Condition Monitoring

Dr.M.D.Jaybhaye
Associate Professor,
Dept. of Manufacturing Engineering I Industrial Management
College of Engineering Pune

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 Maintenance
 Maintenance has been defined to include ‘all work
undertaken to keep or restore every facility to a specified
acceptable condition’.
 Corrective maintenance has been defined as ‘that
maintenance work which is performed to restore an item to
a satisfactory condition after a failure’.
 Preventive maintenance as ‘that maintenance activity
which is preformed to keep or retain an item to a
satisfactory operational condition’.
 Types of
Maintenance
Maintenance

Corrective Preventive
maintenance maintenance
 Maintenance
 As per the above definition, corrective maintenance seems
synonymous to emergency repair, or at best generally to
breakdown maintenance is concerned.
 The B.S. Glossary of Maintenance Terminology (B.S. 3811,
1964) further defines the following terms:
 Emergency Maintenance: Maintenance work necessitated by
unforeseen breakdown or damage
 Planned Breakdown Maintenance: Maintenance work which
is carried out after a failure, but for which advance provision
has been made in the form of spares materials, labour and
material
 Corrective
Maintenance
Corrective Maintenance

Planned maintenance
Breakdown maintenance

Analysis of Corrective
Planned Breakdown Maintenance Jobs
Emergency recommended through
Repair Breakdown
maintenance preventive maintenance
& condition monitoring
 Preventive
Maintenance
Preventive Maintenance

Periodic Preventive Predictive Preventive

maintenance maintenance

Cleaning, Programmed
Lubricating Replacement of On-line Off-line
and Replacement Critical items ( Dynamic) (Static)
of wearing parts
 Condition Monitoring
• It is meant monitoring regularly a selected parameter of a plant
or machinery or system, vitally linked with its functional life, such
that it is possible to detect its deterioration or malfunctioning
while in service.
• Maintenance system based on condition monitoring deals with
many diagnostic techniques and time series analysis of dynamic
data.
• When monitoring is done on static condition, it is called static
condition monitoring, where non-destructive testing ,
ferrographic analysis etc. are used.
• Vibration monitoring and wear debris analysis by ferrograph can
be done in both static as well as dynamic (on-line) condition.
Monitoring Methods to detect and define machine
problems
 Condition Monitoring

On-line Off-line

Vibration Lubrication Noise &

Visual Sound
Signature Monitoring
Monitoring
Quantum
Infra-red camera for Debris Spectrosco
Temp. Monitoring pic Oil Noise
Analysis
Analysis Meter Leak
(SOAP) Detector
Colour,
Shape & Particles Ferrography
Texture Analyser
WEAR PARTICLE ANALYSIS :
• Defects troubles affecting normal operating of m/c
tools, wear of m/c components.
• Machine lubricating oil contains various metallic wear
particles produced by moving contact between
machine component.
• Machine condition deduced from particles contained
in the lubricating oil, mainly by particle size, shape,
composition, concentration and distribution.
Ferrography
 Ferrography was invented by D.Scott, of the National Engineering
Lab, U.K, in 1970.
 Technique enabling magnetic separation of wear debris from a
lubricant sample flowing down a specially prepared microscopic
slide.
Ferrograph Kit
Ferrograph Kit consists of
 The Direct Reading (DR) Ferrograph
 The Dual Ferrography analyser
 Bichromatic Microscope
The Direct Reading (DR) Ferrograph
 Operating condition of a machine can be determined by
the study of the size of the particles. The entry point of
the oil sample into the ferrogram, here the largest
particles are deposited, and at position 5 mm down the
entry where the smaller particles are deposited are most
sensitive locations for detecting a changing wear
situation.
 The DR ferrograph quantifies particles in these 2 ranges.
 DR ferrograph provides 2 readings which correspond to the
concentration of large and small particles in the sample. Some principles
wear indexes which can be produced from these readings are:
A severity of wear index: If
L – quantum of large particles reading
S – quantum of small particle reading
(L+S)  Concentration
(L-S)  Size distribution and
wear severity Index
(W.S.I) = (L2-S2)
Wear particle concentration (WPC) = (L+S)
Percentage Large = (L / L + S) x 100%
Cumulative plots, e.g.  L,  L +  S, (L+S), (L - S).
An abrupt increase in any of these indexes deserts an abnormal wear mode.
The dual ferrogram analyser:
It is used for making ferrograms which are analysed by
metallurgical microscope.

Bichromatic Microscope:
Microscope section uses both reflected and transmitted light.
Observations can be made under white light and/or under the
influence of filters, mainly red and green.
Green transmitted light forms the base and red reflected light
gives the surface characteristics. Metallic particles can be
detected easily.
Principle uses of white light : Colours are visible.
Cu alloys – appear yellow/reddish brown.
Other free metal particles – appear silvery white.
Heating of Ferrograms:

Ferrous particles – display yellow to blue colour.

