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8. lubrication

This document discusses lubrication and lubricants. It begins by explaining the purposes of lubrication which are to reduce friction and wear, transfer heat, clean parts, provide protection, seal parts, and transmit power. It then discusses the principles of lubrication including hydrodynamic, elastohydrodynamic, boundary, and hydrostatic lubrication. The document categorizes lubricants as solid, semi-solid, liquid, and gaseous. Key properties of lubricants that are described include kinematic viscosity, viscosity index, pour point, flash point, and total base number. The document provides examples of how to select lubricants based on factors like temperature, speed, load, and operating conditions. It also discusses lubrication systems

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8.LUBRICATION
CONTENT 1. PURPOSES OF LUBRICATION 2. PRINCIPLES OF LUBRICATION 3. PROPERTIES OF LUBRICANTS 4. CLASSIFICATION OF LUBRICANTS 5. FACTORS TO CONSIDER WHEN SELECTING LUBRICATION SYSTEMS 6. LUBRICATION SYSTEMS 7. SAFETY REQUIREMENTS
Meaning Of Lubrication   Friction – is created when there is relative motion between two surfaces Resistance to motion is defined as friction .  Lubrication is use of a material between surfaces to reduce friction .  Any material used is called a lubricant.
Machines Need Lubrication  Bearings Gears Cylinders and their piston Flexible Coupling Chains Wire ropes
Lubricant Lubricate Cooling Cleaning Protection Sealing Transmit Power What is the function of a Lubricant ? 
Function (1) : Lubricate  Reduce Friction and Wear  The effects of friction • Metal to metal contact • Leads to wear and tear • Generates heat • Results in power loss  Lubricant reduces friction by forming a film • Reduces ill effect of friction
Function (2) : Cooling  Heat Transfer  When fuel is burnt in an engine • 33% is useful power • 33% removed by cooling water • 33% by lube oil and radiation  Lube oil removes heat from all areas and brings it to engine sump  Improper cooling can lead to over heating , lead to wear , distortion and failure.
Function (3) : Cleaning   Clean carbon and Varnish deposits  Flushes the entire system removing • Soot ) ‫ناخدال‬ ‫د‬ ‫ا‬ ‫و‬ ‫س‬ ( • Acids • Wear products • Moisture ) ‫ةب‬ ‫و‬ ‫ط‬ ‫رال‬ (  Removes external contaminants dust ,  moisture ( external )
Function (4) : Protection   Protection against acids and moisture  Very important to increase life of component and equipment
Function (5) : sealing   Oil film • Between piston ring and linear • Helps in creating a gas tight seal
Function (6) : Transmit Power  Function (5) : Noise Reduction
Principles of lubrication   Four main principles : • Hydrodynamic Lubrication • Elastohydrodynamic lubrication • Boundary Lubrication • Hydrostatic Lubrication
types 1. Hydrodynamic or (Thick Film Lubrication) • it exists when the moving surfaces are separated by the pressure of a continuous unbroken film or layer of lubrication. • In this type , the load is taken completely by the oil film. • It depends on the relative speed between the surfaces, oil viscosity, load, and clearance between the moving or sliding surfaces.
L ubricationandits types Application of hydrodynamic lubrication : Delicate instruments. Light machines like watches, clocks, guns, sewing machines. Scientific instruments . Large plain bearings like pedestal bearings, main bearing of diesel engine .
L ubricationandits types 2 . Hydrostatic lubrication • It is essentially a form of hydrodynamic lubrication but the film instead of being self-generated, the separating pressure is supplied by an external oil pump . • Hydrostatic lubrication depends on the inlet pressure of oil and clearance between the surfaces .
L ubricationandits types
L ubricationandits types Application of hydrostatic lubrication : This type of lubrication is mainly used in the following areas : • Two stroke engines . • Bigger machines .
L ubricationandits types 3. Elastohydrodynamic lubrication • Is developed in heavily loaded rolling contacts . • The contacting surface is elastically deformed,distributing the load over a greater area . • High pressure results in increasing viscosity of lubricant , which improves load capacity .
Examples of machinery applications that operate under EHL are: • rolling element bearings, gear teeth and cam contacts (rolling) where high rolling contact loads occur. L ubricationandits types
L ubricationandits types 4. Boundary or thin film lubrication • Lubrication film is insufficient to separate the contacting surfaces. • the oil film thickness is so small . • metal to metal contact occurs between the moving surfaces .
L ubricationandits types • Unlubricated vs boundary lub vs hydrodynamic lub
L ubricationandits types This type of lubrication is used in the following areas : 1. A shaft starts moving from rest. 2. The speed is very low. 3. The load is very high. 4. Viscosity of the lubricant is too low.
L ubricationanditstypes 5. Mixed lubrication . is the transition between Hydrodynamic and Boundary lubrication. . Two surfaces are partly separated, partly in contact .
L ubricationandits types
L ubricationandits types 6. Extreme pressure lubrication . This lubrication is for very high press ,temperature, speed sliding surfaces . . Extreme pressure additives are used along with the lubricants . . They are activated by reacting with the metal surface when the temperatures are elevated due to the extreme pressure and friction . . Then form solid surface films of (S,CL and P) , acts as a barrier to reduce friction, wear, eliminate the possibility of welding .
