Filter Debris Analysis for Aircraft Engine and Gearbox Health Management
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TECHNICAL ARTICLE—PEER-REVIEWED
Filter Debris Analysis for Aircraft Engine and Gearbox Health Management Allison M. Toms Æ Karen Cassidy
Published online: 5 March 2008 Ó Society for Machinery Failure Prevention Technology 2007
Abstract Oil filters capture a tremendous amount of tribology information about the operation of a machine. Removal and analysis of the filter debris has proved to be an effective tool for engine health management by determining wear modes and observing failure progression providing long lead times for maintenance remediation. The process of manual debris removal and analysis in a laboratory, however, is tedious. An automated filter debris analysis system provides a repeatable process for at-line or laboratory use. The filters are automatically cleaned; the particles are counted and sized utilizing a quantitative oil debris sensor; and the debris is deposited on a patch for automatic analysis by an integral energy dispersive X-ray fluorescence spectrometer. The XRF analysis procedure provides metallurgical analysis and an expert determination of engine condition. The system has been successfully applied to two operational aircraft fleets, the Canadian Forces S-61 Sea King helicopter fleet and the US Navy EA-6B Prowler aircraft fleet. In both applications, significant benefits have been realized.
Reprinted with permission from Integration of Machinery Failure Prevention Technologies into Systems Health Management, Proceedings of the 61st Meeting of the Society for Machinery Failure Prevention Technology, Society for Machinery Failure Prevention Technology, 2007, pp. 239–245. A. M. Toms (&) K. Cassidy GasTOPS Inc., 4900 Bayou Blvd., Suite 107, Pensacola, FL 32503, USA e-mail: [email protected] K. Cassidy e-mail: [email protected]
Keywords Condition based maintenance Debris sensor Engine health management Filter debris analysis Operational uptime Wear modes
History of Filter Debris Analysis Fluid filters and strainers play an important role in capturing and removing the debris and contamination that can damage mechanical components. An increase in the effectiveness of the filtration corresponds to a decrease in secondary damage caused by abrasive wear. Filters also capture the history of component wear for the life of the filter and for the capture efficiency of the filter. With the installation of fine filtration [1] (less than 7 microns), traditional wear analysis techniques such as atomic emission spectroscopy (AES) and ferrography become less efficient at detecting the initiation of damage. These filters capture most of the debris that AES and ferrography require for reliable detection and analysis. However, removing and analyzing the deposited particulates from the filter can provide a comprehensive assessment of the wear the asset has undergone during the life of the filter element. Filter debris analysis has been in use since the mid 1980’s. When the Canadian Forces’ Sea King helicopter was plagued with main gearbox debris problems, the Canadian Defense Research E
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