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Fundamentals of Lubrication for CADPI.pdf

The document provides an overview of lubrication topics including definitions of lubricants and their functions, types of friction, lubrication regimes, importance of viscosity, API ratings, lubricant formulations, additives, international standards, service categories, and Phoenix's product portfolio. It describes key lubrication concepts such as the different lubrication regimes, factors that influence viscosity selection, additive functions, and performance standards for various Phoenix lubricant products.

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Lubrication Fundamentals
OUTLINE OF TOPICS 01 ● Lubricants Defined ● Function of Lubricants ● What is Friction? ● Lubrication Regimes ● Importance of Viscosity ● Understanding API Ratings ● Lubricant Formulations ● Additives Overview ● International Standards ● API Service category ● Phoenix Product Portfolio
Lubricant Defined 02 Lubricant -A substance that is primarily used to reduce the effect of friction and wear between surfaces of bodies in contact. - Types of Lubricants: 1.Liquid – oils, water 2.Solid – graphite 3.Gaseous – air 4.Semisolid - greases
Functions of Lubricant 03
Functions of Lubricant 04
Functions of Lubricant 05
Functions of Lubricant 06
Functions of Lubricant 07 Transmit Power ●Hydraulic oils are used to transmit power in heavy equipment and machineries ● Equipment OEM primarily looks at Viscosity and Viscosity Index as parameters for reference in their equipment application ●Power transmission operates by Pascal’s Law
What is friction? 08 Friction: Resistance to motion, a property of interface between two solid bodies In contact. Machines/components affected ●Piston/Cylinders ●Journal Bearings ●Gears ●Cams ●Rolling-element bearings
Types of friction 09 1.Static Friction – resistance to the start of motion 2.Sliding Friction – resistance to one object sliding over another object 3.Rolling Friction – resistance to one object rolling over another object - about 100-1000 time less than static/sliding Static > Sliding > Rolling 4.Fluid Friction - Air Resistance - Moving through water
Lubrication Regimes 10 Protection essentially dependent on boundary anti-wear film Starts, stops, slow moving conditions, and shock load conditions Both the bulk lubricant and boundary film play a role Surfaces separated by bulk lubricant film, affected by viscosity, load and speed Full-speed Conditions (most desired) Boundary Film (anti-wear additive protection) Bulk Lubricant (viscosity protection) Asperities (microscopic projections on Metal surfaces) Legend Boundary Lubrication Mixed-film Lubrication Full-fluid Film Lubrication
Importance of Viscosity 11 Viscosity is an oil’s resistance to flow. - Viscosity affects engine/equipment fuel consumption and efficiency - All OEMs refer to this lubricant property for their oil selection What can you say about the picture above? Key Factors to Consider: 1.Speed 2.Load 3.Temperature
Viscosity Index (VI) 12 Viscosity Index is a parameter for lubricants that shows its sensitivity to temperature fluctuations. Some OEMs, usually for hydraulic oil application, are particular for the lubricant Viscosity Index (VI) specs
Viscosity Classification 13 ISO – International Standards Organization AGMA – American Gear Manufacturers Association SAE – Society of Automotive Engineers
Speed and Load Effects on Viscosity Selection 14 Higher Viscosity Oils ( In Grease ) e.g. Graphite, Molybdenum Disulfide, Talc, Mica, Teflon Higher Viscosity Oils Plus EP additives Higher Viscosity Oils Lower Viscosity Oils Increasing Speed Increasing Unit Load The most common mismatch of a lubricant to a machine application is the selection of wrong viscosity Safest way to determine correct viscosity is to refer to OEM manual
Base Oil Oxidation Stability 15 Group I Mineral Base Oil Group II Synthetic Blend Base Oil Exceed Group II Hydrocracked Base Oil Group III High Viscosity Index ( HVI ) Group IV Poly Alpha Olefin ( PAO) Synthetic Oil High Oxidation Stability Low Oxidation Stability •Acidity •Corrosion •Insolubles •Increase Viscosity •Sludge, tars & varnish •Higher impurities Sulfur , Aromatics
American Petroleum Institute ( API ) Base Oil Categories 16 API GROUP Saturates Sulfur Viscosity Index Group Ⅰ (Solvent Refined ) ＜90% and/or ＞0.03wt% and 80 - 120 Group Ⅱ (Hydrotreated) ≥90% and ≤0.03wt% and 80 - 120 Group Ⅲ (Hydrocracked) ≥90% and ≤0.03wt% and >120 Group Ⅳ PAO (Poly Alpha Olefin) Group Ⅴ Base oils which do not belong to the above Group Ⅰ, Ⅱ, Ⅲ and Ⅳ