Selection Of Lubricant   Temperature of operation  Speed  Load  Oil change interval  Operating conditions and possible contaminants  Method of lubricant application  Size , type and material of elements to be lubricated
Types of Lubricant   Gaseous lubricants  Liquid lubricants  Semi - solid lubricants  Solid lubricants
 Classification of Lubricant  Solid Lubricants : Polymer , metal – solid, carbon and graphite , and ceramic and cermet.
Types of Lubricant  Semi-Solid Lubricant ( Grease )  Advantages Of Greases : • Good for inclined/vertical shafts. • Water resistant & reduce oil vapor problems. • Reduce noise and vibration Disadvantages of Greases : • Because of semi-solid nature of greases, it does not perform the cooling , so poor dissipation of heat. • No filtration .. So contaminants / wear-debris cannot be separated.
 Types of Lubricant  Liquid lubricants , which include: • Vegetable oil and animal oil • Mineral oil from petroleum • Blended oil , doped oil , or compound oil Liquid Lubricants :
 Types of Lubricant  Gas Lubrication : ADVANTAGES : • Temperature range (-2000C) to (20000C). No vaporization , cavitation , solidification , decomposition. Very low viscosity (1000 times less viscous than even the thinnest mineral oil ) , therefore ultra low friction . Possible high speed. Cleanliness. No seal requirement for lubrication.
Types of Lubricant  DISADVANTAGES : • Very low load capacity. Low damping. Ultra low film thickness. Smooth surfaces & very low clearance (to maximize load capacity & minimize flow rate) needs a specialist designers & manufacturer (close tolerance). Less forgiving of errors in estimating loads or of deviations from specifications during manufacture and installation.
Types of Lubricant   Selection of Lubricant Type : Load and speed are two major factors which affect selection of lubricants environment and sealing requirements are additional factors which affect lubricant selection. Apparent area, material conductivity and friction coefficient decide the operating temperature.
Application  Industrial • Hydraulic oils • Air compressor oils • Food Grade lubricants • Gas Compressor oils • Gear oils • Bearing and circulating system oils • Refrigerator compressor oils • Steam and gas turbine oils
Properties of Lubricants   Kinematic viscosity  Viscosity index  Pour point  Flash point  Total Base Number (TBN)
Kinematic viscosity   Internal resistance to flow  Selection of viscosity depends of : • Speed • Load • Temperature
Kinematic viscosity  • Speed : The faster a shaft rotates in a bearing the thinker developing oil wedge will be become . Therefore , for high speed application we need a light-bodied oil ( low viscosity oil ) and , conversely . for low speed applications an oil with heavy body ( high viscosity ) is Required
Kinematic viscosity  • Load : A lightly-loaded application will operate with a lighter-bodied oil (low viscosity oil) than a heavily loaded one, as a lesser load-carrying lubricating film is required.
Kinematic viscosity  • Temperature : Viscosity is dramatically influenced by temperature, . shown in the following diagram illustrating . experiment conducted on the same oil but at varying temperatures. At low temperature , oil does not flow as free, at high temperature. It is, therefore , very important to indicate the temperature at which the viscosity was determined wh. reporting a viscosity.
Kinematic viscosity  Low Viscosity oils used : • High speeds • Low pressure • Low temperature High Viscosity oils used : • Low speeds • High pressure • High temperature
Viscosity index  Measure of fluids change of viscosity with temperature. Higher the VI lower will be the change of viscosity with temperature • high number , less change • low number , more change
Pour Point  • Lowest temperature at which the fluid will flow • Indicates lowest operating temperature • Measured in °C or °F
Flash Point  • Lowest temperature at which the vapor above the liquid will ignite under flame. • Indicated safe maximum temperature of operation. • Indicator of volatility. • Test method - COC and PMCC • Measured in °C
Total Base Number ( TBN )  • Measured the acid neutralizing reserve in oil. • Important for deciding discard of oil • Decreases due to • Oxidation of oil • Water contamination • Fuel contamination • Measured in Mg KOH/g of oil
Lubrication Handling & Storage Introduction :- Proper handling and storage of lubricants can be of great benefit to the customer. Contaminated lubricants can be a major cause of equipment failure. The resulting downtime for repairs is very costly. A small amount of effort spent in organizing oil and grease stocks and making sure that they are handled and stored properly will save time and money by increasing production and reducing maintenance costs. Content :- 1- Receiving New Lubricants. 2- Storage.
Receiving New Lubricants Procedures :- 1 Correct Unloading. 2 Moving Containers/Drums to Storage Area. Techniques :- 1 Using forklift trucks. 2 Manually operated.
1- Using Forklift Trucks :- If containers are palletized, a forklift should be used to unload the lubricants from the shipping vehicle.
1- Using Forklift Trucks :- For drums not shipped on pallets, special drum handling attachments for forklifts should be used to remove the drums from the
2- Manually Operated :-
Storage Target :- “ Reducing Contaminations ”
Contamination Causes :- 1 Damaged Containers or drums. 2 Poor Storage Practices. 3 Dirty handling & dispensing equipment. 4 Moisture seeping into tanks or containers.
Indoors Storage • The recommended method of storing lubricants is indoors in a designated oil area or an oil house. • An oil house or indoor storage facility should have racks and shelving that allow for adequate protection of drums as well as ease of placement and removal.
