Fault diagnosis through Ferrography (Wear Particle Analysis)

2021 ◽  
pp. 303-322
Author(s):  
Anadi Sinha
Keyword(s):  
Nuclear Power ◽  
Power Plants ◽  
Nuclear Power Plants ◽  
Wear Particle ◽  
Stage Ii ◽  
Lubricating Oil ◽  
Particle Analysis ◽  
Wear Particle Analysis ◽  
Analysis Technique ◽  
Detection And Diagnosis

The purpose of Plant Predictive Maintenance (PDM) programme is to improve Reliability of machineries through early detection and diagnosis of equipment problems, and degradation prior to equipment failure. Ferrography (Wear Particle Analysis) is one of the PDM techniques which allows detection, identification and evaluation of the degradation at the very incipient stage so that degradation is timely attended and mitigatory actions initiated. Ferrography is a Wear Particle Analysis technique based upon systematic collection and analysis of sample of lubricating oil from rotating and reciprocating machines. Ferrography analysis is conducted in 2 phases: Stage I – Quantitative, and Stage II – Qualitative. After Stage II analysis, recommendation is issued based on wear rating (Normal, Marginal, or Critical) so that operator can take timely action. Presently, 21 Nuclear Power Plants are operational in India and Forced Shutdown is a very costly affair. Lube oil of around 60 equipment from Indian Nuclear Power Plants is examined quarterly for Ferrography analysis, and failure of several equipment is avoided due to timely action. This paper will elaborate on the basic principles of Ferrography, and how systematic implementation of Ferrography has helped in avoiding forced failure of equipment, and hence prevent Forced Shutdown.

An Experimental Investigation of Industrial Gearbox Condition Using Wear Particle Analysis Technique

2016 ◽  
Author(s):  
Sayed Y. Akl ◽  
Sherif Abd El-Ghafar ◽  
Hamed Mosleh
Keyword(s):  
Condition Monitoring ◽  
Cost Effective ◽  
Wear Particle ◽  
Morphological Data ◽  
Lubricating Oil ◽  
Particle Analysis ◽  
Limit Values ◽  
Wear Particle Analysis ◽  
Analysis Technique ◽  
Wear Modes

In different lubricated machines as engines and gearboxes, the generated wear particles analysis is considered as an effective tool for condition monitoring of these machines. Wear particle analysis as a nondestructive evaluation technique is an effective method to determine the lubricating oil conditions within different lubricated machines, thus monitoring wear modes and imminent failures in these machines. Machine condition monitoring is a cost-effective and reliable system to predict mechanical behavior and efficiency of power plant systems. Qualitative, quantitative and morphological data could be obtained from the wear particle analysis through the periodically taken samples of the lubricant. Different methods are used to detect and analyze wear debris in the lubricant oil, such as ferrograhy, spectrometry, filtergram, particle counters and recently Laser oil analyzer and time-dependent limits monitor factors. The objective of the present work is to apply wear particle analysis technique for condition monitoring of an industrial gearbox transmission over one year period. This transmission belongs to one of the largest carpet manufacturing plant in the world. The chosen gearbox for condition monitoring was a new gearbox installed to the rug textile machine. The gearbox components are elasto-hydrodynamically lubricated with mineral-based oil. The function of the gearbox is to drive the motion (forward and backward) of the knife to cut the fibbers of the carpet during the operation. Periodic oil samples were taken and analyzed through spectrometric technique while selective samples were chosen to be analyzed through ferrography technique. Spectrometric and ferrographic analysis were used where quantitative and qualitative changes in the concentration and size distribution of different particles were analyzed and compared to baseline and limit values. In addition to the sampling process, the gearbox performance was also monitored through measuring the oil temperature that was recorded just after the oil sample intake. The oil temperature is an indication for the gearbox loading which in its turn indicates any failure if it occurs. Results were analyzed, discussed and correlated to the gearbox performance. Also, recommendations were given for better performance based on the investigation and justification of the relevant results.

Condition Monitoring of a Gear-Box Using Wear Particle Analysis Technique

2015 ◽  
Vol 1125 ◽  
pp. 511-515 ◽  
Author(s):  
Sayed Y. Akl ◽  
Ahmed A. Abdel-Rehim
Keyword(s):  
Condition Monitoring ◽  
Wear Particle ◽  
Complete Information ◽  
Lubricating Oil ◽  
Particle Analysis ◽  
Wear Particle Analysis ◽  
Iron Aluminum ◽  
Analysis Technique ◽  
Gear Box ◽  
Wear Modes

Wear particle analysis as a nondestructive evaluation technique is an effective method to determine the lubricating oil conditions within different lubricated machines, thus monitoring wear modes and imminent failures in these machines, such as gear-boxes and engines. Ferrographic analysis of wear particles in lubricating oil could give complete information about ferrous and non-ferrous solid debris present in the oil sample. Spectrometric oil analysis could give a direct measure of elemental metal content in the oil such as Iron, Aluminum, Lead and Cupper. These techniques provide cheap, fast and easy methods to use predictive maintenance methods which can replace other conventional methods. The objective of the present study is to apply wear particle analysis technique for condition monitoring of an industrial gear-box transmission over two year’s period of time. This gear-box belongs to one of the machines of the Oriental Weavers Company (OWC), one of the largest carpet manufacturers in the world. Spectrometric and ferrographic analysis were used where quantitative and qualitative changes in the concentration and size distribution of different particles were analyzed and compared to baseline values.

Design Strength of Primary Structural Welds in Freestanding Structures

1991 ◽  
Vol 113 (3) ◽  
pp. 471-475
Author(s):  
K. P. Singh ◽  
A. I. Soler ◽  
S. Bhattacharya
Keyword(s):  
Nuclear Power ◽  
Power Plants ◽  
Nuclear Power Plants ◽  
Structural Integrity ◽  
Structural Components ◽  
Rational Analysis ◽  
Free Standing ◽  
Design Strength ◽  
Analysis Technique ◽  
Asme Code

A rational analysis technique to evaluate structural integrity of primary welds in free-standing structures in accordance with the ASME Code is presented. This paper is intended to fill the void in the ASME Code rules for analyzing welds under “faulted” (level D) conditions in nonlinear free-standing structural components used in safety-related applications in nuclear power plants.

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