DALLEY, Stephanie - Yahweh in Hamath in the 8th Century (1990)
Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation...
Transcript of Ray Dalley - Predict - Vibration Dalley - Predict - Turbine... · 3/4/2007 1 Predict Presentation...
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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
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The Basics ofFerrographic Analysis
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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
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Density Reading Ferrograph
Quantitative Analysis DR Ferrograph
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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
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Wear Particle AnalysisInstruments
Qualitative Analysis FM Ferrograph
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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
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Wear Particle AnalysisInstruments
Qualitative AnalysisQualitative Analysis Ferroscope VFerroscope V
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Wear Particle Analysis System &Software
PassportSystem V
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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
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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
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Cutting Wear Particles
Low Alloy Steel Copper Alloy
High Alloy Steel
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Bearing Wear
Rolling Fatigue Wear
Flat Platelets WithPerforated Surfaces andIrregular Edges
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Bearing Wear Particles
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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
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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
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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
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Black Oxides Due to High Temperatures at Critical
Contacts Within a Unit
Black Particles
Align in the Ferrous Strings
Indicative of Boundary LubricationCondition
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Black Oxides
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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
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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
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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
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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
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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
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