Indoors Storage • The efficient use of an oil storage area or oil house will also allow better stock rotation. Access to the older stocks should always be open so that the older lubricants will be used first. The First In, First Out (FIFO) method of inventory control will eliminate the risk of deterioration caused by excessive storage period. • Even when stored indoors, contamination can occur when transferring the lubricants to the various pieces of dispensing equipment or when adding to the machine to be lubricated.
Indoors Storage Precautions :- 1. Pumps, funnels, oil cans, hoses, grease guns and other dispensing equipment should be kept clean and stored in a closed vented cabinet or covered when not in use. 2. When adding oil to equipment, do so in a manner that will not add dirt to the system. 3. Always clean the top of the reservoir and around the filler cap before removing the cap. 4. It is also good practice to add the oil through a cloth or metal screen to prevent the accidental entry of dirt into the reservoir.
Outdoors Storage Disadvantages:- 1. When drums are stored outside, the weather and elements can fade important drum markings and labels. If the drums have weathered severely enough that the product inside cannot be identified, this can lead to using the incorrect lubricant in a particular piece of equipment and possibly damaging that equipment. 2. The effects of changing temperature on lubricant containers can be seen in several ways.
Outdoors Storage Precautions :- 1. drums should always be covered with a shelter or at least a plastic drop cloth to protect the drums from rain and other sources of water. 2. The preferred position for outdoor storage is with the drums on their sides and bungs approximately horizontal. 3. Drums should be stored on racks or at least on blocks several inches above the ground, to prevent additional moisture damage.
The effects of changing temperature on lubricant Drums Low-Temperature Degradation of Lubricants • Most good quality synthetic and conventional mineral oils are not affected by storage temperatures below 120°F (49°C). However, storing lubricants near furnaces, steam lines or direct sunlight in high temperature climates for a prolonged time period may cause additives and base oils to oxidize prematurely. • Lubricants that are potentially contaminated with volatile products, including diesel fuel, kerosene, or any other solvent, must never be stored in high temperatures. The presence of solvents can be identified by a test called the flash point test.
The effects of changing temperature on lubricant Drums Low-Temperature Degradation of Lubricants • The major difficulty from cold storage temperature arises from the high viscosity of these fluids and the difficulty of pumping them to operating equipment and transport vessels. • Products that contain significant amounts of water, like water-glycols and oil-water emulsions, should not be exposed to temperatures below 40°F (4°C).
The effects of changing temperature on lubricant Drums(Outdoors Storage) • Alternating periods of extreme hot and cold can cause the metal of a drum to expand and contract. This expansion and contraction can cause the seams of a drum to weaken. As a result, the drums may begin to leak and lubricant may be lost. • If water is allowed to accumulate on the top of a drum, temperature changes - alternating heating and cooling - causes a vacuum, which can cause moist air to be sucked into the drum vapor space.
⦁ Lubrication ⦁ powertransmission ⦁ surface protection ⦁ heat transfer ⦁ surface cleansing
⦁ Reduction of friction ⦁ Corrosion prevention ⦁ Heat removal ⦁ rust prevention
⦁ Transmission parts. ⦁ Bearings. ⦁ Cams. ⦁ Journals. ⦁ Seal faces. ⦁ Any situation involving metal to metal contact.
⦁ SuctionFilter ⦁ PressureFilter ⦁ ReturnFilter ⦁ PilotLinePressureFilter ⦁ DuplexHighPressureFilter ⦁ DuplexLowPressure,HighFlowFilter ⦁ Off-LineFilter(Dedicated) ⦁ Off-LineFilter(Mobile)
⦁ Filter carts have become an essential tool in many hydraulic and lubrication systems. ⦁ Because new oil in drums or totes typically does not meet stringent OEM cleanliness specifications, it should be filtered prior to use in hydraulic or lubrication applications.
⦁ particulate Removal ⦁ WaterRemoval ⦁ AcidRemoval
Signs of Lubricant Starvation
"What is the first indication of lubricant starvation?" • Heat is the direct consequence of lubricant starvation. Once any mechanical system becomes depleted of lubricant, and the lubricating film keeping gears, bearings or slides apart is no longer present to support or protect the surfaces, surface-to-surface contact will occur. When two surfaces slide or rub together, friction is produced, and from friction comes heat.
Before frictional heat is generated, the only way to detect lubricant starvation would be through vibration analysis. Vibration analysis can pick up subtle vibration changes in the machinery and may be able to identify lubricant starvation before the extreme heat from friction is discovered. The effect of friction on the two surfaces rubbing together without lubrication will cause them to heat up quickly. The amount of heat generated will be in direct correlation to how fast the two surfaces are sliding or rotating. For example, gears rotating at only 60 rpm will take much longer to heat up than those rotating at 1,800 rpm. Without proper lubrication, gears rotating at faster speeds not only will heat up quickly but can also lead to failure of the machine.
In the image below, notice the difference between a good oil supply (full lubricant film), an impaired oil supply (boundary contact), and dry friction and wear (caused by lubricant starvation). Welding and galling occur when the two surfaces become so hot that they weld together and then tear apart, resulting in large amounts of debris. This is not something you want happening inside your machine.
