Ferrographic & Oil
Analysis
At Vibe Institute
Piedmont Chapter
May 2008

When it comes to your
machinery s life, don t guess


Se t t i n g U p A Pr o g r a m

Set Goals
Equipment Survey
Set Up Equipment Specific Analysis Programs
Train Personnel in Sampling Techniques & Report
Interpretation
Monitor Results & Progress

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machinery s life, don t guess


Motor
Gear

Im balance
Misalignm ent
Bearings (BAD /COCKED)
Bent shaft
Looseness

Cprsr

Ou t-of-rou nd Jou rnal
Gear Problem s
Im p eller Blad e Problem s
Magnetic N oise
Electrical N oise
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machinery s life, don t guess


Parameter

Comment

Size

Indicates condition severity & wear mechanism

Shape

Indicates wear mechanism

Composition

Indicates source of wear debris

Concentration


Indicates condition severity, rate of particle generation and wear
mechanism.

Morphology

Indicates wear mechanisms

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machinery s life, don t guess


Adhesive

Plastic zone
Adhesive transfer
Wear fragments

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machinery s life, don t guess


Wear Particle Analysis Techniques
Technique

Pro s

Con s

Absolute best method to characterize
size shape, morphology, wear

mechanism and concentration. All
suspended debris, size 1 to 350 micron

Requires specialized laboratory
techniques. Cost is less than approx: $35

Direct Reading Analytical Ferrography

Ferrous particles up to 350 microns

Wear trending device, ferrous only.

Filter analysis

All debris, limited by pore size

Subjective, inconsistent

Patch Test

All debris, limited by pore size

Subjective, inconsistent

Cost is approx: $5

Cannot accurately identify particles greater
than
8 micron


Analytical Ferrography

:

Spectrometers

Selecting the correct technique to meet maintenance goals is critical. Over
emphasizing the value of screening or basic elemental analysis techniques
routinely results in missed expectations and increased costs.
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machinery s life, don t guess


Wear debris particles vary in size, composition, type,
morphology and concentration depending on many factors:
Loading
Materials
Wear Mechanism

No two particles are the same and and no single monitoring techniques is
capable of analyzing all particles.
A world class program incorporates specific techniques applicable to the
application.
The true value and ultimate success of an monitoring program is proper
design; applicability to system being monitored, utilizing correct techniques
and knowledgeable personnel.
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machinery s life, don t guess



Sa m p l i n g Po i n t Se l e c t i o n

COMPONENT

SAMPLING
VALVE

CIRCULATING
LUBRICANT

SAMPLE
BOTTLE

FILTER

PUMP

RESERVOIR

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machinery s life, don t guess


L u b r i c a n t Sa m p l i n g Ob j e c t i v e s

1. Determine wear condition of lubricated
surfaces
2. Determine contaminant levels:
Particulates
Water and other fluids

3. Determine lubricant condition
4. Propose accurate maintenance
recommendations

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machinery s life, don t guess


Sa m p l i n g V a l v e s & Po r t s
Effective lubricant
condition programs begin
with a representative
sample.
A -¼ NPT
B -1.52 (38.64mm)
C - 0.63 (16mm)
Hex 0.67 (17mm)
Length of Extender:
12 , 20 , 30
Tube 3/16 OD
Consistent sampling
logistics maximize the
quality of the analysis
and promotes accurate
condition trending.
Internal check valve opens only when the
appropriate fitting with the the sample
tubing is attached, eliminating leakage.

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machinery s life, don t guess


T a k i n g a Sa m p l e

From valves in return line
Place valve as close to pipe as possible
Use as small diameter pipe as possible
Calculate dead volume & flush 2X amount into waste
can
Clean valve spigot before taking sample
Take sample before closing valve & fill bottle only 3/4
full
Send out same day -- don t wait!

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machinery s life, don t guess


Outboard Bearing

Sample Taps

it comes to your
Inboard When
Bearing

machinery s life, don t guess



Sa m p l i n g H a b i t s

Label Sample Point Locations
Mark Sample Bottles Prior to Sampling
Clean Surfaces Prior to Sampling
Drain Stagnant Oil From Valve
Use New, Clean, Plastic Bottles
Use New Sample Tubing
Ship Samples Immediately

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machinery s life, don t guess


Si ze Co m p a r i s o n Ch a r t

From Schroeder Industries
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machinery s life, don t guess


U OA /WPA A n a l y s i s

Used Oil Analysis: Determines the condition of the OIL.
Wear Particle Analysis: determines the condition of the
MACHINE.
This is the critical difference between the two technologies.
Many confuse the two and will generically refer to it as oil
analysis. The difference always needs to be clarified in the
mind of the user in order to create Value.


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machinery s life, don t guess


U OA T e s t s

Oil Bath
RDE Spectrometer
FTIR Spectrometer
Titration
TAN & TBN
Water
Crackle
Karl Fischer
Particle Count

Viscosity
Elemental Concentration
Oxidation, Nitrates, Sulfates,
Water, Fuel, Glycol, Additive
Degradation
Acid & Base Level Trends
Concentrations to 1,000ppm
Concentrations to 10ppm
NAS & ISO Cleanliness Ratings

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machinery s life, don t guess



U s e d Oi l A n a l y s i s
El e m e n t a l A n a l y s i s

Courtesy of Coastal Training

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machinery s life, don t guess


We a r Pa r t i c l e A n a l y s i s U s i n g Fe r r o g r a p h y ,
PQ, T r i b o m e t r i c s , RPD, X -Ra y Fl u o r e s c e ,
Sp e c t r o m e t e r , Co n t a m a l e r t , L a s e r n e t ,
Oi l a n a l y s e r & Pa r t i c l e Co u n t e r

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machinery s life, don t guess


Spectrometer

Oilanalyzer

Lasernet

Particle Counter

Tribometrics
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machinery s life, don t guess



Rotary Particle Depositor

Particle Counter

ContamAlert

PQ Oil Analyzer

X-Ray Fluoresce
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machinery s life, don t guess


A b r a s i v e We a r
Abrasive Wear Effects
Dimensional changes
Leakage
Lower efficiency
Particles = More particles

Flow

Chip/Grit
Too large to enter
clearance

Ultrafines
Too small to

interact with
surfaces
Silt (clearance size) Interacts w/surfaces
When it comes to your
causes abrasive
wear
machinery s life, don t guess

From Leugner, 1989


T h r e e B o d y A b r a s i v e We a r
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
Lubricant Film

Imbedded Particle

Gouged Metal
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machinery s life, don t guess


T h r e e B o d y A b r a s i v e We a r

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We a r Pa r t i c l e A n a l y s i s
A T h r e e St e p Pr o c e s s
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

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machinery s life, don t guess


Particle Detection Sensitivity

NORMAL WEAR REGION

GRAY AREA
INDICATING
CHANGE TO
ABNORMAL
PARTICLES

ABNORMAL WEAR REGION


Wear Debris

Ferrography
Spectrometry
0.1

1

5

10

100

Wear Particle Size (micron)
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machinery s life, don t guess

1000