rotor hard enough to damage it.
Since the earth’s magnetic field runs in a north-south direction placing the de-
magnetizing field in an east-west direction can help, i.e. the coil openings should
be placed in a east-west direction.

Rotors should be demagnetized on wooden supports. The rotor should be raised

off of concrete floors that contain steel reinforcing rods and should be at least 3
feet from steel building columns or other steel parts.

If the rotor is to be suspended during demagnetization use nylon straps.

Turning the rotor in the air can create changes in the magnetic field due to the
Earth’s magnetic filed and nearby structural steel. For consistency taken all
readings with the rotor in the same direction.

The demagnetizing field is made by wrapping many turns of welding lead around
the part. If there are large shoulders or disks the wraps can be made radially
around the part. The correct process is to apply a diminishing DC field with slow
cycling. The first cycle should be in the opposite direction of the field to a
magnitude slightly higher than the original field strength. Each successive cycle
should produce lower peak values and diminishing residual magnetism.

The best results are achieved when each individual component of an assembly is
demagnetized individually before assembly. An example is a compressor rotor.
The bare shaft should be damagnitized and each individual wheel before
assembly.

When the rotor is in the case it is very difficult to demagnetize because it is

difficult to get the demagnetizing field into the center of the rotor. Demagnetizing
requires wrapping many turns of welding cable on the exposed ends of the rotor.
It is also helpful to wrap the frame feet as well. Removing the coupling spacer
spools is needed also.

Do not degauss stationary case parts with the rotor in the case.

FORMULAS FOR DETERMINING PROPER CURRENT VALUES FOR COILS

and the number of Coils can be found in ASTM Documents (ASTM E709
“Standard Guide for Magnetic Particle Examination” & ASTM E1444-01
“Standard Practice for Magnetic Particle Examination”)