Ferrography Testing
SPECTRO has a vast experience in providing field and laboratory services for lubricants and engine oils, for predicting lubricants failure.
Ferro graphic analysis by SPECTRO provides non-intrusive evaluation of lubricated components while the equipment is in a running state. Our experts offer ferrographic failure analysis to clients across industries and markets. By using the data produced by ferrography analysis, it is possible for clients to avoid costly machine shut-downs and extend component life by taking preventative actions when early-warning abnormal wear is found.
Advantages of Ferrography:
By monitoring particles generated by wear or environmental contamination, ferrography experts are able to detect the critical stage of accelerated wear that precedes costly and dangerous component failures. Ferrographic analyses determine the number, size and shape of wear particles.
Ferrography Diagnosis Report:
After the samples are analyzed by SPECTRO, the client receives a comprehensive diagnosis report by email or in hard copy format. The detailed report includes interpretation and a full color microscope photo of the wear particles.
Ferrography Testing is available for:
- Metallurgical Applications
- Engine Maintenance
- Chemical Plants
- Ships, Barges, Maritime Clients
- Offshore Installations
- Power Stations
- Insurance Companies
- Railroad Industry
- Manufacturing Plants
- Vehicle Fleets, Public Transport
- Food Processors
- General Industry and more
Products and Installations Monitored with Ferrography testing includes:
- Engines, Gears, Pumps
- Compressors, Gas Turbines
- Steam Turbines
- Hydraulic Systems, Refrigeration Systems
- Grease Lubricated Bearings
- Electrical Oil Systems
- Heat Transfer Systems
- Heat Treatment Systems
Our oil condition monitoring (OCM) testing helps clients with valuable engines and related machinery minimize down-times and repair problems caused from lubricant related issues.
Lubricant and other Fluids Tests include:
- Appearance, Color
- Emulsification, Electrical Strength
- Ferrography
- Flash point: Open cup, Closed cup, Seta Flash
- Foam Test
- Oxidation, Nitration
- Particle Count
- Pentane, Heptanes Insoluble’s
- PQ Index, Soot
- Total Base Number, TBN
- Total Acid Number, TAN
- Viscosity 40 C, Viscosity 100 C
- Water Content
- Water by Karl Fisher Volumetric
- Water Content Coulometric Titration
- Wear Metals
ASTM Test Methods Available:
- D-6304 Water Content
- D-5185 Wear Metals in Use Oil Analysis
- D-3278 Flash Point
- D-2982 Anti Freeze Detection
- D-2896 Base Number
- D-1401 Demulsification
- D-893 Insolubles in Used Oil
- D-892 Foam Test
- D-664 Acid Number
- D-445 Viscosity
Lubricant Oil Tests include:
- Acidity: Acid number of Petroleum Products by Potentiometric Titration
- Anti-Freeze: Detecting Glycol-based Anti-Freeze in Used Lubricating Oils
- Caustics: Base Number of Petroleum Products by Potentiometric Perchloric Acid Titration
- Ferrography: Predictive Maintenance Test Based on Wear Debris Analysis.
OCM Products Tested:
- Air Compressor fluids
- Gas-motor, Compressor Fluids
- Refrigeration Compressor Fluids
- Electrical Oils
- Diesel Engine Lubricants
- Power Generator Lubricants
- Petrol, Gasoline Engine Fluids
- Gearbox Oils
- Heat Treatment Fluids, Heat Transfer Fluids
- Hydraulic Oils
- Turbine Steam, Gas Fluids
OCM Lab Tests offer Early Detection of:
- Contamination in used Diesel Crankcase Lubricating Oils
- Water Content in Fuels and Oils
- Engine wear debris in marine lubricants
- Insoluble Content in Industrial Lubricants and Engine Lubricants used in Marine Non-engine Applications
- Additive Elements, Wear Metals and Contaminants in New and Used Lubricating Oils
- Insoluble’s, Water and Oxidation in Used Lubricating Oils
- Insoluble’s in Used Marine Lubricating Oils
- Flash Point of Used Marine Diesel Oils
Oil analysis and ferrography
Oil analysis entails removing a sample of oil from an oil-wetted component and subjecting it to a variety of chemical and physical tests to determine the condition of both the lubricant and the component. It looks at wear debris, contaminants and the general health of the oil.
The most common test involves SOAP (Spectrometric Oil Analysis Programme) analysis of the wear debris - and additives and contaminants - present in the oil.
Although this is a very useful technique, it has a severe limitation in that spectrometric analysis will not detect wear particles greater than 10m. This means that it is possible for a severe wear situation to exist with large wear particles that will not be detected by traditional SOAP analysis.
The obvious solution to this problem would be to filter all oils through a fine filter pad or membrane and examine any debris present under a microscope. Time and cost considerations mean that this is not a practical solution, so some sort of reliable screening test is required.
Spectro has an oil particle counter based on ISO 4402 which gives the NAS value or the size distribution of particles from 2 to 100 microns.
Analytical ferrography
In analytical ferrography, a ferrogram slide is prepared and this is examined under a powerful compound microscope with suitable optics, filters and light sources.
It enables the morphology of particles to be studied to determine wear processes, the origin of the wear particles and sometimes the cause of wear. The common characteristics of the wear particles that are studied are: size, concentration, colour, shape, edge detail and surface texture. The common types of wear modes that can be identified by analytical ferrography are: rolling, sliding, cutting, spherical and rubbing - each indicative of a different wear process. Individual types of wear particles can also be identified, e.g. galling, scoring, pitting, spalling, cracking, smearing, rolling, laminar, striations and corrosion.
