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Condition monitoring for Off-shore tribology
Laboratory Soete
Department of Mechanical construction and production
Ghent University, Belgium
J Sukumaran- Materials meeting, 13th November 2013
Prof. Patrick De Baets
Ir. Jacob Sukumaran
J Sukumaran- Materials meeting, 13th November 2013
Condition monitoring Offshore tribology
• Application areas
• Critical components
• Failure mode
• Standards
• What is needed
• How it is done
• Where are we?
• Procedure
J Sukumaran- Materials meeting, 13th November 2013 3
Tribology in offshore applications
• Offshore drilling
• Deep sea mining
• Offshore power plants
• Tidel plants
• Hydel plants
• Wind turbines
• Dredging
• Marine engineering
J Sukumaran- Materials meeting, 13th November 2013 4
Operating Ring Wear Pads
Seals
Wicket Gate Thrust Bearings
Butterfly Valve Seals
Trunnion Bearings
Screen Bearings and Wear Pads
Pump Shaft Bearings
Control Gate Bearings
Dry-installed dredge pumps
Kaplan Turbine Runner Blade Stem Seals
Kaplan Blade Bushings
Head Gate Bearing Rollers
Thrust Cap Washers
Submersible dredge pumps
• Jet nozzle
• Wearing pads
• Drag head
• Drag pump casing
• Drag pump impeller
• Drag pipe
• Drag head tooth
• Clam shell bucket
• Clam shell bucket tooth
• Dredge valves
• Trailing pipe
• Chisels
• Pick points
• Bilge-water pumps
• Impeller steady bearing
• Vertical turbine pumps
• Guide bearings
• Aerators
• Classifiers
• Vertical sump pumps
• Vertical bowl pumps
• Cutlass bearing
• Stern tube seal
• Stern slide bearing
• Sliding bush
• Waste water pumps/drainage pumps
• hot water pumps
• water jet pumps
Segregation for characterization
J Sukumaran- Materials meeting, 13th November 2013 5
Operating Ring Wear Pads
Seals
Wicket Gate Thrust Bearings
Butterfly Valve Seals
Trunnion Bearings
Screen Bearings and Wear Pads
Pump Shaft Bearings
Control Gate Bearings
Dry-installed dredge pumps
Kaplan Turbine Runner Blade Stem Seals
Kaplan Blade Bushings
Head Gate Bearing Rollers
Thrust Cap Washers
Submersible dredge pumps
• Jet nozzle
• Wearing pads
• Drag head
• Drag pump casing
• Drag pump impeller
• Drag pipe
• Drag head tooth
• Clam shell bucket
• Clam shell bucket tooth
• Dredge valves
• Trailing pipe
• Chisels
• Pick points
• Bilge-water pumps
• Impeller steady bearing
• Vertical turbine pumps
• Guide bearings
• Aerators
• Classifiers
• Vertical sump pumps
• Vertical bowl pumps
• Cutlass bearing
• Stern tube seal
• Stern slide bearing
• Sliding bush
• Waste water pumps/drainage pumps
• hot water pumps
• water jet pumps
Material removal
Material handling
Lubricated systems
3 Main categories
J Sukumaran- Materials meeting, 13th November 2013 6
Components subjected to damage in offshore tribology
• Mud pump
• Sub sea lift
pumps
• Wear pads
Material removal Material handling Lubricated
systems Bearings
• Rudder
• Propeller shaft
• Strut
• Guide
• Drills
• Tooth
J Sukumaran- Materials meeting, 13th November 2013 7
Tribology in offshore applications
Mode
Application
Focus
Offshore tribology
Wear
Material removal
Rigid interaction
Material handling
Free floating
Wear & Friction
Lubricated systems
Water lubrication
J Sukumaran- Materials meeting, 13th November 2013 8
Failure mode: Abrasive wear
Abrasion
Two body Abrasion
Three body Abrasion
Open two body
Closed Two body
Open three body
Closed three body
Material removal
& Lubricated
systems (LS)
Material handling
Material removal
J Sukumaran- Materials meeting, 13th November 2013 9
Abrasive wear: Applications
Drilling
Free-flow Dredging
Abrasion
Two body Abrasion
Three body Abrasion
Open two body
Closed two body
Open three body
Closed three body
Crushing
J Sukumaran- Materials meeting, 13th November 2013 10
Drilling
Abrasion
Three body Abrasion
Closed three body
Impact abrasion
Oil sands Jaw crushers
Abrasive wear: Applications
J Sukumaran- Materials meeting, 13th November 2013 11
Abrasive wear: offshore tribology
Drilling
Abrasion
Two body Abrasion
Three body Abrasion
Particle abrasion
High stress abrasion
Low stress abrasion
Material removal
