ASTM D7919-2014 2909 Standard Guide for Filter Debris Analysis &40 FDA&41 Using Manual or Automated Processes《使用手动或者自动化流程进行过滤器杂物分析(FDA)的标准指南》.pdf

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1、Designation: D7919 14Standard Guide forFilter Debris Analysis (FDA) Using Manual or AutomatedProcesses1This standard is issued under the fixed designation D7919; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revision, the year of last revi

2、sion. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon () indicates an editorial change since the last revision or reapproval.INTRODUCTIONTypically, main lubrication systems incorporate in-system filters to maintain an appropriatelubricant cleanliness level during

3、operation. Since the lubrication filter element removes and retainsa major portion of the solid contamination in the lubrication system, evaluation of the debris capturedwithin the filter element aids in the determination of machine condition and root cause analysis (RCA).The past decade has seen mo

4、re widespread use of filter debris analysis (FDA) as a condition-monitoring tool to detect and analyze abnormal contaminant ingression into the lube system andpredict lube system component wear. This is in part due to the increased use of finer filtration inmachinery which results in a decrease of w

5、ear debris available for detection by traditional sampled oilanalysis. The U. S. military and other militaries around the world as well as Original EquipmentManufacturers have adopted FDAtechniques. Commercial in-service oil laboratories are also utilizinga wide range of FDA techniques, from manual

6、to automated. It is necessary to provide a guide toimprove analysis and comparison of data.1. Scope1.1 This guide pertains to removal and analysis techniquesto extract debris captured by in-service lubricant and hydraulicfilters and to analyze the debris removed.1.2 This guide suggests techniques to

7、 remove, collect andanalyze debris from filters in support of machinery healthcondition monitoring.1.3 Debris removal techniques range from manual to auto-mated.1.4 Analysis techniques vary from visual, particle counting,microscopic, x-ray fluorescence (XRF), atomic emission spec-troscopy (AES), and

8、 scanning electron microscopy energydispersive x-rays (SEMEDX).1.5 This guide is suitable for use with the following filtertypes: screw on, metal mesh, and removable diagnostic layerfilters.1.6 This standard does not purport to address all of thesafety concerns, if any, associated with its use. It i

9、s theresponsibility of the user of this standard to establish appro-priate safety and health practices and determine the applica-bility of regulatory limitations prior to use.2. Referenced Documents2.1 ASTM Standards:2D5185 Test Method for Multielement Determination ofUsed and Unused Lubricating Oil

10、s and Base Oils byInductively Coupled Plasma Atomic Emission Spectrom-etry (ICP-AES)D6595 Test Method for Determination of Wear Metals andContaminants in Used Lubricating Oils or Used HydraulicFluids by Rotating Disc Electrode Atomic Emission Spec-trometryD7669 Guide for Practical Lubricant Conditio

11、n Data TrendAnalysisD7684 Guide for Microscopic Characterization of Particlesfrom In-Service LubricantsD7685 Practice for In-Line, Full Flow, Inductive Sensor forFerromagnetic and Non-ferromagnetic Wear Debris De-termination and Diagnostics for Aero-Derivative and Air-craft Gas Turbine Engine Bearin

12、gs1This guide is under the jurisdiction of ASTM Committee D02 on PetroleumProducts, Liquid Fuels, and Lubricants and is the direct responsibility of Subcom-mittee D02.96.06 on Practices and Techniques for Prediction and Determination ofMicroscopic Wear and Wear-related Properties.Current edition app

13、roved May 1, 2014. Published June 2014. DOI: 10.1520/D7919-14.2For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact ASTM Customer Service at serviceastm.org. For Annual Book of ASTMStandards volume information, refer to the standards Document Summary page onthe ASTM website

14、.Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States1D7690 Practice for Microscopic Characterization of Par-ticles from In-Service Lubricants by Analytical Ferrogra-phyD7720 Guide for Statistically Evaluating Measurand AlarmLimits when Us

15、ing Oil Analysis to Monitor Equipmentand Oil for Fitness and ContaminationD7898 Practice for Lubrication and Hydraulic Filter DebrisAnalysis (FDA) for Condition Monitoring of Machinery2.2 Other Documents:TTCP-AER-TP3-TR01-2010 Filter Debris Analysis Guide,July 2010, published by The Technical Cooper

16、ation Pro-gram (TTCP)3SAE AIR1828 Guide to Oil System Monitoring in AircraftGas Turbine Engines3. Terminology3.1 Definitions:3.1.1 lubricant condition monitoring, na field of technicalactivity in which selected physical parameters associated withan operating machine are periodically or continuously

