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OIL WEAR DEBRIS ANALYSIS 
SHIVAJI CHOUDHURY
Lubricant function 
 Primary functions 
 Reduce friction 
 Reduce heat 
 Reduce wear 
 Secondary functions 
 Protect...
Lube oil testing 
Lubricant testing is recommended for the 
following reasons: 
 To study the condition (wear, and so 
on...
LUBRICANT OIL ANALYSIS 
 Moisture. 
 Mechanical Impurities. 
 Density. 
 Viscosity. 
 Acidity. 
 ASTM D 4378-97 is S...
LUB OIL DIAGNOSIS 
 Degradation of lubricant oil. 
 Impurities in lubricant oil. 
 Wear debris in lubricant oil.
Wear Debris Analysis 
 The continuous trending of wear rate 
monitors the performance of machine 
/machine components and...
OBJECTIVE 
 Minimize component wear. 
 Extend equipment life. 
 Ensure lubricant suitability for continued 
use. 
 Mon...
Wear particle analysis 
 Trending ( quantitative) : 
wear particles concentrations to 
identify onset of abnormal wear. 
...
Trending (quantitative) 
Progressive of wear condition
Particle identification 
 Particle classification 
 Particle source 
 Wear rating 
 Particle type (wear mechanism)
Particle classification 
 Ferrous 
 Non ferrous 
 contaminant
Particle source 
 Bearing 
 Gear 
 Seal 
 Interior surface 
 External particulates 
 Chemical corrosion 
 Additive ...
Wear rating 
 Factor determining severity 
1. Size 
2. Shape 
3. Composition 
4. Concentration 
 Machine wear finger pri...
Wear Modes 
1.Abrasive Wear 
2.Adhesive wear (sliding) 
3.Surface fatigue (rolling) 
4.Corrosion fatigue
Wear 
modes 
abrasive Surface 
fatigue adhesive Corrosion 
fatigue 
cutting rubbing 
plowing 
gouging 
broaching 
Break in...
Abrasive wear 
 Rubbing (Break-In) 
Wear (Abrasive Wear) 
It usually results in a 
smoother, low-wearing 
surface 
 Cutt...
Adhesive wear( sliding) 
 During surface 
adhesion, the 
asperities of two 
contacting surfaces 
flatten each other, 
cre...
Surface fatigue (rolling) 
 Rolling surface 
contact produces 
surface fatigue. 
 This type of wear 
typically occurs wi...
Adhesive 
wear 
Abrasive 
wear
Corrosive wear 
 These particles are 
often too small. 
 Due to acidic 
attack on internal 
surface of machine.
Oxide Particles 
 Oxide particles, which are either red 
or black iron oxides, are produced 
from chemical reactions betw...
Shape of Wear particles 
 Cutting Cutting wear particles are abnormal. 
They are generated as a result of one surface 
pe...
Shape of Wear particles 
 Sliding Sliding particles have long 
shape and irregular edge. They are 
smaller than fatigue p...
WEAR DEBRIS 
ANALYSIS & DIAGNOSIS 
 This monitors equipment condition 
and can identify types and possible 
sources of we...
Wear Debris Analysis Technique
P-F Interval 
(Potential Failure vs. Failure) 
Wear 
Started
Technologies for conditioning monitoring
THANKING YOU
Wear debris analysis
Wear debris analysis
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Wear debris analysis