Material removal & (LS)
Material handling
J Sukumaran- Materials meeting, 13th November 2013 12
Drilling
Material handling
Material removal & (LS)
Material removal
ASTM G 65 ASTM G105
ASTM G132 ASTM G6
ASTM G75
Abrasive wear: offshore tribology ̴Test standards
J Sukumaran- Materials meeting, 13th November 2013 13
Drilling
Abrasion
Two body Abrasion
Three body Abrasion
Material handling
Material removal & LS
Material removal
ASTM G 65 ASTM G105
ASTM G132 ASTM G6
ASTM G75
Abrasive wear: offshore tribology ̴Test standards
Slurry
Specimen
J Sukumaran- Materials meeting, 13th November 2013 14
Drilling
Abrasion
Two body Abrasion
Three body Abrasion
Material handling
Material removal & LS
Material removal
ASTM G 65
ASTM G 105
ASTM G132 ASTM G6
ASTM G75
Impact abrasion
Bearing tester Scratch testing
Slurry pot Customized
Standards
Abrasive wear: offshore tribology ̴Test standards
J Sukumaran- Materials meeting, 13th November 2013
Mechanisms and its connection
Wear analysis for engineers – Raymond G Bayer
-7 -5 -3 -1 1 3 5 7
Thermal wear
Tribo-film
Chemical wear
Mild-repeated cycle
deformation
Severe-repeated cycle
deformation
Mild-abrasion
Severe abrasion
Mild adhesive
Severe adhesive
10-7 10-2 10-1 10-00 10-5 10-4 10-3 10-6
Normalized wear rate
J Sukumaran- Materials meeting, 13th November 2013 16
Why condition monitoring?
• What is critical?
• What is essential?
Benefits
• Cost reduction
• Efficient maintenance plan
• Prolonged service life of equipment
• Calendar based maintenance
• Condition based maintenance
J Sukumaran- Materials meeting, 13th November 2013 17
Condition monitoring: How it’s done?
Depends on the industry
• Route-Based Monitoring
• Portable Machine Diagnostics
• Online Machine Monitoring
Always safety critical element has first priority
Measurements Fault identification Corrective measures
• Over load
• Misalignment
• Insufficient lubrication
• Failed component
• Temperature
• Vibration
• Displacement
• Grease
• Realignment
• Structural integrity
J Sukumaran- Materials meeting, 13th November 2013 18
Typical wear curve
Time
Wear
Run-in Steady stage
Base line information are generally taken here
Baseline information on wear has to be in the severe regime
Condition monitoring here
Beginning of deterioration
J Sukumaran- Materials meeting, 13th November 2013 19
months weeks days
System shutdown
Beginning of deterioration
Vibration
Noise
Smoke
Heat
Mac
hin
e o
r eq
uip
me
nt
con
dit
ion
The machine condition
J Sukumaran- Materials meeting, 13th November 2013 20
months weeks days
System shutdown
Beginning of deterioration
Vibration
Noise
Smoke
Heat
Mac
hin
e o
r eq
uip
me
nt
con
dit
ion
The machine condition: Where are we?
Predictive domain or
Fault domain
J Sukumaran- Materials meeting, 13th November 2013 21
months weeks days
System shutdown
Beginning of deterioration
Vibration
Noise
Smoke
Heat
Mac
hin
e o
r eq
uip
me
nt
con
dit
ion
Accelerometer Proximity probes Gap sensors
RTD or Thermocouple
The machine condition: Sensors
J Sukumaran- Materials meeting, 13th November 2013 22
months weeks days
System shutdown
Beginning of deterioration
Vibration
Noise
Smoke
Heat
Mac
hin
e o
r eq
uip
me
nt
con
dit
ion
The machine condition @ Laboratory scale
Industrial regime
Laboratory regime
J Sukumaran- Materials meeting, 13th November 2013 23
months weeks days
System shutdown
Beginning of deterioration
Vibration
Noise
Smoke
Heat
Mac
hin
e o
r eq
uip
me
nt
con
dit
ion
The machine condition: Offshore tribology
J Sukumaran- Materials meeting, 13th November 2013 24
What has to be done ?
What is the dominant parameter ?
Displacement / temperature / noise / smoke / surface change
Large scale tribo-testing
Signal processing
• Corrosion + Wear, contribution is from the synergetic effects
• Study individual effects and % contribution to the total wear
• A database of built up parameters
J Sukumaran- Materials meeting, 13th November 2013 25
Tribology in Labo soete [ ]
Despite of extensive time consumption, the wear data obtained form real scale
testing is rather exiguous for condition monitoring.
