Ferrographic oil analysis 05 2008

Ferrographic & Oil Analysis At Vibe Institute Piedmont Chapter May 2008 When it comes to your machinery s life, don t guess 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 When it comes to your machinery s life, don t guess Motor Gear Im balance Misalignm ent Bearings (BAD /COCKED) Bent shaft Looseness Cprsr Ou t-of-rou nd Jou rnal Gear Problem s Im p eller Blad e Problem s Magnetic N oise Electrical N oise 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 Concentration Indicates condition severity, rate of particle generation and wear mechanism Morphology Indicates wear mechanisms When it comes to your machinery s life, don t guess Adhesive Plastic zone Adhesive transfer 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 size shape, morphology, wear mechanism and concentration All suspended debris, size to 350 micron Requires specialized laboratory techniques Cost is less than approx: $35 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 Cost is approx: $5 Cannot accurately identify particles greater than micron Analytical Ferrography : Spectrometers 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 Sa m p l i n g Po i n t Se l e c t i o n COMPONENT SAMPLING VALVE CIRCULATING LUBRICANT SAMPLE BOTTLE FILTER PUMP RESERVOIR When it comes to your machinery s life, don t guess L u b r i c a n t Sa m p l i n g Ob j e c t i v e s Determine wear condition of lubricated surfaces Determine contaminant levels: Particulates Water and other fluids Determine lubricant condition Propose accurate maintenance recommendations When it comes to your machinery s life, don t guess 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 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 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 When it comes to your machinery s life, don t guess Sp h e r e s When it comes to your machinery s life, don t guess B e a r i n g We a r Copper Alloy Steel Prior to Heat Treatment Low Alloy Steel Lead/Tin Babbitt Metal When it comes to your machinery s life, don t guess H e a t T r e a t m e n t Pr o c e d u r e s All slides should be heat treated if large or marginal particles are detected Monitor temperature of hot plate to ensure temperature of 330oC, + or - 10oC Maintain slide on hot plate for at least 90 seconds to ensure saturation of oxide layer growth When it comes to your machinery s life, don t guess L o w A l l o y St e e l Inclusion of small amounts of alloys Blue Color When it comes to your machinery s life, don t guess Cast Iron / Medium Alloy Steel @ 330C Inclusions on the surface Less area for ion formation Less oxide growth When it comes to your machinery s life, don t guess Equipment Condition Report When it comes to your machinery s life, don t guess Equipment Condition Report (cont) When it comes to your machinery s life, don t guess 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 When it comes to your machinery s life, don t guess EM S Pr o d u c t s & Se r v i c e s Laboratory services Refrigerant analysis Vibration analysis Surveys & assessments Sampling ports & kits Id tags Vibration instruments & accessories Collection services Oil safe containers Thermography Ultrasound Integrated reporting When it comes to your machinery s life, don t guess Ca s e St u d i e s When it comes to your machinery s life, don t guess M u l l o r Ge a r c a s e Industry: Steel Foundry COMPONENT: Mullor Gearcase; Model: #85B ANALYSIS: 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 When it comes to your machinery s life, don t guess M o t o r & Pu m p A s s e m b l y Industry: Fossil Pow er Plant COMPONENT: Condensate Vertical Pump ANALYSIS: Unit rated Critical due to fatigue spheres and bearing wear particles composed of high alloy steel Inspection of the bearings recommended RESULT: All bearings checked and revealed spalling of the inner race and rolling elements Savings of over $80,000 occurred due to timely inspection When it comes to your machinery s life, don t guess Pr o g r a m M a n a g e m e n t When it comes to your machinery s life, don t guess 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 When it comes to your machinery s life, don t guess ... your machinery s life, don t guess 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 MACHINE This is the critical... 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 U OA T e s t s Oil Bath... guess Spectrometer Oilanalyzer Lasernet Particle Counter Tribometrics When it comes to your machinery s life, don t guess Rotary Particle Depositor Particle Counter ContamAlert PQ Oil Analyzer X-Ray