Other signs that your machine is suffering from lubricant starvation include smoke, an unusual smell and the machine becoming hot to the touch. Smoke is caused by the heating of what is left of the lubricant. This is usually the case when you see some poor soul stranded by the side of the road with smoke pouring out from under the hood of his car. Before a machine even begins to smoke, you can often smell the oil starting to heat up. This provides a good way to detect lubricant starvation. Another excellent method is through touch. Your hands are very sensitive heat detectors and can identify subtle changes in temperature. However, the most effective way to combat lubricant starvation without expensive diagnostic equipment is to check your machinery on a regular basis. Ensure your PMs are appropriate for each machine and take into account the changing conditions around the equipment, such as temperature, moisture and workload
Determining an Oil's Energy Efficiency
"We have two different oils and need to determine which one is more energy efficient. What data should we collect? What parameters can help establish energy efficiency?" Energy efficiency must be measured in terms of the reduction of energy consumption. More specifically, it is related to how much energy the machine consumes in order to operate. This principle applies to machines that convert one type of energy like chemical or electric to a mechanical one, such as electric motors and combustion engines. It is also applicable to machines that transmit mechanical energy, like gearboxes. In some cases, it may be evaluated in a powertrain such as a combination of a combustion engine and a transmission.
The energy saved is measured in terms of what is utilized to move or operate the machine. For example, for a combustion engine, the reduction in fuel consumption would be measured. For an electric motor and/or gearbox, the reduction of electric energy (voltage, current and power factor) would be measured. The energy savings can also be measured indirectly by simply verifying a reduction in the operating temperature. This can be a practical method for electric motors, gearboxes and pillow block bearings. Although it likely will not reveal the amount of energy saved, there will be a clear indication of the reduced energy consumption
It is important to note that certain conditions must be kept consistent for the sake of comparison. These conditions would include using a similar amount of lubricant (the same oil level or regreasing amount), measuring the equipment in similar operating conditions (load and speed), and maintaining similar ambient or room temperatures. Preferably, the same instruments and methods should also be used to measure the energy consumption for both lubricants. Otherwise, similar or comparable instruments should be utilized. Finally, be sure to take several readings to minimize the impact of inevitable variations.
Why should we prevent leakage ??? 🠶It has been estimated that more than 100 million gallons of lubricants could be saved every year if external leakage from pumping systems, hydraulic machines, gear cases and sumps was eliminated . 🠶Studies have indicated that every year the average plant uses four times more oil than its machines actually hold, and this is not accounted for by frequent oil changes.
Why should we prevent leakage ??? 🠶 Approximately 70 to 80 percent of hydraulic oil leaves the system due to leakage, spills, line and hose breakage and fitting failures 🠶 The lack of attention to a few basic details costs millions of dollars annually in make-up oil, cleanup, disposal of external fluid waste, unnecessary maintenance downtime, safety and environmental damage.
What are the causes of leakage ??? 🠶seals and packings . 🠶pipe joints and gaskets 🠶damaged ruptured and corroded lines and vessels 🠶wrong selection improper application 🠶 poor installation and inadequate maintenance practices that are applied to sealing systems.
What are the causes of leakage ??? 🠶Overfilling 🠶 pressurization from plugged vents 🠶 worn seals 🠶over-torqued gaskets
🠶The major reasons for initial seal failure and fluid leakage are cost- cutting by machine design engineers 🠶 incomplete commissioning and plant start-up procedures 🠶inadequate equipment condition monitoring and maintenance practices.
Once a seal has failed and fluid leakage results : 🠶 the problem is perpetuated by purchasing low-quality or incorrect seals 🠶 careless installation practices used during replacement procedures. 🠶 The subsequent leaks, while possibly not considered excessive, can go on and on. Soon plant operating and maintenance personnel accept the leakage as normal.
How to discover leakage !!!!!!! ???? 🠶Leak detection can be by : 🠶 visual inspection . 🠶 possibly aided by the use of dyes . 🠶through make-up oil records.
How to control leakage !!!!! 🠶Engineers should pay more attention for lubrication when designing machines . 🠶Use modern systems . 🠶Now that how leakage are danger and cost phenomena .
Safety tips for handling Lubricants :
In case of contact with the skin : 🠶Respect strict personal and industrial hygiene rules. 🠶To avoid contact with the body: - use oil-proof gloves, wear clothes with an efficient protection, do not wear oil contaminated clothes, solvents, such as petroleum. 🠶petrol must not be used to remove oil from the skin, use a protecting cream.
In case of contact with the eyes : 🠶Wearing safety goggles is highly recommended when oil is likely to splash in the eyes. 🠶 In case oil accidentally splash into your eyes, thoroughly rinse them with water for at least 15 minutes and contact a physician if irritation persists.
In case of inhalation : 🠶Avoid inhaling oil mists and fumes. 🠶Premises should be properly ventilated. 🠶The acceptable limit for an oil mist is 5 mg/m3.

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8. lubrication

  • 1.
  • 2.
    CONTENT 1. PURPOSES OFLUBRICATION 2. PRINCIPLES OF LUBRICATION 3. PROPERTIES OF LUBRICANTS 4. CLASSIFICATION OF LUBRICANTS 5. FACTORS TO CONSIDER WHEN SELECTING LUBRICATION SYSTEMS 6. LUBRICATION SYSTEMS 7. SAFETY REQUIREMENTS
  • 3.
