Ferrography banner 1

Ferrography Testing

Ferrography involves separation of solid particles from the oils and examine them under a microscope for checking the characteristics like particle size, composition, concentration, morphology and surface condition of ferrous as well as non-ferrous wear particles. The total number of particles in unit volume of oil sample is assumed as Wear Particle Concentration (WPC). It is always better to monitor the particles being generated within the oil which gets mixed up from the machine components or environment. It helps to detect the critical stage which may lead to component failure.

Spectro provide services for Ferrography testing of oils which are used in machines and equipments. It enhances the life of equipments by providing an early warning related to failure or damage. These days, Analytical Ferrography has become one of the most powerful techniques to analyze various oil samples. Although the test protocols are lengthy and demands skilled personnel, yet the technique gives excellent return. This technique provides examination at micro level and analyzing the debris present in lubricating oils. These particles may be metallic or non-metallic in nature. By employing Ferrographic Technology, we can extract, classify and visualize the size, shape and number of particles present.

This technique can also be called as Wear Particle Analysis, Wear Debris Analysis or Machine Condition Monitoring. It comprise of both, qualitative as well as quantitative studies.

Analysis of Wear Partical Analysis in Lube Oil

After the complete analysis of oil sample, we provide a comprehensive diagnosis report by an email along with a hard copy. It includes a complete interpretation and colored picture of wear particles taken from microscope.

Available Test Methods:

  • bulletD-6304 Water content
  • bulletD-5185 Wear metals in used oil
  • bulletD-7690 Analytical Ferrography
  • bulletNAS-1638 and ISO-4406 Particle count
  • bulletD-3278 Flash point
  • bulletD-2982 Anti-freeze detection
  • bulletD-2896 Base number
  • bulletD-1401 Demulsifier
  • bulletD-893 Insolubles in used oil
  • bulletD-892 Foam test
  • bulletD-664 Acid number
  • bulletD-445 Viscosity

Advantages of Ferrography Testing:

  • bulletPredicts the condition of lubricants
  • bulletPrevents machine breakdown, thereby saving money
  • bulletProvides correct detail about oil condition and gives tremendous results
  • bulletPrevents the occurrence of accidents
  • bulletProtect equipments
  • bulletExtends the life of components
Ferrography Testing Services are Available For:
  • bulletChemical plants
  • bulletManufacturing industries
  • bulletPower stations
  • bulletMetallurgical applications
  • bulletEngine maintenance
  • bulletOffshore installation
  • bulletRailroad industries
  • bulletFood processing industries
  • bulletVehicle fleets and public transport
The components whose Ferrography Testing is carried out:
  • bulletGear systems
  • bulletCompressor systems
  • bulletBearing systems
  • bulletAll types of engines
  • bulletHydraulic systems
  • bulletPumps
  • bulletTurbines
  • bulletAircrafts
  • bulletAgitators
Tests Conducted for Lubricants and Other Oils:
  • bulletEmulsification, Electrical strength
  • bulletAppearance, Color
  • bulletFlash Point
  • bulletFoam Test
  • bulletNitration, Oxidation
  • bulletParticle Count
  • bulletPQ Index, soot
  • bulletTotal Acid Number (TAN)
  • bulletTotal Base Number (TBN)
  • bulletViscosity (40° C and 100° C)
  • bulletWater Content by Karl Fisher Volumetric and Coulometric Titration
  • bulletWear metals
  • bulletPentane, Heptanes and other insoluble

Our Machine Condition Monitoring (MCM) Testing services helps our customers with valuable engines and related machines for minimizing downtime and repair the problems caused by lubricants.

The Products Tested for MCM are:
  • bulletAir compressor fluids
  • bulletGas motors
  • bulletRefrigeration compressor fluids
  • bulletElectrical oilst
  • bulletDiesel engine lubricating oils
  • bulletPower generator lubricating oils
  • bulletPetrol or gasoline engine fluids
  • bulletGearbox oils
  • bulletHeat transfer/treatment fluids
  • bulletHydraulic oils
  • bulletTurbine steam and gas fluids
MCM Lab Tests Offer Early Detection of Following Cases:
  • bulletWater content in fuels and oils
  • bulletContamination in used diesel crankcase lubricating oils
  • bulletInsoluble content in Industrial and Engine Lubricants used in marine non-engine applications
  • bulletAdditive elements, wear metals and contaminants in used or new lubrication oils
  • bulletOxidation in lubrication oils
  • bulletFlash point of used marine diesel oils
Oil Analysis
Oil Analysis is basically the sampling and analysis of properties of lubricating oils. It is practiced routinely to maintain the accuracy of oils and provide information about the machine condition. Oil analysis is divided into three categories.

1. Analysis of oil properties and condition
2. Analyzing the contaminants
3. Analysis of wear debris from machineries

Oil or wear particle analysis is a combination of spectrometric, ferrographic and filter analysis which is used to detect the abnormalities in various Aviation systems, before the wear or debris causes any serious damage. It indicates when the components are near to failure which provides time to plan the maintenance. The case of flight shutdowns which occur because of failed critical components can be avoided by Wear Check Analysis. It points out the wear signatures of rolling element bearings, transmission systems, gears and other components. It helps avoiding installation errors and frequent failures. This technique makes use of the morphology of wear particles for diagnosing specific wear modes and reduces he cost of equipment components which in turn enhances the aircraft’s reliability.

Advantages of Oil and Wear Particle Analysis for Aviation Equipments:
  • bulletMinimize installation errors
  • bulletIncrease the availability of equipments
  • bulletAvoid In-Flight Shut-Down of engines (IFSDs)
  • bulletVerifying maintenance service plan claims
  • bulletReduces maintenance cost
  • bulletReduces the need of unscheduled maintenance