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Wear debris analysis

  1. 1. OIL WEAR DEBRIS ANALYSIS SHIVAJI CHOUDHURY
  2. 2. Lubricant function  Primary functions  Reduce friction  Reduce heat  Reduce wear  Secondary functions  Protect surfaces  Remove contaminants
  3. 3. Lube oil testing Lubricant testing is recommended for the following reasons:  To study the condition (wear, and so on) of the machine being lubricated. If there is a problem with the lubricant, there is a strong possibility that the machine will need maintenance.  To determine if the lubricant is meeting the specifications.
  4. 4. LUBRICANT OIL ANALYSIS  Moisture.  Mechanical Impurities.  Density.  Viscosity.  Acidity.  ASTM D 4378-97 is Standard Practice for In-Service Monitoring of Mineral Turbine Oils for Steam and Gas Turbines.
  5. 5. LUB OIL DIAGNOSIS  Degradation of lubricant oil.  Impurities in lubricant oil.  Wear debris in lubricant oil.
  6. 6. Wear Debris Analysis  The continuous trending of wear rate monitors the performance of machine /machine components and provide early warning and diagnosis.  Oil condition monitoring can sense danger earlier than vibration technique.
  7. 7. OBJECTIVE  Minimize component wear.  Extend equipment life.  Ensure lubricant suitability for continued use.  Monitor viscosity levels for optimum performance.  Reduce unscheduled downtime.  Increase reliability.  Boost company profit.
  8. 8. Wear particle analysis  Trending ( quantitative) : wear particles concentrations to identify onset of abnormal wear.  Particle identification (qualitative ): microscopic analysis to predict source ,cause and scope of wear .
  9. 9. Trending (quantitative) Progressive of wear condition
  10. 10. Particle identification  Particle classification  Particle source  Wear rating  Particle type (wear mechanism)
  11. 11. Particle classification  Ferrous  Non ferrous  contaminant
  12. 12. Particle source  Bearing  Gear  Seal  Interior surface  External particulates  Chemical corrosion  Additive degradation
  13. 13. Wear rating  Factor determining severity 1. Size 2. Shape 3. Composition 4. Concentration  Machine wear finger print each component wear differently
  14. 14. Wear Modes 1.Abrasive Wear 2.Adhesive wear (sliding) 3.Surface fatigue (rolling) 4.Corrosion fatigue
  15. 15. Wear modes abrasive Surface fatigue adhesive Corrosion fatigue cutting rubbing plowing gouging broaching Break in rolling Sliding spalling pitting brinelling chemical galling siezing fretting cavitation
  16. 16. Abrasive wear  Rubbing (Break-In) Wear (Abrasive Wear) It usually results in a smoother, low-wearing surface  Cutting Wear (Abrasive Wear) This wear mode is often compared to machining swarf from a lathe but on a much smaller scale. It indicative of misalignment or presence of abrasive contaminates.
  17. 17. Adhesive wear( sliding)  During surface adhesion, the asperities of two contacting surfaces flatten each other, creating a fracture on one of the surfaces.
  18. 18. Surface fatigue (rolling)  Rolling surface contact produces surface fatigue.  This type of wear typically occurs with components of rolling motion contact, such as in the case of ball bearings.
  19. 19. Adhesive wear Abrasive wear
  20. 20. Corrosive wear  These particles are often too small.  Due to acidic attack on internal surface of machine.
  21. 21. Oxide Particles  Oxide particles, which are either red or black iron oxides, are produced from chemical reactions between iron and oxygen.  Red oxides are an indication of moisture in the system, while black oxides indicate inadequate lubrication and excessive heat generation in the system.
  22. 22. Shape of Wear particles  Cutting Cutting wear particles are abnormal. They are generated as a result of one surface penetrating another.  Fatigue This class contains particles that are formed as an effect of repeated passes through the system which results in plastic deformation of particles. They have a smooth surface and irregularly shaped circumference.
  23. 23. Shape of Wear particles  Sliding Sliding particles have long shape and irregular edge. They are smaller than fatigue particles.  Sphere Spherical particles can be generated if there is insufficient lubrication or there is a depletion of EP additives in high load.
  24. 24. WEAR DEBRIS ANALYSIS & DIAGNOSIS  This monitors equipment condition and can identify types and possible sources of wear and contamination.  It includes a Particle Count or Ferrography  A Particle Count identify all particles present measuring 4 to 100 microns in size.
  25. 25. Wear Debris Analysis Technique
  26. 26. P-F Interval (Potential Failure vs. Failure) Wear Started
  27. 27. Technologies for conditioning monitoring
  28. 28. THANKING YOU

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