Introduction to the Analex PQ

Ferrous Debris Monitor

By

Mark Mathys
Butler Machinery Company

PQ Ferrous Debris Monitor

What is the PQ
Principle of Operation
How is it Used
Sample Preparation
PQ Results
Case Studies
PQ, ICP, and Particle Count Comparison

What is the PQ
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 with accepted linearity over a
wide range of ferrous debris content and particle
size.

Analex PQA

Principle of Operation
The PQ ferrous debris monitor operates on the
principle that the distortion of a magnetic flux
field associated with a toroidal pick-up coil
occurs when a ferromagnetic sample is placed in
the field.

Principle of Operation
Two magnetic coils are adjusted so they are in
balance when no sample is on the sensor.
When the sample of oil containing ferromagnetic
debris is placed on the sensor the balance
between the coils is altered.
The resulting out-of-balance signal is amplified,
filtered, and displayed as a PQ Index that
relates directly to the mass of ferromagnetic
debris in the sample.

Schematic of PQ Magnet Assembly

How does it work?

Sample bottle

Measurement surface

Upper
Balance coils

Excitation coil

Lower

Ferrite core adjustment

screw
A ferrite rod passes
through the centre of
the coil assembly

How is it Used?
PQ is often employed as a screening device to
help decide which samples justify further testing.
The PQ measurement, like other concentration
measurements obtained by ICP/DCP/AA, should
not be considered absolute due to the size
sensitivity of each technique.

Measurement Methods
Several measurement methods may be employed
Settled-Sample
Time Dependent PQ
Well-Mixed Sample

Settled Sample
The magnitude of the PQ reading may be
increased by allowing the the debris to settle
before measurement.
Settled-sample measurements are only semiquantitative unless sample volume is controlled.
Some users make a preliminary measurement on
a settled sample and then a quantitative
measurement after shaking the bottle.

Time Dependent PQ
If a well shaken sample is left undisturbed on the
PQ instrument, repeat reading of the PQ index
will be seen to increase as debris settle.
A rapid rate of increase is an indication of the
presence of large particles.
The rate of increase is measured by calculating
the slope of the line.

Time Dependent PQ
1600
1400
Slope = 51.6
1200
Final
Hyd
Tandem

PQ Index

1000
800
Slope = 11.1
600
400
200

Slope = 0.3

0
10

20

30

40

50

60

Seconds

70

80

90

100

Well Mixed Sample

At Butler Machinery Company we run all PQ
measurements on well-mixed samples. Samples
are constantly mixed with a sample rotator like
the one we use for particle counting.

Samples with abnormal PQ readings are

filtered and examined with our microscope.

Sample Introduction
There are two methods for handling samples:
Pot Method (used by Cat)
In-Bottle Method (used by Butler)

Pot Method
Uses small disposable plastic containers (pots)
2 mL of sample is dispensed into the pot
The pots are then loaded onto the PQ
Sample should be well mixed prior to dispensing
The PQ instrument measures the total volume of
oil in the pot so settling is not as issue once the
sample has been dispensed.

In-Bottle Method
The In-Bottle method is used for Well-Mixed and
TDPQ measurement
Samples are placed upside down in the sample
holder
Settling is an issue and samples must be well
mixed at the time of measurement

In-Bottle Method
Samples are first mixed with a paint shaker
They are then placed on the rotator
As one sample is removed for measurement
another is placed on the rotator where it remains
for one cycle or about 3 minutes
PQ readings are taken immediately after
removing the sample from the rotating wheel.

In-Bottle Method
It has been shown that a PQ index measurement
on a well-mixed sample is independent of the
volume in the bottle provided it exceeds a critical
depth.
The critical depth is typically about 10mm
Readings are higher (~3x) than the Pot method

Pot Method
Advantages

Disadvantages

Small Sample Volume

Requires Extra Steps

Automatic

Consumables
Pots & Lids
Pipette Tips

Stacker is Expensive
More Waste (plastic)

In-Bottle Method
Advantages

Disadvantages

Minimal extra work

Manual Process

No Consumables

Requires Rotator

Lower cost of
instrument

Results can be affected

by sample volume

PQ Results

PQ Results
When Iron is High and PQ is Low we usually
see Small Particles
When Iron and PQ are approximately the same
but we usually see Small Particles
When PQ is High and Iron is Low we usually
see Large Particles

