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Slide 1: OIL DEBRIS WEAR ANALYSIS IN THERMAL POWER PLANT SHIVAJI CHOUDHURY
Slide 2: 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.
Slide 3: 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.
Slide 4: LUB OIL DIAGNOSIS    Degradation of lubricant oil. Impurities in lubricant oil. Wear debris in lubricant oil.
Slide 5: 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.
Slide 6: Oil Cleanliness Coding ISO 4406 (1999)
Slide 7: CATEGORIES OF WEAR PARTICLES TYPES          Normal rubbing wear Cutting wear Bearing wear Severe sliding wear Nonferrous wear particles Corrosives wear Spheres Black oxides contaminants
Slide 8: NORMAL RUBBING WEAR     Typically ferrous string particles Size less than 10 microns Aligned along to magnetic field The greater the size ,greater the severity
Slide 9: 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
Slide 10: BEARING WEAR    Laminar bearing wear particles are flat Caused by high load Usually more than 20 microns
Slide 11: NONFERROUS WEAR PARTICLES    Copper alloys are yellow Aluminum alloys are white Lead/tin Babbitt is purple when heated
Slide 12: 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
Slide 13: CONTAMINANTS   Sand /dust particles Fibers which are long straight or curly transparent particles cause by filter deterioration
Slide 14: CORROSIVE WEAR   Small particles less than 1 micron Caused by acidic attack on internal surfaces
Slide 15: 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
Slide 16: LUBRICANT OIL THERMAL POWER PLANT      TURBINE BEARING LUB OIL BOILER FEED PUMP TURBINE LUB OIL Mill gear box. FAN BEARING LUB OIL PUMP LUB OIL
Slide 17: 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
Slide 18: 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.
Slide 19: Wear Debris Analysis Technique
Slide 20: THANKING YOU