OIL DEBRIS WEAR ANALYSIS IN THERMAL POWER PLANT

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OIL DEBRIS WEAR ANALYSIS IN THERMAL POWER PLANT

OIL DEBRIS WEAR ANALYSIS IN THERMAL POWER PLANT SHIVAJI CHOUDHURY

OBJECTIVE: 

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.

LUBRICANT OIL ANALYSIS: 

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.

LUB OIL DIAGNOSIS: 

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

Wear Debris Analysis: 

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.

Oil Cleanliness Coding ISO 4406 (1999): 

Oil Cleanliness Coding ISO 4406 (1999)

CATEGORIES OF WEAR PARTICLES TYPES: 

CATEGORIES OF WEAR PARTICLES TYPES Normal rubbing wear Cutting wear Bearing wear Severe sliding wear Nonferrous wear particles Corrosives wear Spheres Black oxides contaminants

NORMAL RUBBING WEAR: 

NORMAL RUBBING WEAR Typically ferrous string particles Size less than 10 microns Aligned along to magnetic field The greater the size ,greater the severity

CUTTING WEAR: 

CUTTING WEAR 2 body wear (metal/metal) softer metal is cut. 3 body wear (metal/contaminant/metal) harder metal is cut curls of metal like lathe swarf 5 μm to 5000 μm in size (10-85 μm usual) bad machining, contaminants, misalignment

BEARING WEAR: 

BEARING WEAR Laminar bearing wear particles are flat Caused by high load Usually more than 20 microns

NONFERROUS WEAR PARTICLES: 

NONFERROUS WEAR PARTICLES Copper alloys are yellow Aluminum alloys are white Lead/tin Babbitt is purple when heated

OXIDES: 

OXIDES Red oxides -Orange/red particles indicating water in oil. Black oxides-black particles aligned in ferrous strings caused by high temperatures at contact points

CONTAMINANTS: 

CONTAMINANTS Sand /dust particles Fibers which are long straight or curly transparent particles cause by filter deterioration

CORROSIVE WEAR: 

CORROSIVE WEAR Small particles less than 1 micron Caused by acidic attack on internal surfaces

SPHERES: 

SPHERES Friction melting of other wear particles Small ball-bearing like spheres 5 μm to 30 μm in size (5 - 15 μm usual) Only during periods of extreme friction

Severe Sliding : 

Severe Sliding

Fatigue : 

Fatigue

LUBRICANT OIL in THERMAL POWER PLANT: 

LUBRICANT OIL in THERMAL POWER PLANT TURBINE BEARING LUB OIL BOILER FEED PUMP TURBINE LUB OIL Mill gear box. FAN BEARING LUB OIL PUMP LUB OIL

OIL ANALYSIS REPORT: MILL GEAR BOX-(wear elements in ppm): 

OIL ANALYSIS REPORT: MILL GEAR BOX-( wear elements in ppm) fe -1334 Cr-11 Ni-28 Cu-1755 Sn-178 Zn-37 Al-44 Si-140 Mn-19 misalignment gear assembly

Typical gear tooth contact patterns: 

Typical gear tooth contact patterns aligned misaligned

WEAR DEBRIS ANALYSIS & DIAGNOSIS: 

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.

Wear Debris Analysis Technique: 

Wear Debris Analysis Technique

THANKING YOU: 

THANKING YOU