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.
Batra Lab 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.
Ferrography Diagnosis Report
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:
• D-6304 Water content
• D-5185 Wear metals in used oil
• D-7690 Analytical Ferrography
• NAS-1638 and ISO-4406 Particle count
• D-3278 Flash point
• D-2982 Anti-freeze detection
• D-2896 Base number
• D-1401 Demulsifier
• D-893 Insolubles in used oil
• D-892 Foam test
• D-664 Acid number
• D-445 Viscosity
Lubricating oil test include:
• Acidity: Acid number of petroleum products by potentiometric titration
• Anti-freeze: Detection of Glycol-based Anti-freeze
• Caustics: Base number of petroleum products by potentiometric perchloric acid titration
• Ferrography: Preventive maintenance test based on wear particleanalysis
Advantages of Ferrography Testing:
• Predicts the condition of lubricants
• Prevents machine breakdown, thereby saving money
• Provides correct detail about oil condition and gives tremendous results
• Prevents the occurrence of accidents
• Protect equipments
• Extends the life of components
Ferrography Testing Services are available for:
• Chemical plants
• Manufacturing industries
• Power stations
• Metallurgical applications
• Engine maintenance
• Offshore installation
• Railroad industries
• Food processing industries
• Vehicle fleets and public transport
The components whose Ferrography Testing is carried out:
• Gear systems
• Compressor systems
• Bearing systems
• All types of engines
• Hydraulic systems
• Pumps
• Turbines
• Aircrafts
• Agitators
Tests conducted for lubricants and other oils:
• Emulsification, Electrical strength
• Appearance, Color
• Flash Point
• Foam Test
• Nitration, Oxidation
• Particle Count
• PQ Index, soot
• Total Acid Number (TAN)
• Total Base Number (TBN)
• Water Content by Karl Fisher Volumetric and Coulometric Titration
• Wear metals
• Pentane, Heptanes and other insoluble
Oil Analysis Aviation
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:
• Minimize installation errors
• Increase the availability of equipments
• Avoid In-Flight Shut-Down of engines (IFSDs)
• Verifying maintenance service plan claims
• Reduces maintenance cost
• Reduces the need of unscheduled maintenance