Condition monitoring for Off-shore tribology - SIM … · Condition monitoring for Off-shore...

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


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


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


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


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


Tribology in offshore applications

Mode

Application

Focus

Offshore tribology

Wear

Material removal

Rigid interaction

Material handling

Free floating

Wear & Friction

Lubricated systems

Water lubrication


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


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


Drilling

Abrasion

Three body Abrasion

Closed three body

Impact abrasion

Oil sands Jaw crushers

Abrasive wear: Applications


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


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


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


Slurry

Specimen


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



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


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


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


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


months weeks days

System shutdown


Vibration

Noise

Smoke

Heat

Mac

hin

e o

r eq

uip

me

nt

con

dit

ion

The machine condition


months weeks days

System shutdown


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


months weeks days

System shutdown


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


months weeks days

System shutdown


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


months weeks days

System shutdown


Vibration

Noise

Smoke

Heat

Mac

hin

e o

r eq

uip

me

nt

con

dit

ion

The machine condition: Offshore tribology


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


Tribology in Labo soete [ ]

Despite of extensive time consumption, the wear data obtained form real scale

testing is rather exiguous for condition monitoring.


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


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


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


Why large scale tribological testing?

Large scale tests includes

• Edge effect

• Wear debris


months weeks days

System shutdown


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


Adaptation of new techniques – optical microscopy

A new method for the determination of wear of machine parts – Khruschov 1960


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


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


Online micrograph system: light microscope + high speed camera


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


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


www.SoeteLaboratory.UGent.be

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