Ferrographic oil analysis 05 2008

Indicates condition severity, rate of particle generation and wear mechanism... Con s Pro s Technique Subjective, inconsistent All debris, limited by pore size Filter analysis Wear trend

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Ferrographic & Oil

Analysis

At Vibe Institute

Piedmont Chapter

May 2008

Se t t i n g U p A Pr o g r a m

Set Goals

Equipment Survey

Set Up Equipment Specific Analysis Programs

Train Personnel in Sampling Techniques & Report Interpretation

Monitor Results & Progress

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Indicates condition severity, rate of particle generation and wear mechanism

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Adhesive

Plastic zone

Adhesive transfer

Wear fragments

Con s Pro s

Technique

Subjective, inconsistent All debris, limited by pore size

Filter analysis

Wear trending device, ferrous only.

Ferrous particles up to 350 microns Direct Reading Analytical Ferrography

Cannot accurately identify particles greater than 8 micron

Cost is approx: $5 Spectrometers

Subjective, inconsistent All debris, limited by pore size

mechanism and concentration All

suspended debris, size 1 to 350 micron

Analytical Ferrography

Wear Particle Analysis Techniques

Selecting the correct technique to meet maintenance goals is critical Over emphasizing the value of screening or basic elemental analysis techniques

routinely results in missed expectations and increased costs

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Wear debris particles vary in size, composition, type,

morphology and concentration depending on many factors:

Loading Materials Wear Mechanism

No two particles are the same and and no single monitoring techniques is capable of analyzing all particles.

A world class program incorporates specific techniques applicable to the

application.

The true value and ultimate success of an monitoring program is proper

design; applicability to system being monitored, utilizing correct techniques and knowledgeable personnel.

SAMPLE BOTTLE

CIRCULATING LUBRICANT

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3 Determine lubricant condition

4 Propose accurate maintenance

recommendations

Sa m p l i n g V a l v e s & Po r t s

Effective lubricant condition programs begin with a representative

sample

Consistent sampling logistics maximize the quality of the analysis and promotes accurate condition trending.

A -¼ NPT

B -1.52 (38.64mm)

C - 0.63 (16mm) Hex 0.67 (17mm) Length of Extender:

12 , 20 , 30 Tube 3/16 OD

Internal check valve opens only when the appropriate fitting with the the sample tubing is attached, eliminating leakage.

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T a k i n g a Sa m p l e

From valves in return line

Place valve as close to pipe as possible

Use as small diameter pipe as possible

Calculate dead volume & flush 2X amount into waste can

Clean valve spigot before taking sample

Take sample before closing valve & fill bottle only 3/4 full

Send out same day don t wait!

Outboard Bearing

Sample Taps

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Sa m p l i n g H a b i t s

Label Sample Point Locations

Mark Sample Bottles Prior to Sampling

Clean Surfaces Prior to Sampling

Drain Stagnant Oil From Valve

Use New, Clean, Plastic Bottles

Use New Sample Tubing

Ship Samples Immediately

Si ze Co m p a r i s o n Ch a r t

From Schroeder Industries

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U OA / WPA A n a l y s i s

Used Oil Analysis : Determines the condition of the OIL

Wear Particle Analysis : determines the condition of the

This is the critical difference between the two technologies Many confuse the two and will generically refer to it as oil analysis The difference always needs to be clarified in the mind of the user in order to create Value.

Acid & Base Level Trends

Concentrations to 1,000ppm Concentrations to 10ppm NAS & ISO Cleanliness Ratings

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El e m e n t a l A n a l y s i s

U s e d Oi l A n a l y s i s

Courtesy of Coastal Training

We a r Pa r t i c l e A n a l y s i s U s i n g Fe r r o g r a p h y ,

PQ, T r i b o m e t r i c s , RPD, X -Ra y Fl u o r e s c e ,

Sp e c t r o m e t e r , Co n t a m a l e r t , L a s e r n e t ,

Oi l a n a l y s e r & Pa r t i c l e Co u n t e r

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Rotary Particle Depositor

ContamAlert

Particle Counter

When it comes to your machinery s life, don t guess

Silt (clearance size) Interacts w/surfaces causes abrasive wear

T h r e e B o d y A b r a s i v e We a r

Due to foreign particles in the oil.

