1. OIL WEAR DEBRIS ANALYSIS
SHIVAJI CHOUDHURY

2. Lubricant function
 Primary functions
 Reduce friction
 Reduce heat
 Reduce wear
 Secondary functions
 Protect surfaces
 Remove contaminants

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. 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. LUB OIL DIAGNOSIS
 Degradation of lubricant oil.
 Impurities in lubricant oil.
 Wear debris in lubricant oil.

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. 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. 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. Trending (quantitative)
Progressive of wear condition

10. Particle identification
 Particle classification
 Particle source
 Wear rating
 Particle type (wear mechanism)

11. Particle classification
 Ferrous
 Non ferrous
 contaminant

12. Particle source
 Bearing
 Gear
 Seal
 Interior surface
 External particulates
 Chemical corrosion
 Additive degradation

13. Wear rating
 Factor determining severity
1. Size
2. Shape
3. Composition
4. Concentration
 Machine wear finger print each
component wear differently

14. Wear Modes
1.Abrasive Wear
2.Adhesive wear (sliding)
3.Surface fatigue (rolling)
4.Corrosion fatigue

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. 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. Adhesive wear( sliding)
 During surface
adhesion, the
asperities of two
contacting surfaces
flatten each other,
creating a fracture
on one of the
surfaces.

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. Adhesive
wear
Abrasive
wear

20. Corrosive wear
 These particles are
often too small.
 Due to acidic
attack on internal
surface of machine.

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.

24. 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.

25. 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.

26. 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.

27. Wear Debris Analysis Technique

28. P-F Interval
(Potential Failure vs. Failure)
Wear
Started

29. Technologies for conditioning monitoring

30. THANKING YOU