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3/4/2007 1
PredictPresentation toPiedmont Chapter Vibe InstituteFerrography Analysis onTurbine Bearings
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Topics of Discussion
Who is Predict? Ferrography Application Wear Particles Questions and Answers
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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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Lab Analysis ReportingEquipment & Lube Condition
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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 therotating metal separated by the lubricant film.
Metal Component
Imbedded Particle
Gouged Metal
Lubricant Film
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Three Body Abrasive Wear
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Two Body Abrasive Wear
Due to a misalignment or an asperity of a hardermetal component gouging the opposite rotatingsofter metal.
Misalignedcomponent
Gouged Metal
Lubricant Film
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Two Body Abrasive Wear
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Air Compressor
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Gear Box
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Power Plant
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Turbine
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Bearing
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Bearing
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Small Bearings
The Basics ofFerrographic Analysis
1. TRENDINGWear Particle Concentrations toIdentify Onset of Abnormal Wear
2. PARTICLE IDENTIFICATIONMicroscopic & Analytical Analysis toDetermine Origin & Severity
3. INTERPRETATIONAnalysis of All Data &Recommendations
Wear Particle AnalysisA Three Step Process
Density Reading Ferrograph
Quantitative Analysis DR Ferrograph
DR General Acceptance LimitsWEAR PARTICLE CONCEN. ACCEPTANCE LIMITS
Vacuum Pumps WPC = 1-5Boiler Feed Pumps WPC = 1-100Gas CompressorsTurbinesFans
WPC = 1-20
Journal Bearings WPC = 1-20Roller Bearings WPC = 5-100EnginesTransmissions
WPC = 10-150
Extruder Gearboxes WPC = 100-600Dragline GearboxesHoist Gearboxes
WPC = 1,000-50,000
Wear Particle AnalysisInstruments
Qualitative Analysis FM Ferrograph
Wear Particle Analysis Testing
Ferrogram MakerDistance in mm
EXIT END
Non-WettingBarrier
0.3x60mm GlassSubstrate
< 0.5mm FerrousParticles
Non-FerrousDebris
-5mm | +5mmFerrous Particles
S Magnet Pole
N Magnet Pole
Flux Lines w/Debris
Non-MagneticBarrier, 2.5mm
ENTRY POINT
Wear Particle AnalysisInstruments
Qualitative AnalysisQualitative Analysis Ferroscope VFerroscope V
Wear Particle Analysis System &Software
PassportSystem V
Particle Classifications NON-FERROUS - COPPER ALLOYS, ALUMINUM,
BABBITTED METALS, ZINC, CHROME, ETC.
FERROUS - MAGNETIC, PARAMAGNETIC; Fe, Fe2O3 , Fe3O4 ;STAINLESS
CONTAMINANT - FLUIDS; DUST, DIRT, EXTERNALPROCESS; MANUFACTURING DEBRIS; FILTER MATERIAL;FRICTION POLYMERS; ORGANIC MATTER
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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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Normal Rubbing Wear Particles
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
Cutting Wear Particles
Low Alloy Steel Copper Alloy
High Alloy Steel
Bearing Wear
Rolling Fatigue Wear
Flat Platelets WithPerforated Surfaces andIrregular Edges
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Bearing Wear Particles
Severe Sliding Wear
Excessive Speeds/Loads onCritical Contacts Within theEquipment
Typically Rectangular ParticlesWith Striations Parallel to theDirection of Elongation
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Severe Sliding Wear Particles
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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Gear Wear Particles
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 aFerrogram
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Corrosive Wear
Black Oxides Due to High Temperatures at Critical
Contacts Within a Unit
Black Particles
Align in the Ferrous Strings
Indicative of Boundary LubricationCondition
Black Oxides
Spheres
Spherical Particles
Usually 5-10 Microns in Size
Indicative of Bearing Fatigue Priorto a Spalling Condition
Black Circles with Shiny Centers
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Spheres
Sand/Dirt Particles
Contaminants Introduced Through BreatherElements, Seals, Cylinder Heads, Etc.
Transparent, Translucent, or Opaque Crystallineor Birefringent Material
Deposits Over the Length of the Slide
Easily Seen Under Polarized Light
Sand and Dirt
UNDER POLARIZED LIGHT
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Sand/Dirt Under Polarized Light
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De Laval Steam Turbine
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Turbine
Journal
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Turbine
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Courtesy of AISE
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Bearings Good/Bad
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Courtesy of AISE
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Turbine Bearings
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Courtesy of AISE
Heat Treatment Procedures
All slides should be heat treatedif large or marginal particles aredetected
Monitor temperature of hot plateto ensure temperature of 330oC,+ or - 10oC
Maintain slide on hot plate for atleast 90 seconds to ensuresaturation of oxide layer growth
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Low Alloy Steel
Inclusion ofsmall amountsof alloys
Blue Color
Inclusions on the surface
Less area for ionformation•Less oxide growth
Cast Iron / Medium Alloy Steel @ 330C
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Journal Bearings
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Turbine Bearings
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Journal Bearings
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Bearings
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Spalled Bearing
What Are The Benefits? Reduced Maintenance Costs Reduced Unscheduled
Downtime Improved OEM Warranty
Programs Adds Proactive
Maintenance/Root CauseAnalysis Capability
Product Quality Improvements Improved Plant Safety
World Class PredictiveMaintenance Solutions
That WorkThat Workfor YOU!!!!for YOU!!!!
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