    Meaning Of Lubrication  Friction – is created when there is relative motion between two surfaces Resistance to motion is defined as friction .  Lubrication is use of a material between surfaces to reduce friction .  Any material used is called a lubricant.
  • 4.
    Machines Need Lubrication  Bearings Gears Cylindersand their piston Flexible Coupling Chains Wire ropes
  • 5.
  • 6.
    Function (1) :Lubricate  Reduce Friction and Wear  The effects of friction • Metal to metal contact • Leads to wear and tear • Generates heat • Results in power loss  Lubricant reduces friction by forming a film • Reduces ill effect of friction
  • 7.
    Function (2) :Cooling  Heat Transfer  When fuel is burnt in an engine • 33% is useful power • 33% removed by cooling water • 33% by lube oil and radiation  Lube oil removes heat from all areas and brings it to engine sump  Improper cooling can lead to over heating , lead to wear , distortion and failure.
  • 8.
    Function (3) :Cleaning   Clean carbon and Varnish deposits  Flushes the entire system removing • Soot ) ‫ناخدال‬ ‫د‬ ‫ا‬ ‫و‬ ‫س‬ ( • Acids • Wear products • Moisture ) ‫ةب‬ ‫و‬ ‫ط‬ ‫رال‬ (  Removes external contaminants dust ,  moisture ( external )
  • 9.
    Function (4) :Protection   Protection against acids and moisture  Very important to increase life of component and equipment
  • 10.
    Function (5) :sealing   Oil film • Between piston ring and linear • Helps in creating a gas tight seal
  • 11.
    Function (6) :Transmit Power  Function (5) : Noise Reduction
  • 12.
    Principles of lubrication  Four main principles : • Hydrodynamic Lubrication • Elastohydrodynamic lubrication • Boundary Lubrication • Hydrostatic Lubrication
  • 13.
    types 1. Hydrodynamic or(Thick Film Lubrication) • it exists when the moving surfaces are separated by the pressure of a continuous unbroken film or layer of lubrication. • In this type , the load is taken completely by the oil film. • It depends on the relative speed between the surfaces, oil viscosity, load, and clearance between the moving or sliding surfaces.
  • 16.
    L ubricationandits types Application of hydrodynamiclubrication : Delicate instruments. Light machines like watches, clocks, guns, sewing machines. Scientific instruments . Large plain bearings like pedestal bearings, main bearing of diesel engine .
  • 17.
    L ubricationandits types 2 . Hydrostaticlubrication • It is essentially a form of hydrodynamic lubrication but the film instead of being self-generated, the separating pressure is supplied by an external oil pump . • Hydrostatic lubrication depends on the inlet pressure of oil and clearance between the surfaces .
  • 18.
  • 20.
    L ubricationandits types Application of hydrostaticlubrication : This type of lubrication is mainly used in the following areas : • Two stroke engines . • Bigger machines .
  • 21.
    L ubricationandits types 3. Elastohydrodynamic lubrication •Is developed in heavily loaded rolling contacts . • The contacting surface is elastically deformed,distributing the load over a greater area . • High pressure results in increasing viscosity of lubricant , which improves load capacity .
  • 23.
    Examples of machineryapplications that operate under EHL are: • rolling element bearings, gear teeth and cam contacts (rolling) where high rolling contact loads occur. L ubricationandits types
  • 24.
    L ubricationandits types 4. Boundary orthin film lubrication • Lubrication film is insufficient to separate the contacting surfaces. • the oil film thickness is so small . • metal to metal contact occurs between the moving surfaces .
  • 25.
    L ubricationandits types • Unlubricated vsboundary lub vs hydrodynamic lub
  • 26.
    L ubricationandits types This type oflubrication is used in the following areas : 1. A shaft starts moving from rest. 2. The speed is very low. 3. The load is very high. 4. Viscosity of the lubricant is too low.
  • 27.
    L ubricationanditstypes 5. Mixed lubrication .is the transition between Hydrodynamic and Boundary lubrication. . Two surfaces are partly separated, partly in contact .
  • 28.
  • 29.
    L ubricationandits types 6. Extreme pressurelubrication . This lubrication is for very high press ,temperature, speed sliding surfaces . . Extreme pressure additives are used along with the lubricants . . They are activated by reacting with the metal surface when the temperatures are elevated due to the extreme pressure and friction . . Then form solid surface films of (S,CL and P) , acts as a barrier to reduce friction, wear, eliminate the possibility of welding .
  • 31.
    Selection Of Lubricant  Temperature of operation  Speed  Load  Oil change interval  Operating conditions and possible contaminants  Method of lubricant application  Size , type and material of elements to be lubricated
  • 32.
    Types of Lubricant  Gaseous lubricants  Liquid lubricants  Semi - solid lubricants  Solid lubricants
  • 33.
     Classification of Lubricant Solid Lubricants : Polymer , metal – solid, carbon and graphite , and ceramic and cermet.
  • 34.
