Oil Debris Analysis
Overview
A gearbox within a heavy industrial process was included in a routine oil condition monitoring programme.
The Challenge
The gearbox operated continuously under high mechanical load and failure would have resulted in extended production downtime.
Investigation
Lubricant samples were analysed to assess oil condition and wear debris content.
The analysis included:
- Measurement of ferrous particle levels
- Evaluation of particle morphology
- Assessment of lubricant degradation and contamination
Findings
Wear debris analysis identified an increasing concentration of ferrous particles within the lubricant, indicating abnormal internal wear.
Outcome
The gearbox was inspected during a scheduled shutdown where early stage gear wear was confirmed.
Because the issue was detected early:
- Major gearbox failure was avoided
- Repairs were carried out during planned maintenance
- Production downtime was minimised
Oil debris analysis provided early warning of developing mechanical damage within the gearbox.