Aluminium, Chromium, Silver & titanium – remain

unaffected by heat treatment upto 5500 except for titanium-
tans slightly at 4000 C.

Cu alloys – can be identified without heating as no other

metal except gold shows yellow colour.
 Wear Forms:
Spall particles -due to material removal as a spall or pit opens up.
Spherical particles -roller bearing cracks, cavitation erosion, welding
& grinding. (Lubrication oils contain spherical particles)
Laminar particles – due to passage of a wear particle through a
rolling contact. Increase of laminar bearing fatigue microcracks
leading spalling.
Combined rolling and sliding (Gear System)- pitch line failure/
scuffing/scoring Major dimension to thickness ratio = 9:1 to 10:1
smooth surface & irregular shape.
Severe sliding wear: due to excessive wear surface stresses are
generated due to load/ speed. Shear mixed layer becomes unstable
& large particles break away causing an increase in the wear rate.

Ferrographic indications of wear debris can be recorded as under,

based on ferrographic microstructure showing wear type as well as
classification
Gears in Action
 Spectrometric Oil Analysis Program
(SOAP)
 Spectrometric Oil Analysis Program (SOAP) is a
powerful analytical tool/technique for elemental
analysis of structural metal & other material particles
(up to approximately 5 micron in size) entrained in
machinery Oil Samples.
 Generation of Wear metals & other particles in an
‘Engine-Oil’ system can indicate the changing
conditions of its various parts, like Oil Pump, Gears,
Bearings, & other metallic parts. The various elements
(Metals & Non-Metals) present in the base oil are
identified & measured in parts per million (ppm) by
weight.
 Spectrometric Oil Analysis Program
(SOAP)
 This term is specifically used in the Aviation industry,
& the corresponding term in the Military sector
(especially US Armed Forces) is Jet Oil Analysis
Program (JOAP). Spectrometric or Spectrochemical Oil
analysis was first used on an industrial scale in 1960.
 Analysis is done by the use of Atomic Spectroscopic
methods like Atomic Absorption & Atomic Emission
Spectrometry.
 Spectrometric Oil Analysis Program
(SOAP)
 SOAP is a Proactive Condition Monitoring/Maintenance
tool/technique which helps to assess the relative wear
conditions of the lubricated/Oil-wetted parts on the
basis of the concentration of the Wear particles in the
Used Oil. Besides, it can also indicate the rate of Wear
& its source.
 Hence, it can provide an early warning of Abnormal
Wear occurring (Wear Anomaly), & also about Failure
of any engine component.
 Spectrometric Oil Analysis Program
(SOAP)
 By carrying out analysis of Used Oil (for a particular
machine/engine) at periodical intervals, which is also
called ‘Trend Analysis’, Baseline Data can be recorded
which can be used for addressing problems related to
specific internal engine components based on the
knowledge about the metals used for the construction
of the engine.
 Such an analysis can also be used for comparison
purposes & also to predict ‘Failure’ of a machine.
 Spectrometric Oil Analysis Program
(SOAP)
The main advantages of a well-planned SOAP are:
1. Prevention of Catastrophic Failures which endangers
Safety of personnel,
2. Reduction/Prevention of non-scheduled Downtime,
3. Reduction of expenditure due to repairs,
4. Prolonged Machinery Life,
5. Increase in Efficiency of Machines.
 The basic limitation of a SOAP analysis is its inability to
detect larger particles, especially larger than 10 μm. For
analysis of larger particles, other methods like
‘Ferrography’ have to be used.
 Spectrometric Oil Analysis Program
(SOAP)
The analyzed elements in Lubricating Oil can be
categorized into 3 categories:
 Wear Metals: These originate from Friction & Corrosion of the
engine components, like pistons & bearings. Examples
include Iron, Chromium, Nickel, Aluminium etc. Iron is the
most prominent of all analyzed elements.
 Contamination: Contaminants can come from external
sources, like dirt, leaks, or residual metal pieces. Examples
include Silicon (from Sand) etc.
 Additives: These are added in order to reduce engine wear, &
can be used as detergents, anti-oxidants, & anti-wear agents.
Examples include Phosphorus, Calcium, & Zinc.
Possible Sources of the elements found in Used Oil
analysis:
Element/Elements Possible Source/Sources
Iron (Fe) Shafts, Gears, Piston Rings, Cylinder Walls
Chromium (Cr) Piston Rings, Roller Bearings, Cylinder Walls
Copper (Cu) Bearings, Bushings, Thrust Washers
Aluminium (Al) Pistons, Pumps, Bearings, Thrust Washers
Nickel (Ni) Pumps, Gear Platings, Valves
Tin (Sn) Journal Bearings, Bearing Cages, Solder
Lead (Pb) Anti-Wear Gears, Bearings
Silicon (Si) Dirt, Airborne Dust, Defoamant Additive
Boron (B) Anti-Corrosion in Coolants
Zinc (Zn) Anti-Wear Additive
Calcium (Ca) Detergent Additive, Dispersant Additive
Magnesium (Mg) Coolant Additive
Phosphorus (P) Anti-Wear Additive, Extreme Pressure Gear Additive
Molybdenum (Mo) Extreme Pressure Additive
Sodium (Na) Detergent Additive, Coolant Additive
Titanium (Ti) Alloy in high quality Steel for Gears & Bearings
 Wear particles with their mechanism [2]