    Types of Lubricant  Semi-SolidLubricant ( Grease )  Advantages Of Greases : • Good for inclined/vertical shafts. • Water resistant & reduce oil vapor problems. • Reduce noise and vibration Disadvantages of Greases : • Because of semi-solid nature of greases, it does not perform the cooling , so poor dissipation of heat. • No filtration .. So contaminants / wear-debris cannot be separated.
  • 35.
     Types of Lubricant Liquid lubricants , which include: • Vegetable oil and animal oil • Mineral oil from petroleum • Blended oil , doped oil , or compound oil Liquid Lubricants :
  • 36.
     Types of Lubricant Gas Lubrication : ADVANTAGES : • Temperature range (-2000C) to (20000C). No vaporization , cavitation , solidification , decomposition. Very low viscosity (1000 times less viscous than even the thinnest mineral oil ) , therefore ultra low friction . Possible high speed. Cleanliness. No seal requirement for lubrication.
  • 37.
    Types of Lubricant  DISADVANTAGES: • Very low load capacity. Low damping. Ultra low film thickness. Smooth surfaces & very low clearance (to maximize load capacity & minimize flow rate) needs a specialist designers & manufacturer (close tolerance). Less forgiving of errors in estimating loads or of deviations from specifications during manufacture and installation.
  • 38.
    Types of Lubricant  Selection of Lubricant Type : Load and speed are two major factors which affect selection of lubricants environment and sealing requirements are additional factors which affect lubricant selection. Apparent area, material conductivity and friction coefficient decide the operating temperature.
  • 39.
    Application  Industrial • Hydraulic oils •Air compressor oils • Food Grade lubricants • Gas Compressor oils • Gear oils • Bearing and circulating system oils • Refrigerator compressor oils • Steam and gas turbine oils
  • 40.
    Properties of Lubricants  Kinematic viscosity  Viscosity index  Pour point  Flash point  Total Base Number (TBN)
  • 41.
    Kinematic viscosity   Internalresistance to flow  Selection of viscosity depends of : • Speed • Load • Temperature
  • 42.
    Kinematic viscosity  • Speed: The faster a shaft rotates in a bearing the thinker developing oil wedge will be become . Therefore , for high speed application we need a light-bodied oil ( low viscosity oil ) and , conversely . for low speed applications an oil with heavy body ( high viscosity ) is Required
  • 43.
    Kinematic viscosity  • Load: A lightly-loaded application will operate with a lighter-bodied oil (low viscosity oil) than a heavily loaded one, as a lesser load-carrying lubricating film is required.
  • 44.
    Kinematic viscosity  • Temperature: Viscosity is dramatically influenced by temperature, . shown in the following diagram illustrating . experiment conducted on the same oil but at varying temperatures. At low temperature , oil does not flow as free, at high temperature. It is, therefore , very important to indicate the temperature at which the viscosity was determined wh. reporting a viscosity.
  • 45.
    Kinematic viscosity  Low Viscosityoils used : • High speeds • Low pressure • Low temperature High Viscosity oils used : • Low speeds • High pressure • High temperature
  • 46.
    Viscosity index  Measure offluids change of viscosity with temperature. Higher the VI lower will be the change of viscosity with temperature • high number , less change • low number , more change
  • 47.
    Pour Point  • Lowesttemperature at which the fluid will flow • Indicates lowest operating temperature • Measured in °C or °F
  • 48.
    Flash Point  • Lowesttemperature at which the vapor above the liquid will ignite under flame. • Indicated safe maximum temperature of operation. • Indicator of volatility. • Test method - COC and PMCC • Measured in °C
  • 49.
    Total Base Number( TBN )  • Measured the acid neutralizing reserve in oil. • Important for deciding discard of oil • Decreases due to • Oxidation of oil • Water contamination • Fuel contamination • Measured in Mg KOH/g of oil
  • 50.
    Lubrication Handling & Storage Introduction:- Proper handling and storage of lubricants can be of great benefit to the customer. Contaminated lubricants can be a major cause of equipment failure. The resulting downtime for repairs is very costly. A small amount of effort spent in organizing oil and grease stocks and making sure that they are handled and stored properly will save time and money by increasing production and reducing maintenance costs. Content :- 1- Receiving New Lubricants. 2- Storage.
  • 51.
    Receiving New Lubricants Procedures:- 1 Correct Unloading. 2 Moving Containers/Drums to Storage Area. Techniques :- 1 Using forklift trucks. 2 Manually operated.
  • 52.
    1- Using ForkliftTrucks :- If containers are palletized, a forklift should be used to unload the lubricants from the shipping vehicle.
  • 53.
    1- Using ForkliftTrucks :- For drums not shipped on pallets, special drum handling attachments for forklifts should be used to remove the drums from the
  • 54.
  • 55.
  • 56.
    Contamination Causes :- 1Damaged Containers or drums. 2 Poor Storage Practices. 3 Dirty handling & dispensing equipment. 4 Moisture seeping into tanks or containers.
  • 57.
    Indoors Storage • Therecommended method of storing lubricants is indoors in a designated oil area or an oil house. • An oil house or indoor storage facility should have racks and shelving that allow for adequate protection of drums as well as ease of placement and removal.
  • 58.