High Iron & Low PQ

PQ-209 Iron-22

PQ-109 Iron-27

PQ-243 Iron-35

PQ-1219 Iron-416

PQ-58 Iron-15

PQ-43 Iron-9

PQ-53 Iron-4

PQ-5380 Iron-36

PQ-9701 Iron-600

PQ-2822 Iron-498

PQ-79 Iron-22

PQ-926 Iron-18

Iron & PQ Approximately Equal

PQ-66 Iron-64

PQ-40 Iron-42

PQ-65 Iron-64

PQ-52 Iron-56

PQ-107 Iron-103

PQ-53 Iron-49

Sand & Dirt

We frequently find Large Dirt Particles
in samples with High PQ readings

PQ-139 Si-25 Iron-136

PQ-69 Si-30 Iron-129

PQ-42 Si-10 Iron-33

PQ-41 Si-9 Iron-77

PQ-38 Si-7 Iron-13

PQ-51 Si-46 Iron-67

Anomalies
Readings Are High but No Metal is Found

PQ-1157 Iron-154

PQ-1883 Iron-8

PQ-39 Iron-21

PQ-120 Iron-298

PQ-89 Iron-289

PQ-53 Iron-14

Examples

Iron

PQ

600

500

400

300

200

100

Mill Gear Box

Iron vs PQ
R2 = 0.59
600

Iron
500

Iron

400

300

200

100

0
0

100

200

300
PQ Index

400

500

600

Iron

500

400

300

200

100

Off Highway Truck Diesel Engine

This example shows how PQ readings compare with Iron and Silicon

600

Iron

PQ

500

400

300

200

100

Off Highway Truck Diesel Engine

When Iron is elevated PQ may or may not be elevated. When both are high or
when Iron is higher than PQ it usually indicates small particles are present.

600

Iron

PQ

Silicon

500

400

300

200

100

Off Highway Truck Diesel Engine

In this example PQ, Iron, and Silicon are all high.

350

PQ

Silicon

300

250

200

150

100

50

Off Highway Truck Diesel Engine

PQ is frequently elevated in cases of dirt entry or contamination, especially
if the dirt is too large to be seen with the ICP. Iron may or may not be elevated.

600

Iron

PQ

Silicon

500

400

300

200

100

Off Highway Truck Diesel Engine

A microscope exam confirms heavy contamination. When
PQ is high we expect to see abnormal amounts of iron and
other debris.

70

Iron

60

50

40

30

20

10

637D Front Transmission

PQ - Relationship with other elements

70
Iron

PQ

60

50

40

30

20

10

637D Front Transmission

PQ and Iron
The high PQ suggests some large particles are present

70
Iron

PQ

75 Micron

60

50

40

30

20

10

637D Front Transmission

PQ, Iron, 75 Micron PC
Particle count also indicates the presence of large particles

70
Iron

PQ

75 Micron

60

50

40

30

20

10

637D Front Transmission

Microscope confirms presence of large debris

300
Iron

250

200

150

100

50

637D Rear Transmission (same machine)

PQ - Relationship with other elements

300
Iron

250

200

150

100

50

637D Rear Transmission

PQ and Iron

PQ

300 *

Iron

PQ

75 Micron

250

200

150

100

50

637D Rear Transmission

PQ, Iron, 75 Micron

* 300 represents Baseline High

300
Iron

250

200

150

100

50

637D Rear Transmission

PQ - Relationship with other elements - PQ, Iron, 75 Micron
Without the PQ information it would be possible to misinterpret the
downward trend in particle count

75 Micron

300
Iron

250

200

150

100

50

637D Rear Transmission

Microscope confirm presence of large debris

PQ

75 Micron

70
Iron

PQ

60

50

40

30

20

10

0
300

Iron

250

200

150

100

50

Viewing the data from both transmissions

provides a clue as to the cause of the high
readings

PQ

300
Iron

250

200

150

100

50

637D Rear Transmission

Customer shut down machine and dispatched a field service man
to inspect unit and resample. Upon further investigation he found
the sample had been taken from the filter housing. The front
sample was also taken from the filter housing.

PQ

75 Micron

80

Iron
70

60

50

40

30

20

10

Truck Engine

PQ

80
Iron
70

60

50

40

30

20

10

Truck Engine
PQ shows a significant spike, microscope exam shows large
amount of metal and carbon.

PQ

80
Iron
70

60

Engine Replaced
50

40

30

20

10

Truck Engine
Sample taken 12-30-98 arrived in lab 01-18-99. When we
called to let them know where was a problem they said they
knew there was a problem because it was in the shop with a
hole in the block.

