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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!!!!