    Indoors Storage • Theefficient use of an oil storage area or oil house will also allow better stock rotation. Access to the older stocks should always be open so that the older lubricants will be used first. The First In, First Out (FIFO) method of inventory control will eliminate the risk of deterioration caused by excessive storage period. • Even when stored indoors, contamination can occur when transferring the lubricants to the various pieces of dispensing equipment or when adding to the machine to be lubricated.
  • 59.
    Indoors Storage Precautions :- 1.Pumps, funnels, oil cans, hoses, grease guns and other dispensing equipment should be kept clean and stored in a closed vented cabinet or covered when not in use. 2. When adding oil to equipment, do so in a manner that will not add dirt to the system. 3. Always clean the top of the reservoir and around the filler cap before removing the cap. 4. It is also good practice to add the oil through a cloth or metal screen to prevent the accidental entry of dirt into the reservoir.
  • 60.
    Outdoors Storage Disadvantages:- 1. Whendrums are stored outside, the weather and elements can fade important drum markings and labels. If the drums have weathered severely enough that the product inside cannot be identified, this can lead to using the incorrect lubricant in a particular piece of equipment and possibly damaging that equipment. 2. The effects of changing temperature on lubricant containers can be seen in several ways.
  • 61.
    Outdoors Storage Precautions :- 1.drums should always be covered with a shelter or at least a plastic drop cloth to protect the drums from rain and other sources of water. 2. The preferred position for outdoor storage is with the drums on their sides and bungs approximately horizontal. 3. Drums should be stored on racks or at least on blocks several inches above the ground, to prevent additional moisture damage.
  • 62.
    The effects ofchanging temperature on lubricant Drums Low-Temperature Degradation of Lubricants • Most good quality synthetic and conventional mineral oils are not affected by storage temperatures below 120°F (49°C). However, storing lubricants near furnaces, steam lines or direct sunlight in high temperature climates for a prolonged time period may cause additives and base oils to oxidize prematurely. • Lubricants that are potentially contaminated with volatile products, including diesel fuel, kerosene, or any other solvent, must never be stored in high temperatures. The presence of solvents can be identified by a test called the flash point test.
  • 63.
    The effects ofchanging temperature on lubricant Drums Low-Temperature Degradation of Lubricants • The major difficulty from cold storage temperature arises from the high viscosity of these fluids and the difficulty of pumping them to operating equipment and transport vessels. • Products that contain significant amounts of water, like water-glycols and oil-water emulsions, should not be exposed to temperatures below 40°F (4°C).
  • 64.
    The effects ofchanging temperature on lubricant Drums(Outdoors Storage) • Alternating periods of extreme hot and cold can cause the metal of a drum to expand and contract. This expansion and contraction can cause the seams of a drum to weaken. As a result, the drums may begin to leak and lubricant may be lost. • If water is allowed to accumulate on the top of a drum, temperature changes - alternating heating and cooling - causes a vacuum, which can cause moist air to be sucked into the drum vapor space.
  • 66.
    ⦁ Lubrication ⦁ powertransmission ⦁surface protection ⦁ heat transfer ⦁ surface cleansing
  • 67.
    ⦁ Reduction offriction ⦁ Corrosion prevention ⦁ Heat removal ⦁ rust prevention
  • 68.
    ⦁ Transmission parts. ⦁Bearings. ⦁ Cams. ⦁ Journals. ⦁ Seal faces. ⦁ Any situation involving metal to metal contact.
  • 69.
    ⦁ SuctionFilter ⦁ PressureFilter ⦁ReturnFilter ⦁ PilotLinePressureFilter ⦁ DuplexHighPressureFilter ⦁ DuplexLowPressure,HighFlowFilter ⦁ Off-LineFilter(Dedicated) ⦁ Off-LineFilter(Mobile)
  • 72.
    ⦁ Filter cartshave become an essential tool in many hydraulic and lubrication systems. ⦁ Because new oil in drums or totes typically does not meet stringent OEM cleanliness specifications, it should be filtered prior to use in hydraulic or lubrication applications.
  • 74.
    ⦁ particulate Removal ⦁WaterRemoval ⦁ AcidRemoval
  • 77.
  • 78.
    "What is thefirst indication of lubricant starvation?" • Heat is the direct consequence of lubricant starvation. Once any mechanical system becomes depleted of lubricant, and the lubricating film keeping gears, bearings or slides apart is no longer present to support or protect the surfaces, surface-to-surface contact will occur. When two surfaces slide or rub together, friction is produced, and from friction comes heat.
  • 79.
    Before frictional heatis generated, the only way to detect lubricant starvation would be through vibration analysis. Vibration analysis can pick up subtle vibration changes in the machinery and may be able to identify lubricant starvation before the extreme heat from friction is discovered. The effect of friction on the two surfaces rubbing together without lubrication will cause them to heat up quickly. The amount of heat generated will be in direct correlation to how fast the two surfaces are sliding or rotating. For example, gears rotating at only 60 rpm will take much longer to heat up than those rotating at 1,800 rpm. Without proper lubrication, gears rotating at faster speeds not only will heat up quickly but can also lead to failure of the machine.
  • 80.
    In the imagebelow, notice the difference between a good oil supply (full lubricant film), an impaired oil supply (boundary contact), and dry friction and wear (caused by lubricant starvation). Welding and galling occur when the two surfaces become so hot that they weld together and then tear apart, resulting in large amounts of debris. This is not something you want happening inside your machine.