The harder dirt particle imbeds itself in a softer metal and gouges the metal away from the rotating metal separated

by the lubricant film.

Metal Component

Imbedded Particle

Gouged Metal

Lubricant Film

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T h r e e B o d y A b r a s i v e We a r

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Wear Particle Size ( micro n)

ABNORMAL WEAR REGION NORMAL WEAR REGION

We a r Pa r t i c l e A n a l y s i s I n s t r u m e n t s

Q uantitativ e Analysis

D R Ferrograph

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DR Sc h e m a t i c

READOUT

SIGNAL CONDITIONERS PHOTO DETECTORS

PRECIP TUBE

WASTE MAGNET

LAMP FIBER OPTICS

CAPILLARY TUBE

L

S

Direct Reading Ferrograph

Produces two numbers DL and DS

Trends data to identify the onset of abnormal wear

Sensitive to ferrous particles only

WPC = DL + DS

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A i r Co m p r e s s o r

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Dr a g l i n e , M i n i n g Eq u i p m e n t

We a r Pa r t i c l e A n a l y s i s I n s t r u m e n t s

Q ualitativ e Analysis

FM Ferrograph

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S Magnet Pole

N Magnet Pole Flux Lines w/Debris

Non-Magnetic Barrier, 2.5mm

ENTRY POINT

We a r Pa r t i c l e A n a l y s i s I n s t r u m e n t s

Q ualitativ e Analysis

Ferroscope V

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We a r Pa r t i c l e A n a l y s i s Sy s t e m & So f t w a r e

Passport System V

Dirt Fibers Contaminant Spheres

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M a t c h i n g DR Re s u l t s

Results may not correspond in the case of

massive water contamination

A n a l y t i c a l Fe r r o g r a p h y

Courtesy of Coastal Training

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Black Oxides

Lubricant Starvation

Looking for a predominance and an increase from the previous

sample in one of these types of debris

Pa r t i c l e I d e n t i f i c a t i o n

Normal Rubbing Wear

Cutting Wear

Bearing Wear

Long curly strips

Chains of small particles

aligned with magnetic field

Platelets with irregular edges

Gear Wear

Scuffing & Scoring

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Lead/Tin Babbitt

White in color Turns blue/purple when heated

B l a c k Ox i d e s

Optical 1000X

Black Oxides

Magnetic Strings

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B l a c k Ox i d e s

CRACK PROPAGATION

FATIGUE

CYCLING

SURFACE FAILS, PARTICLES RELEASED

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Re d Ox i d e s

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Sp h e r e s

Spherical Particles

Usually 5-10 Microns in Size

Indicative of Bearing Fatigue Prior to a Spalling Condition

Black Circles with Shiny Centers

Sp h e r e s

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B e a r i n g We a r

Low Alloy Steel

Steel Prior to Heat Treatment Lead/Tin Babbitt Metal

Copper Alloy

Maintain slide on hot plate for at least 90

seconds to ensure saturation of oxide layer growth

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L o w A l l o y St e e l

Inclusion of small

amounts of alloys

Blue Color

Inclusions on the surface

Less area for ion formation

Less oxide growth

Cast Iron / Medium Alloy Steel

@ 330C

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Equipment Condition Report

Equipment Condition Report

(cont)

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L a b A n a l y s i s Re p o r t i n g

Eq u i p m e n t & L u b e Co n d i t i o n

Laboratory services

Refrigerant analysis

Vibration analysis

Surveys & assessments

Sampling ports & kits

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Ca s e St u d i e s

Critically high wear rate.

Large quantities of copper alloy & low alloy gear wear particles particles ranging up to 130 microns in size.

RESULT:

Inspection revealed pinion gear

disintegrated.

Gearbox was replaced

$10,000 Savings for replacement

Unscheduled downtime was

estimated at $50,000 per day.

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RESULT:

All bearings checked and revealed spalling of the inner race and rolling elements.

Savings of over $80,000 occurred due to timely inspection

Pr o g r a m M a n a g e m e n t

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Wo r l d Cl a s s Pr e d i c t i v e M a i n t e n a n c e

So l u t i o n s