J Sukumaran- Materials meeting, 13th November 2013
Testrigs in Laboratory Soete
Radial bearings
Test scale [-]
Test
sta
nd
ard
[-]
Large Small Medium
Normal force 1350 kN Bearing Torque 100
kNm Velocity 20 mm/sec Bearing dia : 300 –
400mm
Normal force 200 kN Velocity 50 mm/sec
Normal force 1000 N Velocity
100 mm/sec
Normal force 6500 kN Velocity max 40 mm/sec
Normal Force 1000 N Sliding speed 2m/s
Modified FZG
computer vision Sick-Slip
tester
Pin
-o
n-
Dis
c Fl
at –
on
- Fl
at
Cu
sto
mis
ed
Torque 100 N/m Slip ratio 30%
Large scale bearing
Normal force 20 N
Velocity 1 m/sec
Normal force 20 N
Velocity 50 mm/sec
Shackle chain tester
Conveyor chain tester
Tensile force 10 kN
Tensile force 20 kN Normal force 10 kN
J Sukumaran- Materials meeting, 13th November 2013
Experimental simulation: Tribological characterization
Applications Configuration Laboratory Soete Specification
Bearing
elements
Bearing tester Radial load 1350 kN
Velocity 200 mm/s
Ø 300 mm w:300 mm
Sea water lubricated
Guide, wear
pads
Flat on flat Normal force 6500 kN
Velocity: 40 mm/s
300 X 220 mm
Sea water lubricated
Tooth, wear
pads
Ball on flat Normal force 250 N
2.5 – 50 Hz
10 X 10 mm
Water/Dry lubricated
Large scale flat
Radial Bearing
Ball on flat
J Sukumaran- Materials meeting, 13th November 2013
Applications Configuration Laboratory Soete
Bearing
elements
Twin disc testrig Normal force 490 N
Speed 2.5 m/s
Ø 95 mm, 30% Slip
Water/Dry lubricated
Mooring
chains
Shackle chain
tester
Tensile force 10 kN
1Hz
Dry/ Water/Sand
Drag head
Jet nozzle
Dry/ Water/Sand
Experimental simulation: Tribological characterization
Modified FZG
Shackle chain tester
Slurry pot tester
J Sukumaran- Materials meeting, 13th November 2013
Why large scale tribological testing?
Large scale tests includes
• Edge effect
• Wear debris
J Sukumaran- Materials meeting, 13th November 2013 30
months weeks days
System shutdown
Beginning of deterioration
Vibration
Noise
Smoke
Heat
Mac
hin
e o
r eq
uip
me
nt
con
dit
ion
Back to the machine condition
Surface change ?
The root cause of deterioration = wear
J Sukumaran- Materials meeting, 13th November 2013 31
Adaptation of new techniques – optical microscopy
A new method for the determination of wear of machine parts – Khruschov 1960
J Sukumaran- Materials meeting, 13th November 2013
Indirect measure
Direct measure •Friction force •Wear
Change in surface morphology
• Mild wear • Transition • Severe wear
Temperature (Counter material)
Online monitoring
Rate of change in heat output
Wear mechanism
Thermal wear
Tribo-film
Chemical wear
Mild-repeated cycle
deformation
Severe-repeated
cycle deformation
Mild-single cycle
deformation
Severe-single cycle
deformation
Mild adhesive
Severe adhesive
10-7 10-2 10-1 10-00 10-5 10-4 10-3 10-6
Online monitoring
J Sukumaran- Materials meeting, 13th November 2013 33
Quantified surface scars from post microscopy
Abrasion Abrasion R
aw im
age
fro
m O
M
Segm
enta
tio
n
imag
e
An example showing difference in severity of abrasion from worn polymer surface
J Sukumaran- Materials meeting, 13th November 2013 34
Online micrograph system: light microscope + high speed camera
J Sukumaran- Materials meeting, 13th November 2013 35
Online Imaging in condition monitoring
Classifier
Condition of the component
Atlas of Wear scars
Damaged Surface
Quantitative & Qualitative evaluation
Laboratory test Onsite inspection
• Parameters • Materials
• Videoscopy • Borescope • Micrographs
J Sukumaran- Materials meeting, 13th November 2013 36
What has to be done in offshore tribology • Wear testing in accordance with the three conditions
1. Rigid interaction
2. Free flowing
3. water Lubricated systems
• Identifications of rate of change in deterioration zone
(temperature, vibration and surface change)
• An appropriate model has to be developed (specifically for offshore conditions)
• Including these new techniques in the condition monitoring strategy
Can be done at Labo Soete • Large scale testing confirming to offshore conditions
• Rate of change for wear, friction and temperature, in the severe regime.
• Interpretation of the rate of change for base line information in the severe region
• Monitoring online images of moving surface
• Building up database “Atlas for wear scars”
• New techniques for quantification of micrographs
J Sukumaran- Materials meeting, 13th November 2013
www.SoeteLaboratory.UGent.be
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