Using PQ to Save Compartments

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Using PQ to Save Compartments

• Steve Eller
• Carter Machinery Co., Inc.
• Salem, Virginia

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Analex PQ Ferrous Debris Monitor

• What is the PQ Ferrous Debris Monitor?
• How Does it Work?
• How is it Used?
• Sample Methods and Introduction
• PQ Results
• What the Results Mean to Your Customer

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What is the PQ Ferrous Debris Monitor

• A Sensitive Magnetometer that measures the mass
  of ferrous debris in a sample and displays this
  as a PQ Index

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What is the PQ Ferrous Debris Monitor

• A Sensitive Magnetometer that measures the mass
  of ferrous debris in a sample and displays this
  as a PQ Index
• The PQ Index is a quantitative unitless number
  that can be trended

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What is the PQ Ferrous Debris Monitor

• A Sensitive Magnetometer that measures the mass
  of ferrous debris in a sample and displays this
  as a PQ Index
• The PQ Index is a quantitative unitless number
  that can be trended
• Can identify larger ferrous particles that are
  missed by other analytical techniques

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How Does It Work?

• PQ instruments work on the principle that the
  ferrous debris in a sample positioned over the
  sensor upsets the balance of its magnetic field.

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How Does It Work?

• PQ instruments work on the principle that the
  ferrous debris in a sample positioned over the
  sensor upsets the balance of its magnetic field.
• The electronics in the instrument can detect this
  very small field distortion and will give the
  results as a PQ Index

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How Does It Work?

• PQ instruments work on the principle that the
  ferrous debris in a sample positioned over the
  sensor upsets the balance of its magnetic field.
• The electronics in the instrument can detect this
  very small field distortion and will give the
  results as a PQ Index
• The PQ does not make absolute measurements- it
  monitors trends.

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How is it Used?

• Instrument is calibrated using a supplied
  standard
• Each sample takes about 10 seconds
• PQ is often used as a screening device to help
  decide which samples justify further examination

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Samples with abnormal PQ readings are filtered
with a 5um filter and examined with our microscope
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Methods

• Demands maximum consistency in every aspect to
  insure repeatability

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Methods

• Demands maximum consistency in every aspect to
  insure repeatability
• Samples must be well shaken and consistently
  mixed until the sample is processed

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Methods

• Demands maximum consistency in every aspect to
  insure repeatability
• Samples must be well shaken and consistently
  mixed until the sample is processed
• Bottle caps must be Flat

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Methods

• Demands maximum consistency in every aspect to
  insure repeatability
• Samples must be well shaken and consistently
  mixed until the sample is processed
• Bottle caps must be Flat
• Data can be retrieved by computer or manually

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Methods

• Demands maximum consistency in every aspect to
  insure repeatability
• Samples must be well shaken and consistently
  mixed until the sample is processed
• Bottle caps must be Flat
• Data can be retrieved by computer or manually
• PQ Software (optional) is compatible with SOS
  Services Manager

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Sample Methods

• Different methods may be used
• Well Mixed Sample
• Time dependent PQ
• Settled Sample

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Well Mixed Sample

• Samples are constantly mixed using a sample
  rotator like the one used for particle counting

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Well Mixed Sample

• Samples are constantly mixed using a sample
  rotator like the one used for particle counting
• The PQ measurement on a well mixed sample is
  independent of volume in sample bottle providing
  the Critical Depth is exceeded (10mm)

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Well Mixed Sample

• Samples are constantly mixed using a sample
  rotator like the one used for particle counting
• The PQ measurement on a well mixed sample is
  independent of volume in sample bottle providing
  the Critical Depth is exceeded (10mm)
• Carter and Butler chosen method

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Time Dependant PQ

• A well shaken sample left undisturbed on the PQ
  instrument with multiple readings

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Time Dependant PQ

• A well shaken sample left undisturbed on the PQ
  instrument with multiple readings
• The PQ index will increase as debris settles

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Time Dependant PQ

• A well shaken sample left undisturbed on the PQ
  instrument with multiple readings
• The PQ index will increase as debris settles
• A rapid increase is an indication of larger
  particles present

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Settled Sample

• The PQ reading may be increased by allowing the
  debris to settle before measurement

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Settled Sample

• The PQ reading may be increased by allowing the
  debris to settle before measurement
• Settled sample measurements are only
  semi-quantitative unless the sample volume is
  controlled

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Sample Introduction

• Methods used for sampling
• Pot Method
• In Bottle Method

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Pot Method

• Uses small disposable plastic containers

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Pot Method

• Uses small disposable plastic containers
• 2 ml of sample dispensed into the pot

