Ferrography Presentation
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Naveen ChodagiriFerrography Presentation
Uploaded by
Naveen ChodagiriFERROGRAPHY
Condition Monitoring
through
Oil Analysis
Condition Monitoring Through
Oil Analysis
• Monitoring the Condition Of the Oil
• Monitoring the Debris in the Oil
Oil Analysis
• Viscosity
• Water by Karl Fischer
• TAN/TBN Titration
• FTIR Spectroscopy (Infrared)
• Flash Point
• Fire Point
• Wear metals in ppm
• Particle Counting
• Chip detection Etc.,
Used Oil Analysis
Vs
Ferrography
• Used Oil Analysis Oil Condition
• Ferrography Machine Condition
Effective Range of Particle Detection
NORMAL WEAR REGION ABNORMAL WEAR REGION
Wear Debris
Ferrography
Spectrometry
0.1 1 100 1000
5 10
Wear Particle Size (Micrometers m)
FERROGRAPHY
WEAR PARTICLE ANALYSIS
The Lab
FERROGRAPHY-HISTORY
• Developed in 1971
• Used to monitor U.S military
aircraft,submarines etc.,
FERROGRAPHY
• NON INTRUSIVE EXAMINATION OF THE
OIL WETTED PARTS
• PARTICLES CONTAINED IN THE OIL
CARRY DETAILED INFORMATION ABOUT
THE CONDITION OF THE MACHINE
• PARTICLE CHARECTERISTICS ARE
SPECIFIC TO OPERATING WEAR MODES
The Concept
Every lubricated wear surface generates particles
There is a gradual build up of small particles in a normal system
When abnormal wear begins, there is no sharp instantaneous increase in the
concentration of small particles present in the system
Large particles, however, reach a dynamic equilibrium in a normal system
(filtration)
When abnormal wear begins, there is a dramatic increase in the
concentration of large particles
Therefore, detection, measurement and analysis of these large wear
particles can provide early and accurate information about the condition of
the machine
Wear Particle Analysis
Trending
ANALYSIS
• QUANTITATIVE
• QUALITATIVE
QUANTITATIVE
• DIRECT READING FERROGRAPHY
• DR III
• DL > 5 microns
• DS < 5 microns
• DL+DS = WPC (Wear Particle Concentration)
DR-5 Direct Reading Ferrograph
• Separates wear debris
from lubricant according
to size
• Trends small & large
particles for wear
condition
• DL & DS, 5 micron
breakpoint
QUALITATIVE
• ANALYTICAL FERROGRAPHY
• FM III
• FERROSCOPE
• PASSPORT- DATA MANAGEMENT
FM-IIId Ferrogram Maker
• Makes slides to examine with
Ferroscope
• Particle sorting by size, shape,
concentration & composition
• Ferrous particles align with
magnetic lines of flux
• Analyzed to determine root cause
of the particle formation
Ferrogram principle
Non-Ferrous Distance in mm Flux Lines w/Debris
Debris
N Magnet
EXIT END
Pole
Non-Magnetic
Barrier,
Non-Wetting 2.5mm
Barrier S Magnet
Pole
0.3x60mm ENTRY POINT
< 0.5 µ Ferrous <5µ >5µ
Glass Substrate Particles Ferrous Particles
Particle Classification
• Ferrous
Low alloy,Medium alloy and High alloy
• Non-Ferrous
Copper Alloys, Aluminum alloys, Babbitt
Metals
• Contaminants
Dust, Dirt, External Process, Manufacturing
Debris, Filter Material, Friction Polymers,
Ferroscope 5
• Multiple Objectives
• Two light sources
• Video Camera for computer
screen captures
• Filters to identify Sand/dirt
and red oxides
Trending
Wear Particle Concentrations
WPC=10 WPC=50 WPC=100 WPC=500 WPC=1000
Particles Identified in
Ferrography
Normal Rubbing Wear
Description
- Flat platelets
- Less than 15 microns in
major dimension
Causes
- Normal machine wear
Severe Sliding wear
Description
- Flat elongated particles
with striations
- Greater than 20 microns
in major dimension
Causes
- Excessive load
- Excessive speed
on sliding surface
Gear wear
Description
- Flat striated particles
Causes
- Fatigue
- Scuffing
- Scoring
of gear teeth
Bearing wear
Description
- Laminar platelets
Causes
- Rolling contact failure
Spheres
Description
- Small spheres