Common Additive Applications 17 Machine Common Additives Used Percent of Oil Volume Engine Antioxidant, corrosion inhibitor, detergent/dispersant, anti-wear, antifoam, alkalinity improver 10-30% Steam Turbine Antioxidant, corrosion inhibitor, demulsifier, antifoam 0.5-5% Gears, Spiral or Bevel Antiwear, antioxidant, antifoam, sometimes 1-10% Gears, worm Extreme pressure, antioxidant, corrosion inhibitor, fatty acids 3-10% Hydraulic System Antioxidant, antiwear, antifoam, corrosion inhibitor, viscosity index improver 2-10%
Additives 18 Additives are organic and inorganic compounds Dissolved or suspended ( as solids) in the oil . Can represent from 0.1% to 30% of formulated oil volume 63% Of lubrication professionals monitor additive Health as part of their oil analysis program According to a recent poll at Machinerylubrication.com Purpose of Additives ● Enhance existing base oil properties. ex. Antioxidants Corrosion Inhibitor, Anti-foam Agents, Demulsifying Agents ● Suppress undesirable base oil properties. Ex. Pour point depressant, VI Improver ● Impart new properties to base oil. Ex. EP Additives, Detergents, Metal Deactivators, Tackiness Agent
Additives Overview 19 Dispersants and Detergents Antirust and Corrosion ●Detergent and Dispersant additives work hand in hand and is critical in diesel and marine engine oil applications. ●Detergents are measured in BN typically using calcium and magnesium chemistry and functions to neutralize acids. ●Acts as a protective barrier that repels water and moisture from metal surfaces ●Common in almost all types of oils and greases
Additives Overview 20 Antiwear (AW) Extreme Pressure (EP) ●Prevents metal to metal contact during boundary lubrication by forming a protective film layer on metal surfaces ●Typically uses Zinc Compounds (ZDDP) and Phosphorus based elements ●Protects in a similar principle to antiwear however it is more chemically aggressive. ●Commonly used in gear oil application and has a strong sulphur smell
Additives Overview 21 Antioxidants Foam Inhibitors ●Minimize lubricant thickening and degradation when oxygen reacts with lubricants at high temperatures. ●Oxidation of oils are determined by its AN levels where acceptable levels are generally recommended within an increase of 0.2-0.3 mg KOH/gm from fresh oil levels ●Reduces surface tension of the lubricants to allow easy escape of bubble formations Rule of Thumb: “Lubricant life decreases for every 10 o C increase in temperature above 75 o C”. – Arrhenius Rule
How to choose the correct engine oil 22 The quality and viscosity of the engine oil is specified by the international standards. SAE viscosity grade Service Classifications: API, ILSAC, ACEA SAE 10W-40 API: SM/CF ILSAC: GF-5 ACEA: A3/B3 “W” stands for “Winter”
SAE 15 W 40 API CI-4 / SL Low Temp. Viscosity High Temp. Viscosity Diesel Engine Service Category Gasoline Engine Service Category Understanding Lubricants Category 23
International Standards 24 ENGINE OIL PERFORMANCE STANDARDS • ILSAC: International Lubricant Standardization and Approval Committee •API: American Petroleum Institute •ACEA: Association of European Automotive Manufacturers •API and ILSAC are based in the U.S. and ACEA in Europe. These organizations are used to specify automotive and diesel engine oils throughout the world Engines Gasoline Diesel Specifications From To From To API SA SN CA CK-4 ILSAC GF-1 GF-5 N/A N/A ACEA A1(A4) A5 B1 B/5 API DONUT MARK
API Service Classifications 25 Category Status Service CF-4 Obsolete For model year 1994 and older engines CG-4 Obsolete For model year 1998 and older engines. Valid when preceded by certain C categories CH-4 Current CH-4 oils are specifically compounded for use with diesel fuels ranging in sulfur content up to 0.5% weight. CI-4 Current CI-4 oils are formulated to sustain engine durability where exhaust gas recirculation (EGR) is used and are intended for use with diesel fuels ranging in sulfur content up to 0.5% weight. CJ-4 Current For high-speed four-stroke cycle diesel engines designed to meet 2010 model year on-highway and Tier 4 non-road exhaust emission standards as well as for previous model year diesel engines CK-4 Current CK-4 oils are designed to provide enhanced protection against oil oxidation, viscosity loss due to shear, and oil aeration as well as protection against catalyst poisoning, particulate filter blocking, engine wear, piston deposits, degradation of low- and high-temperature properties, and soot-related viscosity increase. Diesel Engines C “ Compression” Ignited or “Service” Oils
