Ferrographic & Oil Analysis At Vibe Institute Piedmont Chapter May 2008 When it comes to your machinery s life, don t guess
Set t ing Up A Program Set Goals Equipment Survey Set Up Equipment Specific Analysis Programs Train Personnel in Sampling Techniques & Report Interpretation Monitor Results & Progress When it comes to your machinery s life, don t guess
Motor Gear Cprsr Imbalance Out-of-round Journal Misalignment Gear Problems Bearings (BAD /COCKED) Impeller Blade Problems Bent shaft Magnetic Noise Looseness Electrical Noise When it comes to your machinery s life, don t guess
Parameter Comment Size Indicates condition severity & wear mechanism Shape Indicates wear mechanism Composition Indicates source of wear debris Indicates condition severity, rate of particle generation and we ar Concentration mechanism. Morphology Indicates wear mechanisms When it comes to your machinery s life, don t guess
Adhesive Plastic zone Plastic zone Adhesive transfer Adhesive transfer Wear fragments Wear fragments When it comes to your machinery s life, don t guess
Wear Particle Analysis Techniques Technique Pro s Con s Absolute best method to characterize Requires specialized laboratory size shape, morphology, wear techniques. Cost is less than approx: $35 Analytical Ferrography mechanism and concentration. All suspended debris, size 1 to 350 micron : Direct Reading Analytical Ferrography Ferrous particles up to 350 microns Wear trending device, ferrous only. Filter analysis All debris, limited by pore size Subjective, inconsistent Patch Test All debris, limited by pore size Subjective, inconsistent Spectrometers Cannot accurately identify particles greater than 8 micron Cost is approx: $5 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. When it comes to your machinery s life, don t guess
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. When it comes to your machinery s life, don t guess
Sam pling Point Selec t ion COMPONENT SAMPLING VALVE CIRCULATING SAMPLE LUBRICANT BOTTLE FILTER RESERVOIR PUMP When it comes to your machinery s life, don t guess
Lubric ant Sam pling Objec t ives 1. Determine wear condition of lubricated surfaces 2. Determine contaminant levels: Particulates Water and other fluids 3. Determine lubricant condition 4. Propose accurate maintenance recommendations When it comes to your machinery s life, don t guess
Sam pling Valves & Port s Effective lubricant condition programs begin with a representative sample. 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 Consistent sampling logistics maximize the quality of the analysis and promotes accurate condition trending. Internal check valve opens only when the appropriate fitting with the the sample tubing is attached, eliminating leakage. When it comes to your machinery s life, don t guess
Tak ing a Sam ple 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! When it comes to your machinery s life, don t guess
Outboard Bearing Outboard Bearing Sample Taps Inboard Bearing Inboard Bearing When it comes to your machinery s life, don t guess
Sam pling Habit 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 When it comes to your machinery s life, don t guess
Size Com parison Chart From Schroeder Industries When it comes to your machinery s life, don t guess
UOA/WPA Analysis Used Oil Analysis : Determines the condition of the OIL. Wear Particle Analysis : determines the condition of the MACHINE. 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. When it comes to your machinery s life, don t guess
UOA Test s Viscosity Oil Bath Elemental Concentration RDE Spectrometer FTIR Spectrometer Oxidation, Nitrates, Sulfates, Water, Fuel, Glycol, Additive Degradation Titration Acid & Base Level Trends TAN & TBN Water Concentrations to 1,000ppm Crackle Concentrations to 10ppm Karl Fischer NAS & ISO Cleanliness Ratings Particle Count When it comes to your machinery s life, don t guess
