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3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

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Page 1: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 1

PredictPresentation toPiedmont Chapter Vibe InstituteFerrography Analysis onTurbine Bearings

Page 2: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 2

Topics of Discussion

Who is Predict? Ferrography Application Wear Particles Questions and Answers

Page 3: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

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

Page 4: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 4

Lab Analysis ReportingEquipment & Lube Condition

Page 5: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

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 therotating metal separated by the lubricant film.

Metal Component

Imbedded Particle

Gouged Metal

Lubricant Film

Page 6: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 6

Three Body Abrasive Wear

Page 7: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 7

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

Page 8: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 8

Two Body Abrasive Wear

Page 9: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 9

Page 10: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 10

Air Compressor

Page 11: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 11

Gear Box

Page 12: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 12

Power Plant

Page 13: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 13

Turbine

Page 14: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 14

Bearing

Page 15: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 15

Bearing

Page 16: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 16

Small Bearings

Page 17: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

The Basics ofFerrographic Analysis

Page 18: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

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

Page 19: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

Density Reading Ferrograph

Quantitative Analysis DR Ferrograph

Page 20: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

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

Page 21: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

Wear Particle AnalysisInstruments

Qualitative Analysis FM Ferrograph

Page 22: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

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

Page 23: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

Wear Particle AnalysisInstruments

Qualitative AnalysisQualitative Analysis Ferroscope VFerroscope V

Page 24: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

Wear Particle Analysis System &Software

PassportSystem V

Page 25: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

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

Page 26: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

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

Page 27: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 27

Normal Rubbing Wear Particles

Page 28: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

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

Page 29: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

Cutting Wear Particles

Low Alloy Steel Copper Alloy

High Alloy Steel

Page 30: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

Bearing Wear

Rolling Fatigue Wear

Flat Platelets WithPerforated Surfaces andIrregular Edges

Page 31: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 31

Bearing Wear Particles

Page 32: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

Severe Sliding Wear

Excessive Speeds/Loads onCritical Contacts Within theEquipment

Typically Rectangular ParticlesWith Striations Parallel to theDirection of Elongation

Page 33: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 33

Severe Sliding Wear Particles

Page 34: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

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

Page 35: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 35

Gear Wear Particles

Page 36: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

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

Page 37: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 37

Corrosive Wear

Page 38: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

Black Oxides Due to High Temperatures at Critical

Contacts Within a Unit

Black Particles

Align in the Ferrous Strings

Indicative of Boundary LubricationCondition

Page 39: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

Black Oxides

Page 40: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

Spheres

Spherical Particles

Usually 5-10 Microns in Size

Indicative of Bearing Fatigue Priorto a Spalling Condition

Black Circles with Shiny Centers

Page 41: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 41

Spheres

Page 42: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

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

Page 43: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

Sand and Dirt

UNDER POLARIZED LIGHT

Page 44: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 44

Sand/Dirt Under Polarized Light

Page 45: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 45

De Laval Steam Turbine

Page 46: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 46

Turbine

Journal

Page 47: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 47

Turbine

Page 48: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 48

Courtesy of AISE

Page 49: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 49

Bearings Good/Bad

Page 50: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 50

Courtesy of AISE

Page 51: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 51

Turbine Bearings

Page 52: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 52

Courtesy of AISE

Page 53: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

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

Page 54: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 54

Low Alloy Steel

Inclusion ofsmall amountsof alloys

Blue Color

Page 55: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

Inclusions on the surface

Less area for ionformation•Less oxide growth

Cast Iron / Medium Alloy Steel @ 330C

Page 56: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 56

Journal Bearings

Page 57: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 57

Turbine Bearings

Page 58: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 58

Journal Bearings

Page 59: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 59

Bearings

Page 60: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

3/4/2007 60

Spalled Bearing

Page 61: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

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

Page 62: Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation to Piedmont Chapter Vibe Institute Ferrography Analysis on Turbine Bearings

World Class PredictiveMaintenance Solutions

That WorkThat Workfor YOU!!!!for YOU!!!!