Type of Particles Morphology Mechanism

Rubbing Random shape in boundary outline Broken parts of shear mixed layer
with smooth surface

Cutting Long, curved particles Generated due to abrasive wear

Spherical Small ball like structure Generated due to bearing fatigue,

erosion, cavitations

Chunk Chunky particles with one flat/worked Generated due to the combined
surface, while the other three effect of rolling and fatigue
perpendicular dimensions are uneven
and irregular

Laminar Random boundary shape with Formed due to rolling contact

frequently occurring holes between two surfaces

Severe Sliding A surface with scratches presented in Generated by severe sliding wear
parallel grooved sets
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Rubbing Wear Cutting Wear Spherical Wear

Chunk Wear Laminar Wear Severe Sliding Wear

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Wear Particle Analysis

• Wear Particle Analysis deals with analysis of oil, finding properties

of oil, to get a clue of failure mechanism or wear and tear
mechanism of components of machine

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Factors in wear particle analysis:

• Quantity of wear particle being generated (particle concentration and

size distribution )

• Morphology of wear particle (shape, structure)

• Color of wear particle

• Chemical composition of wear particle

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condition monitoring in maintenance

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need for ferrography
• Wear debris analysis is not being used in the industry to its full
potential, it requires human expertise which makes the
assessment subjective in nature

• Existing system of ferrography requires expert advice to detect

wear particles accurately and to study wear particle morphology.
This process is costly and time consuming.

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need for ferrography

• To eliminate the dependency on human expertise there is need to

automate this process by developing an algorithm which can detect
type of wear particle (morphology of wear particle) so that it can
predict the wear trend in selected system, also can suggest
maintenance policy

• The computer image analysis is solution for some of the problems

associated with the conventional techniques.

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methodology
Collection of lubricating oil sample through system under
consideration or industrial case studies (Lubricating oil from gearbox,
engine, compressor)

Wear particle analysis using ferrography

a) Quantitative analysis to find wear severity index and wear particle
concentration using Direct Reading Ferrography (DR Ferrography-
V)
b) Qualitative analysis to find morphology of wear particle using
Analytical Ferrography (Dual Slide Ferrogram Maker- III & Bi-
chromatic Microscope- Olympus BX51)
c) Developing an algorithm to determine area and aspect ratio to
distinguish type of wear particle

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methodology
 Applying fractal analysis to calculate fractal dimension for
profile and edge detection of wear particles

 Developing a methodology which will suggest the condition

based maintenance policy

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Ferrography
• Ferrography is a technique for measuring
wear rate through analysis of contaminants
in lubricating oil

• Ferrography is used to identify abnormal wear

conditions before they become significant enough to
adversely affect component life and to prevent
catastrophic failure of machine or equipment.

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 Direct Reading Ferrography
• Direct reading ferrography is a
machine condition wear monitoring
technique used to provide basic
wear trend

•Quantitative analysis of oil

WPC (Wear Particle Concentration) =

(DL + DS )

PLP (Percentage of Large Particles)=

[(DL )/ (DL + DS ) ]x100%

WI (Wear Severity Index)= [(DL + DS ) x (DL - DS)] =

(DL2 - DS2 )

DL: Reading of large size wear particle

DS : Reading of small size wear particle 50
 Analytical Ferrography
• Analytical Ferrography is used to
examine wear particles present in
a sample

• Qualitative analysis of oil

• This test separates wear particle

from a lubricating oil for
microscopic evaluation to study
wear particle size and shape

• There is no limitation on machine

or lubricant type being monitored

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 Gears Oil Sample Ferrography

Ferrographic
Ferrogram Slide
Analysis: Bichromatic Image
Microscope Processing

Wear Debris Images

Wear Debris Features: Quantity, Wear Characteristics: Severity,

Size, Composition, Morphology Wear Rate, Type, Source
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 Case Study: Gearbox Setup

