Ferrography Testing

Preventive medicine :

When used as trend analysis, accelerated wear of critical equipment is accurately detected and correctly diagnosed for planned maintenance before production and safety are jeopardized. Our Ferrographic services enable equipment and maintenance managers to protect their critical production equipment and extend the component life of gear boxes, turbines, hydraulic systems, compressors, wheel motors, and transmissions by detecting and measuring abnormal wear before it creates problems.

Ferrography :

Ferrography is a powerful tool used for oil analysis. It involves separating out solid particles from a lubricant and examining them under a microscope checking characteristics like particle size, concentration, composition, morphology and surface condition of the ferrous and non-ferrous wear particles. This testing is commonly called "Ferrography' / "Wear Particle Analysis" / “Wear Debris Analysis” / "Equipment Condition Monitoring".

Ferrography consists of two mai activities :

Quantitative Analysis
Qualitative Analysis (Analytical Analysis)

Quantitative analysis : What is wear particle concentration (WPC)?

The count of number of particles in unit volume of oil sample is considered as wear particle concentration (WPC). We also offer weight of particles in unit volume of oil samples for trending.

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.

Qualitative analysis Or Analytical Ferrography :

Analytical ferrography is among the most powerful diagnostic tools in used oil analysis today . The technique of Wear Debris Analysis (Analytical Ferrography) is gaining popularity in the field of Machine Condition Based Maintenance System. To perform analytical ferrography the solid debris suspended in a lubricant is separated and systematically deposited onto a glass slide. The slide is examined under a microscope to distinguish particle size, shape , concentration, composition, morphology and surface condition of the ferrous and non-ferrous wear particles. The particles contained in a lubricating fluid carry detailed and important information about the condition of the machine components.

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:

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 Monitored with Ferrography testing :

All type used lubricants (oil and Grease) moving equipments parts,i.e-

All Type Engine
Gear System
Compressors System
Hydraulic Systems
Bearings System
Pumps
Aviation
Turbines
Agitator

Our Machine Condition Monitoring (MCM) 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

Test Methods Available:

D-6304 Water Content
D-5185 Wear Metals in Use Oil Analysis
D-7690 Analytical Ferrography
NAS-1638 & ISO-4406 Particle Count
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: Preventive 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 :

Oil Analysis is the sampling and laboratory analysis of a lubricant's properties, suspended contaminants, and wear debris. Oil Analysis is performed during routine preventive maintenance to provide meaningful and accurate information on lubricant and machine condition. By tracking oil analysis sample results over the life of a particular machine, trends can be established which can help eliminate costly repairs. The study of wear in an machinery is called tribology. Tribologists often perform or interpret oil analysis data.

Oil Analysis can be divided into three categories:

1. analysis of oil properties & Condition ,
2. analysis of contaminants,
3. analysis of wear debris from machinery

Oil Analysis Aviation:

Oil and wear particle analysis is a combination of spectrometric, ferrographic, and filter analysis. when used as part of your quality assurance program, oil and wear particle analysis will detect abnormal wear modes in aviation systems, long before the wear can lead to any serious damage. Wear Check's analysis will indicate when components are near failure. this gives you time to plan maintenance. Worn components can be replaced at your local facility avoiding rental, and shipping charges. In flight shutdowns, as a result of failed critical components, are avoided, as Wear Check's analysis pinpoints the wear signatures of rolling element bearings, gears, transmission system, and other critical components. Wear Check's filter and ferrographic analysis utilizes the morphology of wear particles to detect specific wear modes. Avoid installation errors, and rapid failures, when analysis detects cutting wear from misaligned components. Wear Check's oil and wear particles analysis will allow you to realize a reduction in the cost of equipment maintenance, and an increase in aircraft availability and reliability.

The Benefits of Oil and Wear Particle Analysis for Aviation equipment:

Avoidance of In Flight Shut-Down of engines (IFSDs)
Reduction in unscheduled maintenance
Increase in equipment availability
Reduction in maintenance costs
Minimization of installation errors
Verification of maintenance service plan claims