17、sensed,measured, and recorded for the interim purpose of reducing,analyzing, comparing, and displaying the data and informationso obtained and for the ultimate purpose of using interim resultto support decisions related to the operation and maintenanceof the machine.3.1.2 machinery health, na qualit

18、ative expression of theoperational status of a machine sub-component, component, orentire machine, used to communicate maintenance and opera-tional recommendations or requirements in order to continueoperation, schedule maintenance, or take immediate mainte-nance action.3.1.3 prognostics, na forecas

19、t of the condition or remain-ing usable life of a machine, fluid, or component part.3.1.4 remaining useful life, na subjective estimate basedupon observations, or average estimates of similar items,components, or systems, or a combination thereof, of thenumber of remaining time that an item, compone

20、nt, or systemis estimated to be able to function in accordance with itsintended purpose before replacement.3.2 Definitions of Terms Specific to This Standard:3.2.1 filter debris analysis (FDA), nthe analysis of debrisspecifically extracted from a system filter for the purpose ofdetermining the healt

21、h of the oil-wetted components withinthat system or the source of significant contaminants.4. Summary of Guide4.1 This guide provides practical guidance on filter debrisanalysis of in-service lubricant filters. Various techniques fordebris removal, collection, and analysis are presented withtheir as

22、sociated benefits and limitations.5. Significance and Use5.1 This guide is intended to provide machinery mainte-nance and monitoring personnel with a guideline for perform-ing filter debris analysis as a means to determine machinecondition. Correlating the filter contaminants to normal andabnormal l

23、ube system operation provides early indication ofa contaminant or component wear related lube system problem.Analysis of the contaminant collected within the lube filterelement provides a tool to identify the failure mode, its rate ofprogression, and the source of the contamination.5.2 FDA differs f

24、rom traditional oil analysis in that the filteris sampled instead of the fluid. Debris from the filter isremoved for analysis. FDA is an effective means of monitoringequipment wear because the wear history is efficiently capturedin the filter matrix. Typically, more than 95 % of all releasedmetal pa

25、rticles larger than the filter pore size are captured in thefilter (1).5In addition, other types of particulate contamination,including seal wear material and environmental contaminationsare captured, which can also provide diagnostic information.6. Interferences6.1 Time-on-Filter InformationIf the

26、time-on-filter is notknown, it is not possible to set limits for rate and severity ofparticulate generation.6.2 Analysis TechniquesTo compare filter debris from likeequipment, the same filter extraction and analysis techniquesmust be utilized. Note some of the techniques in this guide arequite subje

27、ctive such as visual analysis and manual extraction,which makes interpretation of results subjective.6.3 Operating ConditionsMachine operational intensityimpacts how quickly a component wears and how rapidly afault progresses. Similar equipment operating under differentconditions can generate differ

28、ent wear and be exposed todifferent contaminants. A relevant indicator of machine usagemust be included in any trend and limit calculations. (SeeGuides D7669 and D7720.) The selected usage indicator mustreflect actual machine usage, that is, life consumed forexample, stop/start cycles, megawatt hour

29、s, hours of use, orfuel consumption.6.4 Maintenance PracticesCare should be taken duringremoval of the filter to ensure that maintenance practices do notcontaminate the filter.7. Procedures7.1 Typically, main lubrication systems incorporate in-system filters to maintain an appropriate lubricant clea

30、nlinesslevel during operation. The filter is incorporated either in thepressure line after the main lubricant pump or on the scavengeline prior to the lubricant tank. Filter elements are full-flow andprovide a coherent surface for capturing contamination in thelubricant. The porosity of the filtrati

31、on medium can be opti-mized for filtration efficiency, subject to the desired filterelement service life.7.2 Filter MediaSeveral filter media types are presentedthat are suitable for FDA.3Available from Technical Cooperation Program (TTCP), http:/www.acq.osd.mil/ttcp/index.html.5The boldface numbers

32、 in parentheses refer to the list of references at the end ofthis standard.D7919 1427.2.1 Metal Mesh FiltersThese filters are common inengine and gearbox applications. Any of the debris extractionmethods discussed in 7.3 can be utilized.7.2.2 Removable Diagnostic LayerSome lubrication filterelements

33、 are fabricated with a removable (pull-out) diagnosticlayer, comprised of a porous medium layer. Fig. 1 depicts anengine lube filter element with a diagnostic layer. Typically, theporosity of the diagnostic layer allows for efficient retention oflarger size debris (50+ m) of diagnostic interest in e