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Pot Method

• Uses small disposable plastic containers
• 2 ml of sample dispensed into the pot
• The pots are loaded into the PQ

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Pot Method

• Uses small disposable plastic containers
• 2 ml of sample dispensed into the pot
• The pots are loaded into the PQ
• Sample should be well mixed prior to dispensing

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Pot Method

• Uses small disposable plastic containers
• 2 ml of sample dispensed into the pot
• The pots are loaded into the PQ
• Sample should be well mixed prior to dispensing
• The PQ measures the total volume of the oil in
  the pot so settling is not an issue once the
  sample is dispensed

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Pot Method

• Uses small disposable plastic containers
• 2 ml of sample dispensed into the pot
• The pots are loaded into the PQ
• Sample should be well mixed prior to dispensing
• The PQ measures the total volume of the oil in
  the pot so settling is not an issue once the
  sample is dispensed

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In Bottle Method

• The in bottle method is used for well mixed and
  time dependant measurements

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In Bottle Method

• The in bottle method is used for well mixed and
  time dependant measurements
• Samples are placed upside down in the sample
  holder

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In Bottle Method

• The in bottle method is used for well mixed and
  time dependant measurements
• Samples are placed upside down in the sample
  holder
• Settling IS an issue and samples must be well
  mixed at time of measurement

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In Bottle Method

• The in bottle method is used for well mixed and
  time dependant measurements
• Samples are placed upside down in the sample
  holder
• Settling IS an issue and samples must be well
  mixed at time of measurement
• Readings are three times higher than Pot Method

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Pot vs In Bottle Method

• There are pluses and minuses for both methods
• In Bottle method was chosen by Carter due to
  faster processing time and cost
• Both methods must be trended
• With higher readings for In Bottle method one
  method must be chosen for your lab

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PQ Results

• Iron is high and PQ is Low we usually see Small
  Particles

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PQ Results

• Iron is high and PQ is Low we usually see Small
  Particles
• Iron and PQ are about the same we usually see
  small particles

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PQ Results

• Iron high and PQ Low, usually see Small
  Particles
• Iron and PQ about the same, usually see Small
  Particles
• PQ High and Iron Low, we usually see Large
  Particles

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PQ Results

• Iron is high and PQ is Low we usually see Small
  Particles
• Iron and PQ are about the same we usually see
  small particles
• PQ is High and Iron is Low we usually see Large
  Particles
• Large Dirt Particles often found in High PQ
  Samples along with other Debris

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ICP/DCP VS PQ

• ICP/DCP and PQ measures Iron

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ICP/DCP VS PQ

• ICP/DCP and PQ measures Iron
• Because ICP/DCP measures only small particles (lt5
  um) and PQ measures all particles there is
  little correlation

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ICP/DCP VS PQ

• ICP/DCP and PQ measures Iron
• Because ICP/DCP measures only small particles (lt5
  um) and PQ measures all particles there is
  little correlation
• Engine Hydraulics have few large particles

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ICP/DCP VS PQ

• ICP/DCP and PQ measures Iron
• Because ICP/DCP measures only small particles (lt5
  um) and PQ measures all particles there is
  little correlation
• Engine Hydraulics have few large particles
• We have found PQ most useful in geared
  compartments

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ICP/DCP VS PQ

• ICP/DCP and PQ measures Iron
• Because ICP/DCP measures only small particles (lt5
  um) and PQ measures all particles there is
  little correlation
• Engine Hydraulics have few large particles
• We have found PQ most useful in geared
  compartments
• PQ is useful in all compartments

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Anomalies

• There are samples that will have High PQ
  readings and No Iron or other Debris will be
  found
• The use of microscope backup is a necessity!
• The microscope eliminates the false alarms
  and nails the real ones.

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What the Results Mean to Your Customers

• Lower Cost - Wear and failures in process are
  identified that would have been missed
• 785 Front Axle Example traditional results
  normal PQ up times 3
• Failure was in process

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What the Results Mean to Your Customers

• The PQ data will give your customers a repair
  opportunity before catastrophic failure
• 9/22 High wall miner iron trending down last
  three samples PQ was going up dramatically
  microscope confirmed failure in process

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What the Results Mean to Your Customers

• 9/23 785B Transmission iron up, particle
  count up PQ urgent, microscope confirmed
  failure in process
• CMCo lab finds two to three samples almost daily
  that result in additional action

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Summary

• The PQ is not designed to make absolute
  measurements
• The PQ Monitors Trends
• The PQ allows us to narrow the window of
  interpretation
• PQ will reduce the number of times you explain
  why a failure wasnt caught!