Predict Presentation to Piedmont Chapter Vibe Institute - - PowerPoint PPT Presentation

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Predict Presentation to Piedmont Chapter Vibe Institute - - PowerPoint PPT Presentation

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Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings 3/4/2007 1 Topics of Discussion Who is Predict? Ferrography Application Wear Particles Questions and Answers 3/4/2007 2

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3/4/2007 1

Predict

Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

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SLIDE 2

3/4/2007 2

Topics of Discussion

 Who is Predict?  Ferrography  Application  Wear Particles  Questions and Answers

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3/4/2007 3

Lab Service Products

 New & used lubricant & grease testing  Hydraulic fluid testing  Fuels testing  Transformer oil testing  Coolant testing  Wear particle analysis (Ferrography)  Supplies (pumps, oil taps, tubing, etc.)  Training  Program management

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3/4/2007 4

Lab Analysis Reporting Equipment & Lube Condition

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3/4/2007 5

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 Imbedded Particle Gouged Metal

Lubricant Film

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3/4/2007 6

Three Body Abrasive Wear

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3/4/2007 7

Two Body Abrasive Wear

 Due to a misalignment or an asperity of a harder

metal component gouging the opposite rotating softer metal.

Misaligned component Gouged Metal

Lubricant Film

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3/4/2007 8

Two Body Abrasive Wear

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3/4/2007 9

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3/4/2007 10

Air Compressor

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3/4/2007 11

Gear Box

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3/4/2007 12

Power Plant

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3/4/2007 13

Turbine

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3/4/2007 14

Bearing

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3/4/2007 15

Bearing

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3/4/2007 16

Small Bearings

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The Basics of Ferrographic Analysis

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  • 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

Wear Particle Analysis

A Three Step Process

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Density Reading Ferrograph

Quantitative Analysis

 DR Ferrograph

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DR General Acceptance Limits

WEAR PARTICLE CONCEN. ACCEPTANCE LIMITS Vacuum Pumps WPC = 1-5 Boiler Feed Pumps WPC = 1-100 Gas Compressors Turbines Fans WPC = 1-20 Journal Bearings WPC = 1-20 Roller Bearings WPC = 5-100 Engines Transmissions WPC = 10-150 Extruder Gearboxes WPC = 100-600 Dragline Gearboxes Hoist Gearboxes WPC = 1,000-50,000

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Wear Particle Analysis Instruments

Qualitative Analysis

 FM Ferrograph

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Wear Particle Analysis Testing

Ferrogram Maker

Distance in mm EXIT END Non-Wetting Barrier 0.3x60mm Glass Substrate < 0.5mm Ferrous Particles Non-Ferrous Debris

  • 5mm | +5mm

Ferrous Particles S Magnet Pole N Magnet Pole Flux Lines w/Debris Non-Magnetic Barrier, 2.5mm ENTRY POINT

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Wear Particle Analysis Instruments

Qualitative Analysis Qualitative Analysis

  Ferroscope V

Ferroscope V

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Wear Particle Analysis System & Software

Passport System V

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Particle Classifications

 NON-FERROUS - COPPER ALLOYS, ALUMINUM,

BABBITTED METALS, ZINC, CHROME, ETC.

 FERROUS - MAGNETIC, PARAMAGNETIC; Fe, Fe2O3 , Fe3O4 ;

STAINLESS

 CONTAMINANT - FLUIDS; DUST, DIRT, EXTERNAL

PROCESS; MANUFACTURING DEBRIS; FILTER MATERIAL; FRICTION POLYMERS; ORGANIC MATTER

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3/4/2007 26

Types of Particles

 Normal Rubbing Wear  Cutting Wear  Bearing Wear  Severe Sliding Wear  Gear Wear  Nonferrous Wear Particles  Corrosive Wear  Black Oxides  Red Oxides  Fe2O3  Fe2O3  Spheres  Sand & Dirt  Friction Polymers  Contaminant Spheres  Fibers  Evidence of Water

Contamination

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3/4/2007 27

Normal Rubbing Wear Particles

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Cutting Wear

 Indicative of Misalignment or Presence of

Abrasive Contaminants

 Long, Curly Strips of Material  Aspect Ratios Ranging From 5:1 to 50:1

(Length to Width)

 Never Considered Normal

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Cutting Wear Particles

Low Alloy Steel Copper Alloy High Alloy Steel

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Bearing Wear

 Rolling Fatigue Wear  Flat Platelets With

Perforated Surfaces and Irregular Edges

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3/4/2007 31

Bearing Wear Particles

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Severe Sliding Wear

 Excessive Speeds/Loads on

Critical Contacts Within the Equipment

 Typically Rectangular Particles

With Striations Parallel to the Direction of Elongation

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3/4/2007 33

Severe Sliding Wear Particles

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Gear Wear

 Combined Rolling and Sliding Wear  Flat Platelets  Fatigue Spall - Similar to Bearing Wear Debris  Adhesive Wear - May have striations or other

surface features

 Scuffing and Scoring - Similar to Severe Sliding

Wear Debris

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3/4/2007 35

Gear Wear Particles

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Corrosive Wear

 Due to Acidic Attack on the Internal Surfaces of

Equipment

 Small Particles <1 Micron in Size  Align Themselves on the Outer Edges of a

Ferrogram

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3/4/2007 37

Corrosive Wear

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Black Oxides

 Due to High Temperatures at Critical

Contacts Within a Unit

 Black Particles  Align in the Ferrous Strings  Indicative of Boundary Lubrication

Condition

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SLIDE 39

Black Oxides

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Spheres

 Spherical Particles  Usually 5-10 Microns in Size  Indicative of Bearing Fatigue Prior

to a Spalling Condition

 Black Circles with Shiny Centers

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3/4/2007 41

Spheres

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Sand/Dirt Particles

 Contaminants Introduced Through Breather

Elements, Seals, Cylinder Heads, Etc.

 Transparent, Translucent, or Opaque Crystalline

  • r Birefringent Material

 Deposits Over the Length of the Slide 

Easily Seen Under Polarized Light

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Sand and Dirt

UNDER POLARIZED LIGHT

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3/4/2007 44

Sand/Dirt Under Polarized Light

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3/4/2007 45

De Laval Steam Turbine

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3/4/2007 46

Turbine

Journal

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3/4/2007 47

Turbine

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3/4/2007 48

Courtesy of AISE

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3/4/2007 49

Bearings Good/Bad

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3/4/2007 50

Courtesy of AISE

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3/4/2007 51

Turbine Bearings

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3/4/2007 52

Courtesy of AISE

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Heat Treatment Procedures

 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

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3/4/2007 54

Low Alloy Steel

 Inclusion of

small amounts

  • f alloys

 Blue Color

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Inclusions on the surface Less area for ion formation

  • Less oxide growth

Cast Iron / Medium Alloy Steel

@ 330C

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3/4/2007 56

Journal Bearings

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3/4/2007 57

Turbine Bearings

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3/4/2007 58

Journal Bearings

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3/4/2007 59

Bearings

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3/4/2007 60

Spalled Bearing

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What Are The Benefits?

 Reduced Maintenance Costs  Reduced Unscheduled

Downtime

 Improved OEM Warranty

Programs

 Adds Proactive

Maintenance/Root Cause Analysis Capability

 Product Quality Improvements  Improved Plant Safety

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SLIDE 62

World Class Predictive Maintenance Solutions

That Work That Work for YOU!!!! for YOU!!!!