34、nginelubrication systems (2). Since most porous media used indiagnostic layers are comprised of random fiber matrices, thediagnostic layer exhibits lower, but significant, efficiencies inretaining contamination in the smaller size ranges. A primaryadvantage of the diagnostic layer is that it allows

35、for a range ofdebris analysis from simple on-site visual or microscopicexamination to more extensive laboratory analysis for deter-mining the chemical elemental composition of the debris.7.2.3 Reusable FiltersSome filters are reusable andshould be treated as a serviceable part. The filter elementman

36、ufacturer should be consulted to determine appropriatemethod to extract debris and to determine which tests arerequired to ensure integrity of the filter for reuse.7.2.4 Canister Filters (Screw-on Cartridge Filter)Cartridge filters are common in diesel applications. If manuallycleaning a canister fi

37、lter, the outer casing may need to be cutopen to reveal the filter element for processing. Dedicated filtercutters are available that shear the canister open rather thansawing it, which minimizes any metallic contaminant ingressresulting from the opening process. Note there is the possibilityof swar

38、f contamination from the casing material during cutting.7.3 Debris Extraction ProcessThere are several methodsfor extracting debris from filters. They range from manuallyremoving large particles from the filter to automated filter backflushing.7.3.1 ManualManual debris removal from filters has beenp

39、racticed for decades. Different means for removing the debrisrange from manually extracting large debris from the filter toimmersing the entire filter or sections of the filter in a solvent(such as polyol ester) compatible with the component oilsystem, separating the debris removed from the solvent

40、bysuction flask or simple gravity drain through cellulose mediasuch as a coffee filter, and then analyzing the debris by visual,microscopic, or elemental methods. While manual techniquescan be subjective and prone to interpretation anomalies, theycan produce some limited information where procedures

41、 arestrictly adhered to and where other techniques may not bepractical.7.3.2 Ultrasonic AgitationUltrasonic agitation improvesthe debris extraction from a filter element. The filter issubmerged in a solvent and exposed to ultrasonic waves for aspecified period of time. The solvent should be compatib

42、lewith the component oil. Note some reusable filter elementscannot be cleaned using ultrasonic baths as damage to theelement filter media may result. The debris is then separatedfrom the solvent as in 7.3.1.7.3.3 AutomatedParticle recovery from filters can be per-formed automatically and efficiently

43、 using an automated filter-washing instrument. An automated system is available thatautomatically counts, sizes and discriminates between ferrousand non-ferrous particles, prepares a patch and providesassociated elemental and alloy data utilizing its internal x-rayfluorescence (XRF) spectrometer. Th

44、e automated FDA instru-ment provides a repeatable process by incorporating an auto-mated filter back-washing fluid circuit utilizing a pulsedair/fluid mixture to remove up to 95 % of retained debris fromthe filter (1). As the filter is backwashed, debris particles flowthrough a wear debris sensor (F

45、ig. 2) and are deposited on amembrane patch. See Figs. 3 and 4, and 7.4. The patch is thenanalyzed by an internal XRF spectrometer for elemental andalloy determination. The patch may also be analyzed by othermeans such as a microscopic analysis, SEM/EDXRF, orindividual particle analysis. See 7.5. Th

46、is automated technique,with no manual handling, provides a repeatable process forestablishing limits and trends.7.3.4 Sectional TestingSections of the filter may also becut from the filter for extraction of debris. The assumption isthat the debris is representative for the entire filter and anestima

47、tion of total debris is made. Any of the debris extractiontechniques mentioned above can be used. See Practice D7898.7.4 Media for Debris DepositionOnce the debris has beenextracted from the filter, it must be captured on some media toenable further analysis. Membrane patches are typically uti-lized

48、. Membrane patches come in a variety of diameters (forexample, 47 mm and 25 mm diameter), porosities (forexample, 20 m to 100 m) and materials (for example, nylonand cellulose). The choice of membrane pore size is generallya compromise between particle isolation and prevention ofclogging by finer co

49、ntaminants such as oil degradation prod-ucts and soot; and compatibility with fluids in the filters andthose used for the extraction process.FIG. 1 Filter Element with Removable Diagnostic Layer FIG. 2 Particles Counted and SizedD7919 1437.5 Debris Analysis TechniquesDebris composition, sizedistribution, and morphology provide valuable informationabout the origin of the debris as well as potential fluid systemcomponent failure modes.7.5.1 VisualDebris extracted from filters can be visuallyinspected for a qualitative estimation of quantity of debris an