- Less than 5 microns in
diameter
Causes
- Early warning of rolling
element bearing failure
Pb/Sn BABBITT
Cutting wear
Description
- Long, curled strips
Causes
- Misalignment
- Abrasive contaminant
in the lubricant
Cutting Wear
Black Oxides
Description
- Black particles aligned
in magnetic field
Causes
- Insufficient
lubrication
Red Oxides
Corrosive Wear
Description
- Heavy concentration
of fine particles at exit
of ferrogram
Causes
- Oil additive depletion
Cast Iron
Copper Alloy Particle
Aluminum Alloy Particle
Pb/Sn BABBITT
Fibers
Sand/Dirt
Friction Polymer
Evaluation
• Wear particle concentration(WPC)
• Size of the particles
• Shape of the particles
• Surface texture
• Concentration and orientation
• Morphology
Severity Ratings
0 45 78 10
NORMAL MARGINAL CRITICAL
Ratings are purely subjective based on
Machine being monitored
Morphology of particles
WPC
Case Study 1
Facility : Power Plant
Equipment : ID Fan Fluid Coupling
• In Sample dated 16/9/01 Cu alloy particles of size ranging up to 400
microns were observed and inspection of the internals was
recommended after analyzing another sample.Samples dated
11/10/01 and 22/12 /01 have shown bearing wear particles along
with Copper alloy particles.
• Inspection was carried out on5/01/02.It was found that output shaft
bearing cage was completely worn out.Coupling was changed.
• Savings : 1.Savings on loss of generation due to downtime itself
was around 9 million units amounting to 90 lakhs approx.
2.Secondary damage to fan and coupling avoided.
Acrobat Document
Acrobat Document
Case study 2
Facility : Power Plant
Equipment : Cooling tower fan Gear box.
• Sample dated 06.09.02,report rated critical
due to the presence of abnormal bearing
wear(fatigue) particles and advised inspection
can be carried out after analyzing another
sample.
• Based on this report Inspection was carrried
out severe fatigue wear found on the outer &
inner race and all rollers of output shaft
bearing.
Acrobat Document
APPLICATION
• Bearings • Steel
• Gear Boxes • Refinery
• Pumps • Cement
• Turbines • Fertilizer
• Engines • Paper
• Compressors • Power Plants
• Earth Moving Equipment • Mining & Quarrying
• Tool room equipment • Tool Room
• Very Large ,Very Slow • Railways/Locos,Road
speed M/c
• Ships Etc.,
BENEFITS
• Ferrography identifies Wear Particles as
well as Contamination
• Hence, Life extension benefits of Pro-
active Maintenance(controlling
contamination etc.,) and early warning
benefits of Predictive Maintenance can
be simultaneously achieved.
CONCLUSION
• Many New Technologies are being invented
and applied for Condition Monitoring of
Equipments
• None is all inclusive,yet each has a valuable
contribution to play.
• Combination Of Technologies helps in finding
a meaningful solution.
• We look for the benefits of the technology
without fulfilling the requirements.
SAMPLING TECHNIQUES
GARBAGE IN,GARBAGE OUT
An analytical report,no matter how
brilliantly written,is worse than
meaningless if the samples taken
are not representative of the
system being monitored
SELECTION OF SAMPLING
POINT
• Sample tap in return line of the last
lubricated component.
• Sample(valve) at about 2/3rd distance
from top in case of reservoirs,tanks.
• In circulating portion of the reservoir at
entry end near mid-height of the
reservoir.
Sampling Point Selection
COMPONENT
. .
SAMPLING
VALVE
CIRCULATING
LUBRICANT SAMPLE
FILTER BOTTLE
PUMP RESERVOIR
SAMPLING CAUTION
• Do not sample more than 15 minutes
after shut down.
• Do not sample down stream of Filter.
• Do not sample at dead areas of the
system.
• Do not sample from top or bottom of the
reservoir.
Sampling from Tanks when
there is no Provision From
Return Line
Sampling from Sump
THANK YOU
