Analytical Ferrography - Make It Work

For You
Michael Barrett, Insight Services Matt McMahon, Insight Services
Tags: wear debris analysis, oil analysis
Introduction
Analytical ferrography is among the most powerful diagnostic tools in oil analysis today. When
implemented correctly it provides a tremendous return on your oil analysis dollars. Yet, it is frequently
excluded from oil analysis programs because of its comparatively high price and a general
misunderstanding of its value.
The test procedure is lengthy and requires the skill of a trained analyst. As such, there are significant
costs in performing analytical ferrography not present in other oil analysis tests. But, if time is taken to
fully understand what analytical ferrography uncovers, most agree that the benefits significantly outweigh
the costs and elect to automatically incorporate it when abnormal wear is encountered.

Figure 1. Ferrogram Slide Maker

Separates Particles from the Oil

Principle
To perform analytical ferrography the solid debris suspended in a lubricant is separated and
systematically deposited onto a glass slide. The slide is examined under a microscope to distinguish
particle size, concentration, composition, morphology and surface condition of the ferrous and non-
ferrous wear particles.
This detailed examination, in effect, uncovers the mystery behind an abnormal wear condition by
pinpointing component wear, how it was generated and often, the root cause.

Ferrogram
Analytical ferrography begins with the magnetic separation of machine wear debris from the lubricating oil
in which it is suspended using a ferrogram slide maker (Figure 1). The lubricating oil sample is diluted for
improved particle precipitation and adhesion. The diluted sample flows down a specially designed glass
slide called a ferrogram. The ferrogram rests on a magnetic cylinder, which attracts ferrous particles out
of the oil (Figure 2).
Due to the magnetic fluid, the ferrous particles align themselves in chains along the length of the slide
with the largest particles being deposited at the entry point. Nonferrous particles and contaminants,
unaffected by the magnetic field, travel downstream and are randomly deposited across the length of the
slide. The deposited ferrous particles serve as a dyke in the removal of nonferrous particles. The absence
of ferrous particles substantially reduces the effectiveness with which nonferrous particles are removed.
After the particles are deposited on the ferrogram, a wash is used to remove any remaining lubricant. The
wash quickly evaporates and the particles are permanently attached to the slide. The ferrogram is now
ready for optical examination using a bichromatic microscope.

Figure 2. Ferrogram Slide Maker

Separates Particles from the Oil

Particle Identification
The ferrogram is examined under a polarized bichromatic microscope equipped with a digital camera.
The microscope uses both reflected (top) and transmitted (bottom) light to distinguish the size, shape,
composition and surface condition of ferrous and nonferrous particles (Figure 4). The particles are
classified to determine the type of wear and its source.
Particle composition is first broken down to six categories: white nonferrous, copper, babbitt,
contaminants, fibers and ferrous wear. In order to aid the identification of composition, the analyst will
heat treat the slide for two minutes at 600F.

White nonferrous particles, often aluminum or chromium, appear as bright white particles both
before and after heat treatment of the slide. They are deposited randomly across the slide surface
with larger particles getting collected against the chains of ferrous particles. The chains of ferrous
particles typically act as a filter, collecting contaminants, copper particles and babbitt.
Copper particles usually appear as bright yellow particles both before and after heat treatment
but the surface may change to verdigris after heat treatment. These also will be randomly
deposited across the slide surface with larger particles resting at the entry point of the slide and
gradually getting smaller towards the exit point of the slide.
Babbitt particles consisting of tin and lead, babbitt particles appear gray, sometimes with
speckling before the heat treatment. After heat treatment of the slide, these particles still appear
mostly gray, but with spots of blue and red on the mottled surface of the object. Also, after heat
treatment these particles tend to decrease in size. Again, these nonferrous particles appear
randomly on the slide, not in chains with ferrous particles.
Contaminants are usually dirt (silica), and other particulates which do not change in appearance
after heat treatment. They can appear as white crystals and are easily identified by the
 transmitted light source, that is, they are somewhat transparent. Contaminants appear randomly
on the slide and are commonly dyked by the chains of ferrous particles.
Fibers, typically from filters or outside contamination, are long strings that allow the transmitted
light to shine through. They can appear in a variety of colors and usually do not change in
appearance after heat treatment. Sometimes these particles can act as a filter, collecting other
particles. They can appear anywhere on the ferrogram, however they tend to be washed towards
the exit end.

Figure 3. The Metal Alloy of the Particles

Determines Whether They Line up
On or Adjacent to the Magnetic Field
Ferrous particles can be broken down to five different categories, high alloy, low alloy, dark metallic
oxides, cast iron and red oxides. Large ferrous particles will be deposited on the entry end of the slide
and often clump on top of the other. Ferrous particles are identified using the reflected light source on the
microscope. Transmitted light will be totally blocked by the particle.