PQ

Iron

80

70

60

50

40

30

20

10

0
01-14-97

04-14-97

07-14-97

10-14-97

3406 Truck Engine

01-14-98

04-14-98

07-14-98

10-14-98

01-14-99

04-14-99

07-14-99

10-14-99

01-14-00

04-14-00

Iron

PQ

80

70

60

50

40

30

20

10

0
01-14-97

04-14-97

07-14-97

10-14-97

3406 Truck Engine

01-14-98

04-14-98

07-14-98

10-14-98

01-14-99

04-14-99

07-14-99

10-14-99

01-14-00

04-14-00

80

70

60

50

40

30

20

10

3406 Truck Engine

We let customer know about bad sample and they immediately took
another sample. Oil was not changed but second sample did not have
any debris and the PQ had returned to normal. No problem was found.
We believe the bad sample was the result of improper sample
technique.

Iron

PQ

Sampling Location is a Factor

Sample from tap on filter:

Iron - 10
PQ - 6

Sample from dipstick:

Iron - 8
PQ - 23

Typical Results

Average Values

Diesel Engines - 14
Hydraulic Systems - 14
Power Shift Transmissions - 22
Axles/Differentials - 154
Final Drives - 108
Tandems - 297

Cat Diesel Engines

5000
4500
4000

Diesel Engines
Count
46378
Mode
12
Median
13
Mean
14
Standard Deviation
7
Range
99
Minimum
1
Maximum
100

3500
3000
2500
2000
1500
1000
500

PQ Index

100

97

93

89

85

81

77

73

69

65

61

57

53

49

45

41

37

33

29

25

21

17

13

Cat Hydraulic Systems

1200

1000

Hydraulic Systems
Count
10308
Mode
12
Median
13
Mean
14
Standard Deviation
8
Range
99
Minimum
1
Maximum
100

800

600

400

200

PQ Index

100

97

93

89

85

81

77

73

69

65

61

57

53

49

45

41

37

33

29

25

21

17

13

Cat Transmississioons
1200

1000

Transmissions
Count
14548
Mode
12
Median
16
Mean
22
Standard Deviation
31
Range
560
Minimum
1
Maximum
561

800

600

400

200

PQ Index

197

190

183

176

169

162

155

148

141

134

127

120

113

106

99

92

85

78

71

64

57

50

43

36

29

22

15

Cat Differentials/Axles
1400
1200

Differentials/Axles
Count
9059
Mode
16
Median
53
Mean
154
Standard Deviation
518
Range
16896
Minimum
1
Maximum
16897

1000
800
600
400
200

PQ Index

1000

950

900

850

800

750

700

650

600

550

500

450

400

350

300

250

200

150

100

50

Cat Final Drives

1600
1400

Final Drives

1200

Count
9834
Mode
25
Median
57
Mean
108
Standard Deviation 158
Range
1909
Minimum
2
Maximum
1911

1000
800
600
400
200

PQ Index

1000

970

930

890

850

810

770

730

690

650

610

570

530

490

450

410

370

330

290

250

210

170

130

90

50

10

Cat Tandems
250

200

Tandems
Count
3501
Mode
94
Median
213
Mean
297
Standard Deviation 298
Range
6999
Minimum
1
Maximum
7000

150

100

50

PQ Index

2000

1940

1860

1780

1700

1620

1540

1460

1380

1300

1220

1140

1060

980

900

820

740

660

580

500

420

340

260

180

100

20

Cat Engines PQ vs Iron

32,000 Samples

Cat Engines PQ vs Iron

32,000 Samples

Cat Transmissions 5 Micron vs PQ

Cat Transmissions 10 Micron vs PQ

Cat Transmissions 15 Micron vs PQ

Cat Transmissions 20 Micron vs PQ

Cat Transmissions 25 Micron vs PQ

Cat Transmissions 50 Micron vs PQ

Cat Transmissions 75 Micron vs PQ

Cat Transmissions 100 Micron vs PQ

Why the low Correlation?

Since ICP/DCP is measuring Iron you would expect a
strong correlation between PQ and Iron.
But because the ICP/DCP measures only small
particles (<5 Microns) the correlation is low.
The PQ tells us if we have large particles or lots of
small particles.
Most engines do not have large particles, in fact most
engines do not normally have very many metal
particles at all.

Why the low Correlation?

In the case of transmissions (& other compartments)
many of the high particle count samples are due to the
presence of sand and dirt

Summary
When Iron is High and PQ is Low we usually
see Small Particles
When Iron and PQ are approximately the same
but we usually see Small Particles
When PQ is High and Iron is Low we usually
see Large Particles

Summary
TDPQ yields the most useful information by
providing information about the settling rate
The PQ in not designed to make absolute
measurements - The PQ monitors trends
To be significant to PQ Index must change by at
least 10% relative

The End