Used Oil Analysis Elem ent al Analysis Courtesy of Coastal Training When it comes to your machinery s life, don t guess
Wear Part ic le Analysis Using Ferrography, PQ, Tribom et ric s, RPD, X-Ray Fluoresc e, Spec t rom et er, Cont am alert , Lasernet , Oilanalyser & Part ic le Count er When it comes to your machinery s life, don t guess
Spectrometer Spectrometer Oilanalyzer Oilanalyzer Lasernet Lasernet Particle Counter Particle Counter Tribometrics Tribometrics When it comes to your machinery s life, don t guess
Rotary Particle Depositor Particle Counter Rotary Particle Depositor Particle Counter ContamAlert ContamAlert PQ Oil Analyzer X- -Ray Fluoresce Ray Fluoresce PQ Oil Analyzer X When it comes to your machinery s life, don t guess
Abrasive Wear Abrasive Wear Effects Dimensional changes Leakage Lower efficiency Particles = More particles Flow Ultrafines Chip/Grit Too small to Too large to enter interact with clearance surfaces Silt (clearance size) Interacts w/surfaces When it comes to your causes abrasive wear machinery s life, don t guess From Leugner, 1989
Three Body Abrasive Wear 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 Lubricant Film Imbedded Particle Gouged Metal When it comes to your machinery s life, don t guess
Three Body Abrasive Wear When it comes to your machinery s life, don t guess
Wear Part ic le Analysis A Three St ep Proc ess 1. TRENDING Wear Particle Concentrations to Identify Onset of Abnormal Wear 2. PARTICLE IDENTIFICATION Microscopic & Analytical Analysis to Determine Origin & Severity 3. INTERPRETATION Analysis of All Data & Recommendations When it comes to your machinery s life, don t guess
Particle Detection Sensitivity GRAY AREA NORMAL WEAR REGION ABNORMAL WEAR REGION INDICATING CHANGE TO ABNORMAL Wear Debris PARTICLES Ferrography Spectrometry 0.1 1 100 5 1000 10 Wear Particle Size ( micro n) Wear Particle Size ( micro n) When it comes to your machinery s life, don t guess
Wear Part ic le Analysis Inst rum ent s Quantitative Analysis DR Ferrograph When it comes to your machinery s life, don t guess
DR Sc hem at ic L READOUT S SIGNAL CONDITIONERS PHOTO DETECTORS CAPILLARY TUBE PRECIP. TUBE FIBER OPTICS MAGNET WASTE LAMP When it comes to your machinery s life, don t guess
Ferrography 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 When it comes to your machinery s life, don t guess
DR General Ac c ept anc e Lim it s WEAR PARTICLE CONCEN. ACCEPTANCE LIMITS Vacuum Pumps WPC = 1-5 Boiler Feed Pumps WPC = 1-100 Gas Compressors WPC = 1-20 Turbines Fans Journal Bearings WPC = 1-20 Roller Bearings WPC = 5-100 Engines WPC = 10-150 Transmissions Extruder Gearboxes WPC = 100-600 Dragline Gearboxes WPC = 1,000-50,000 Hoist Gearboxes When it comes to your machinery s life, don t guess
Air Com pressor When it comes to your machinery s life, don t guess
Dragline, Mining Equipm ent When it comes to your machinery s life, don t guess
Wear Part ic le Analysis Inst rum ent s Qualitative Analysis FM Ferrograph When it comes to your machinery s life, don t guess
Wear Part ic le Analysis Test ing Ferrogram Maker Distance in mm Non - Ferrous Flux Lines w/Debris Debris N Magnet Pole EXIT END Non - Magnetic Barrier, 2.5mm Non - Wetting S Magnet Pole Barrier 0.3x60mm Glass ENTRY POINT < 0.5mm Ferrous - 5mm | +5mm Substrate Particles Ferrous Particles When it comes to your machinery s life, don t guess
Wear Part ic le Analysis Inst rum ent s Qualitative Analysis Qualitative Analysis Ferroscope V Ferroscope V When it comes to your machinery s life, don t guess
Wear Part ic le Analysis Syst em & Soft w are Passport System V When it comes to your machinery s life, don t guess
Recommend
More recommend