High Alloy Steel - particles are found in chains on the slide and appear gray-white before and
after heat treatment. The distinguishing factor in the identification between high alloy and white
nonferrous is position on the slide. If it is white and appears in a chain, its deemed to be high
alloy. Otherwise, its considered white nonferrous The frequency of high alloy on ferrograms is
rare.
Low Alloy Steel - particles are also found in chains and appear gray-white before heat treatment
but then change color after heat treatment. After heat treatment they usually appear as blue
particles but can also be pink or red.
Dark Metallic Oxides - deposit in chains and appear dark gray to black both before and after
heat treatment. The degree of darkness is indicative of the amount of oxidation.
Cast Iron - particles appear gray before heat treatment and a straw yellow after the heat
treatment. They are incorporated in chains amongst the other ferrous particles.
Red Oxides (Rust) - polarized light readily identifies red oxides. Sometimes they can be found in
chains with the other ferrous particles and sometimes they are randomly deposited on the slide
surface. A large amount of small red oxides on the exit end of the slide is generally considered to
be a sign of corrosive wear. It usually appears to the analyst as a beach of red sand.
After classifying the composition of particles the analyst then rates the size of the particles using a
micrometer scale on the microscope. Particles with a size of 30 microns or greater are given the rating of
severe or abnormal. Severe wear is a definite sign of abnormal running conditions with the equipment
being studied.

Figure 4. Red and Green Filters Help

the Analyst Differentiate Wear Particles
from Organic and Translucent Materials
Often, the shape of a particle is another important clue to the origin of the wear particles. Is the particle
laminar or rough? Laminar particles are signs of smashing or rolling found in bearings or areas with high
pressure or lateral contact. Does the particle have striations on the surface? Striations are a sign of
sliding wear. Perhaps generated in an area where scraping of metal surfaces occurs. Does the particle
have a curved shape, similar to drill shavings? This would be categorized as cutting wear. Cutting wear
can be caused by abrasive contaminants found in the machine. Is the particle spherical in shape? To the
analyst, these appear as dark balls with a white center. Spheres are generated in bearing fatigue cracks.
An increase in quantity is indicative of spalling.

Conclusion
Analyzing the size, shape, color, magnetism light effects and surface detail of wear particles, a skilled
analyst can paint a picture above the nature, severity and root cause of abnormal wear. This information
enables maintenance to implement effective corrective action.

Case Study I
Equipment: Ingersoll Rand single-stage centrifugal pump.
Application: A steel mill uses this pump to boost the water pressure it supplies to the hot mill for
descaling. Thin scale forms rapidly on the hot slab and must be removed before entering the mill stands.
The high pressure descaling water breaks it loose from the slab and removes it. The pump has babbitt
sleeve bearings with a Kingsbury thrust bearing on the outboard bearings. This is a 12,000 gpm, single
inlet pump driven by a 2000 hp motor at 1780 rpm.
History: Oil samples from this pump are routinely sent for analysis and historically have exhibited normal
machine and lubricant conditions. Spectroscopic analysis and direct reading ferrography are routinely
performed in order to trend the wear of the lubricated bearings. Analytical ferrography is automatically
performed when there is a machine abnormality.
Problem Sample: The sample drawn on 7/3/00 exhibited excess iron wear, abnormal silicon and
excessive total ferrous wear. The machine was given a critical condition and analytical ferrography was
automatically initiated to pinpoint the source of the problem.
 100X 500X
Analytical Ferrography
Analytical ferrography showed high amounts of dark metallic oxides and low alloy. This correlated with
the data from the spectrometer and the direct read ferrography.
Conclusions: The maintenance department issued a work ticket to change the oil and inspect the pump
bearings. Upon inspection it was found that the thrust bearing was severely damaged. The thrust shoes
were deeply scored and the thrust assembly was badly damaged. The pump was pulled from operation.
The routine oil analysis uncovered a problem that was easy to repair. The inspection occurred on a
planned basis, thus preventing possible downtime. If the pump were left in service, it would have
catastrophically failed. This pump costs more than $50,000!

Case Study II
Equipment: Westinghouse 5,000 HP Motor.
Application: A steel mill uses this motor to drive a double reduction gearbox on a roughing mill at an
input speed of 450 rpm. The motor has babbitt sleeve bearings and is coupled to the gearbox with a #11
Kop-Flex gear coupling.
History: Oil samples from this motor are routinely sent for analysis and historically have exhibited normal
machine and lubricant conditions. Spectroscopic analysis and direct reading ferrography are routinely
performed in order to trend the wear of the lubricated bearings. Analytical ferrography is automatically
performed when there is a machine abnormality.
Problem Sample: The sample drawn on 5/18/00 exhibited excess lead wear, excess tin wear and a high
total ferrous wear count. The customer was called and submitted another sample. The sample drawn on
5/24/00 exhibited the same abnormalities and the machine was given a marginal condition and analytical
ferrography was automatically initiated to pinpoint the source of the problem.
Click Here to View Spectrometer and Direct Read Ferrography Data
 500X 500X
Analytical Ferrography
Analytical ferrography showed high amounts of low alloy steel and dark metallic oxides. The colored
particles on the top slide are low alloy steel that changed color after heat treatment.
Conclusions: The results of the oil analysis initiated a visual inspection, which revealed that the coupling
appeared to be locked. The maintenance department issued a work order to inspect the motor bearing
and coupling. Upon removal of the bearing cap, it was found that the faces of the bearing were wiped.
The bearing surface that the shaft rode on was also starting to wipe. The bearing was changed.

Replaced Motor Bearing

Maintenance completed the repairs on a planned basis with no delay to the mill. If left unrepaired, the
motor bearing would have failed catastrophically. Such a failure while the mill was running would have
caused a four-hour delay to the mill with a cost in excess of $60,000!