  • 81.
    Other signs thatyour machine is suffering from lubricant starvation include smoke, an unusual smell and the machine becoming hot to the touch. Smoke is caused by the heating of what is left of the lubricant. This is usually the case when you see some poor soul stranded by the side of the road with smoke pouring out from under the hood of his car. Before a machine even begins to smoke, you can often smell the oil starting to heat up. This provides a good way to detect lubricant starvation. Another excellent method is through touch. Your hands are very sensitive heat detectors and can identify subtle changes in temperature. However, the most effective way to combat lubricant starvation without expensive diagnostic equipment is to check your machinery on a regular basis. Ensure your PMs are appropriate for each machine and take into account the changing conditions around the equipment, such as temperature, moisture and workload
  • 82.
    Determining an Oil'sEnergy Efficiency
  • 83.
    "We have twodifferent oils and need to determine which one is more energy efficient. What data should we collect? What parameters can help establish energy efficiency?" Energy efficiency must be measured in terms of the reduction of energy consumption. More specifically, it is related to how much energy the machine consumes in order to operate. This principle applies to machines that convert one type of energy like chemical or electric to a mechanical one, such as electric motors and combustion engines. It is also applicable to machines that transmit mechanical energy, like gearboxes. In some cases, it may be evaluated in a powertrain such as a combination of a combustion engine and a transmission.
  • 84.
    The energy savedis measured in terms of what is utilized to move or operate the machine. For example, for a combustion engine, the reduction in fuel consumption would be measured. For an electric motor and/or gearbox, the reduction of electric energy (voltage, current and power factor) would be measured. The energy savings can also be measured indirectly by simply verifying a reduction in the operating temperature. This can be a practical method for electric motors, gearboxes and pillow block bearings. Although it likely will not reveal the amount of energy saved, there will be a clear indication of the reduced energy consumption
  • 85.
    It is importantto note that certain conditions must be kept consistent for the sake of comparison. These conditions would include using a similar amount of lubricant (the same oil level or regreasing amount), measuring the equipment in similar operating conditions (load and speed), and maintaining similar ambient or room temperatures. Preferably, the same instruments and methods should also be used to measure the energy consumption for both lubricants. Otherwise, similar or comparable instruments should be utilized. Finally, be sure to take several readings to minimize the impact of inevitable variations.
  • 86.
    Why should weprevent leakage ??? 🠶It has been estimated that more than 100 million gallons of lubricants could be saved every year if external leakage from pumping systems, hydraulic machines, gear cases and sumps was eliminated . 🠶Studies have indicated that every year the average plant uses four times more oil than its machines actually hold, and this is not accounted for by frequent oil changes.
  • 87.
    Why should weprevent leakage ??? 🠶 Approximately 70 to 80 percent of hydraulic oil leaves the system due to leakage, spills, line and hose breakage and fitting failures 🠶 The lack of attention to a few basic details costs millions of dollars annually in make-up oil, cleanup, disposal of external fluid waste, unnecessary maintenance downtime, safety and environmental damage.
  • 88.
    What are thecauses of leakage ??? 🠶seals and packings . 🠶pipe joints and gaskets 🠶damaged ruptured and corroded lines and vessels 🠶wrong selection improper application 🠶 poor installation and inadequate maintenance practices that are applied to sealing systems.
  • 89.
    What are thecauses of leakage ??? 🠶Overfilling 🠶 pressurization from plugged vents 🠶 worn seals 🠶over-torqued gaskets
  • 90.
    🠶The major reasonsfor initial seal failure and fluid leakage are cost- cutting by machine design engineers 🠶 incomplete commissioning and plant start-up procedures 🠶inadequate equipment condition monitoring and maintenance practices.
  • 91.
    Once a sealhas failed and fluid leakage results : 🠶 the problem is perpetuated by purchasing low-quality or incorrect seals 🠶 careless installation practices used during replacement procedures. 🠶 The subsequent leaks, while possibly not considered excessive, can go on and on. Soon plant operating and maintenance personnel accept the leakage as normal.
  • 92.
    How to discoverleakage !!!!!!! ???? 🠶Leak detection can be by : 🠶 visual inspection . 🠶 possibly aided by the use of dyes . 🠶through make-up oil records.
  • 93.
    How to controlleakage !!!!! 🠶Engineers should pay more attention for lubrication when designing machines . 🠶Use modern systems . 🠶Now that how leakage are danger and cost phenomena .
  • 94.
  • 95.
    In case ofcontact with the skin : 🠶Respect strict personal and industrial hygiene rules. 🠶To avoid contact with the body: - use oil-proof gloves, wear clothes with an efficient protection, do not wear oil contaminated clothes, solvents, such as petroleum. 🠶petrol must not be used to remove oil from the skin, use a protecting cream.
  • 96.
    In case ofcontact with the eyes : 🠶Wearing safety goggles is highly recommended when oil is likely to splash in the eyes. 🠶 In case oil accidentally splash into your eyes, thoroughly rinse them with water for at least 15 minutes and contact a physician if irritation persists.
  • 97.
    In case ofinhalation : 🠶Avoid inhaling oil mists and fumes. 🠶Premises should be properly ventilated. 🠶The acceptable limit for an oil mist is 5 mg/m3.