Gear
Box
Proximity
Motor
Sensor

Base

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Ferrogram slide preparation

Top View of Dual Slide Ferrogram Slide

Ferrogram Maker
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Wear Severity index

Machine 200 Hrs 400 Hrs 600 Hrs 800 Hrs

Running

Large Size 82.5 87.9 144.7 173.6

Particles
Small Size 65.7 71.8 118.3 151.1
Particles
Wear Severity 2489.76 2571.17 6943.20 7305.75
Index

Percentage of 11.33 10.08 10.03 6.92

Large
Particles

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 Particle Concentration
200

180
173.6

160
Particle Concentration 151.1
144.7
140

120 118.3

100 Large Size Par-

87.9 ticles
80 82.5
71.8
60
65.7 Small Size Par-
ticles
40

20

0
200 400 600 800

Machine Running Hours

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 Wear Severity Index
8000

7305.75
7000 6943.2

6000

5000
Wear Severity Index

4000
Wear Severity Index
3000
2571.17

2000 2489.76

1000

0
200 400 600 800

Machine Running Hours

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• Concentration of large size particle and wear severity index
increases drastically after 400hrs of running machine.

• Wear severity index at 800hrs of machine running is 7305.75

• The percentage increase in the large and small size particles for
the last reading of 800hrs of running was 47.52% and 43.48%
respectively compared with initial reading at 200hrs.

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Microscopic images of wear particles

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Area calculation using imageJ
• ImageJ is a Java based image processing software used for area/
perimeter/ angle calculation, image calibration, geometric
transformation like scaling/ rotation.

• ImageJ can display, edit, analyze, process, save and print 8-bit color
and grayscale, 16-bit integer and 32-bit floating point images

• It can read many image file formats, including TIFF, PNG, GIF, JPEG,
BMP, DICOM, and FITS

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Steps for area calculation
Open ImageJ

Open Image which is used to calibrate the scale for

required dimension

Open required image containing wear particle

Convert RGB image to 8-bit image

Smoothen image using smooth option

Adjust threshold value to separate wear

particle from background

Select required wear particle

Calculate area using ROI tool manager

Repeat the process for 3-4 times and take

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average value of area
Original Image 8-Bit image

Threshoulded Image

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Area calculation of cutting particle

Average Area = (83.11 + 80.33 + 79.66 + 81.94)/ 4

= 81.26 micron2

Average Perimeter = (135.67 + 133.39 + 132.83 + 134.71)/ 4

= 134.15 micron

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Area calculation for overlapped wear particle

• If two or more types of wear particles overlapped with each

other, during threshoulding required wear particle get mixed with
background therefore, it is difficult to calculate accurate area of
individual particle

• The required particle is selected using freehand selection tool,

then area is calculated using ROI tool manager

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 Original Image 8-Bit Image

Freehand Selection Tool Threshoulding issue for Overlapped 65

particle
Area calculation for Red Oxide

Average Area = (1327.01 + 1291.04 + 1277.26 + 1289.15)/ 4

= 1296.115 micron2

Average Perimeter = (204.56 + 199.03 + 197.00 + 197.67)/ 4

= 199.565 micron

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CONCLUSIONS
• Quantitative analysis using Direct reading ferrography gives wear
severity index

• Qualitative analysis using Analytical ferrography shows presence

of Sliding, rubbing and cutting wear particles.

• Area and perimeter for irregular shaped wear particles were

calculated using ImageJ software.

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 References
1. D. Scott, V. C. Westcott, Predictive Maintenance by Ferrography, Wear, Volume
44, (1977) 173-182
2. G.J. Wright, M.J. Neale, Wear-Debris Analysis as an Integral Component of
Machinery Condition Monitoring, Journal of The South African Institute of
Mining And Metallurgy, Volume 87, Issue No. 8, (1987) 253-260
3. L.V. Morkova, N.K Myshkin, H. Kong, M.S Semenyuk, Optical Ferroanalyzer and
its Application to Wear Monitoring in Tribosystem, Journal of Friction and Wear,
Volume 22, (2001) 47-54
4. B.J. Roylance, Ferrography- Then and Now, Tribology International, Volume 38,
(2005) 857-862
5. N Govindarajan, R Gnanamoorthy, Ferrography- A procedure for Measuring
Wear Rate, International Journal of Engineering and Material Sciences, Volume
15, (2007) 377-381
6. Tonggang Liu, Xiaohang Tang, Zhiyi Yang, The Theory of Debris Group in
Ferrographic Analysis, Proceedings of CIST, (2008) 361-365
7. O. Levi, N. Eliaz, Failure Analysis and Condition Monitoring of an Open-Loop Oil
System using Ferrography, Springer- Tribology Letter, Volume 36, (2009) 17-29
.

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