11/16/2017 Using wear metals in oil analysis to determine gearbox health

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Using wear metals in oil analysis to determine gearbox health

April 20, 2013 Paul Dvorak : 0 Comments

Ted Vasiliw / Wind Aftermarket Technical Manager / Castrol Industrial / www.castrol.com

A quality used-oil-analysis program is an excellent method to

determine the condition of the oil within the gearbox. We all know
the importance of a lubricant’s ability to reduce friction and wear in
gearbox components, thereby improving the reliability of the entire
wind turbine. However, most drivetrain failures are not lubrication
related. Oil analysis can also be useful in determining the condition,
or health of the gearbox itself. Using oil analysis to determine wear
conditions in the gears or bearings, corrective actions can be taken
Enewsletter
to prevent premature failures. The di erent analysis tools include
spectrographic analysis, PQ Index, and wear particle analysis. Each tells a little something di erent. The Wind Team delivers up to the
news, wind resources, wind produ
Wear metals in oil analysis and more.

Spectrometric analysis methods can determine the elemental

content of oil samples, including wear debris. Typical wear metals
reported may include Iron (Fe), Chromium (Cr), Nickel (Ni), Aluminum
(Al), Lead (Pb), and Copper (Cu).

Spectrographic Analysis shows typical wear metals in an oil analysis Author Ted
report. Fe has higher counts because most everything in a gearbox is Vasiliw
made of steel. The values are in parts per million (PPM).

These magni ed particles are
generated by normal gear-
rubbing wear as seen using
Ferrography.
Wind turbine gear-oil analysis usually requires close monitoring of iron and copper
because these metals are most common. Sources of iron include bearings, shafts, and
gears while copper wear usually originates from bronze alloy bearing cages.

When wear metal levels approach or exceed established limits, additional actions are
required. Such actions can range from inspecting the gearbox and lter, to re-sampling to verify the results. One
sample report provides limited data, so the trending of historical data is best practice for a more complete picture.
Typical wind turbine gearbox wear metal limits for used oil are <70 ppm for Fe and <55 ppm for Cu (with brass bearing
cages).

PQ Index
Wear metal particles detected by spectroscopy are typically less than 5 to 10 microns in size. These small particles can
be generated by rubbing wear or false brinelling (fretting corrosion). Larger particles are generated by more severe
wear modes such as fatigue wear, pitting and spalling, contamination wear, and indentations. These larger ferrous
particles present in the used oil sample can be detected by using the Particle Quantifying, or PQ method. PQ exposes
the sample to a magnetic eld and is reported as a “PQ Wear Index.” The PQ Index gives us a better understanding of
any wear that may be occurring in the gearbox.

The PQ Index is an arbitrary number which can be compared to the Fe ppm from the Spectro Analysis. If the PQ Index
is smaller than the Fe ppm, then it is unlikely that particles larger than 5 microns are present. Alternately, if the PQ
Index increases signi cantly while the Fe ppm remains consistent, then larger ferrous particles are being generated
and further diagnostics should be performed.

Wear particle analysis – Ferrography

Direct-Reading (DR) Ferrography gives a direct measure of wear metals. It also separates large and small ferrous
particles. DR is useful for trending and identifying when accelerated, abnormal wear is occurring.

Analytical Ferrography visually examines ferrous and non-ferrous solid debris present in the oil sample. Under
magni cation, particle size, shape, color, and surface texture are observed and categorized. Particle composition is
broken into categories including: ferrous wear, white non-ferrous, copper, and bers. Further, ferrous particles can be Upcoming Events
identi ed as steel, cast iron, dark oxides, or red oxides (rust). A skilled analyst can also determine if metallic wear
particles are caused by cutting wear versus rolling or sliding wear. WPE
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