API Service Classifications 26 Gasoline Engines S “ Spark” Ignited or “Service” Oils Category Status Service SG Obsolete For model year 1993 and older engines SH Current For model year 1996 and older engines. Valid when preceded by certain C categories SJ Current For all automotive engines presently in use. Introduced in the API service Symbol in 1996 SL Current May be used where API categories SJ and earlier are recommended SM Current Improved fuel economy, lower phosphorous, high base oil quality SN Current Improved in resource conserving ( oil, fuel, emissions). SP Current Fuel economy and fuel economy retention, improved emissions control system protection, improved sludge and varnish control, minimize low-speed pre-ignition, improved high temperature deposit for pistons and turbochargers
Phoenix Lubricants
Phoenix Lubricants Overview 28 AUTOMOTIVE OILS.. •ENGINE OILS ( PCMO/HDEO/MCO) •AUTOMOTIVE GEAR OIL •AUTOMATIC TRANSMISSION FLUID •MOTORCYCLE ENGINE OILS •BRAKE FLUID •RADIATOR COOLANT INDUSTRIAL OILS.. •HYDRAULIC OIL •INDUSTRIAL GEAR OIL •TURBINE OIL •HEAT TRANSFER OIL •COMPRESSOR OIL •MARINE ENGINE OILS SPECIALTY PRODUCT,, •GREASES ( LITHIUM/LITHIUM CMP) •SCOOTER GEAR OILS •DEGREASER
Phoenix Zoelo : Heavy Duty Engine Oil 29 SAE Grade Oil Category Specifications 5W-40 Full Synthetic API CJ-4 10W-30 / 10W-40 Semi Synthetic API CI-4 15W-40 Mineral API CI-4/SL 15W-40 Mineral API CH-4/SL 10W/30/40 Mineral API CF/SF PHOENIX ZOELO is formulated with a blend of high performance base oils and HDD Formula to deliver vigorous cleaning action on engines against deposit build-up and acidic combustion. It also provides outstanding soot dispersancy, deposit control and wear protection
Phoenix Gear Oils 29 SAE Grade Oil Category Specifications Application 75W-90 Full Synthetic API GL-5 Manual gear transmissions, rear axles and differentials, hypoid gears 80W-90 / 85W-140 Mineral API GL-5 Spiral bevel and hypoid differentials, and oil-lubricated steering axle wheel bearings 90 / 140 Mineral API GL-4 Spiral bevel and hypoid differentials PHOENIX GEAR OILS is formulated with a sulfur-phosphorus extreme pressure additive technology that provides good thermal and oxidation stability
Phoenix Radiator Coolant 29 PHOENIX RADIATOR COOLANT a water based OAT coolant with carboxylate organic inhibitor that provides low toxicity, environmentally friendly, nitrite free that provides long lasting protection for cooling systems. Long Service life, at least 960,000KMS or 6 years Meets Performance Standards: ● Yanmar ● Wartsila 32-9011 ● MTU MTL 5049 ● Mercedez Benz 312 ● Leibherr MD 10360139 ( DCA)
Phoenix Hydraulic Oils 35 PHOENIX Hydraulic Oils are premium anti-wear hydraulic fluid, specifically designed for use in mobile and stationary high-pressure hydraulic systems. Meets Performance Standards: ● Parker Hannifin (Denison Hydraulics) HF-0(ISO 32,46,68) ● Eaton Vickers I-286-S (industrial applications), M2950-S ● (mobile applications)(ISO 32,46,68) ● David Brown Industrial Gears 0A(ISO 32),1A(ISO 46), ● 2A(ISO 68), 3A(ISO 100), 4A(ISO 150), 5A(ISO 220) ● Bosch Rexroth former specification RE 90220 ● DIN 51502:1990, HLP Fluid ● DIN 51524:2006-04 Part 2 HLP ● Cincinnati Machine P-68, P-60, P-70 ● ISO 6743:1999 Part 4 HM Fluid ● ISO 11158:2009, HM ● SAE MS1004 HM ● US Steel 126 and 127
Phoenix Industrial Gear Oils 35 PHOENIX Industrial Gear Oils are premium quality oil formulated with highly refined base stocks and sulfur-phosphorus additive technology. It is widely recommended for the lubrication of a wide variety of industrial and mobile equipment applications. Meets Performance Standards: ● Meets ISO VG Classification ● DIN 51515/3 ● US Steel 224 ● AGMA 9005 E02-RO ● ISO 12925-1 ● Textron Power Transmission: 2E(VG 68), 3E(VG 100), ● 4E(VG 150), 5E(VG 220)
Phoenix Turbine Oils 35 PHOENIX Turbine Oils are premium quality turbine oil formulated from highly refined base stocks and special rust, oxidation and foam inhibitors designed to use for steam and hydraulic turbines operating under all service conditions Meets Performance Standards: ● DIN 51515 ● Alstom Power HTGD 90117 ● Siemens TLV 901305 ● General Electric GEK 32568, GEK 107395, GEK 46506 ● Five Cincinnati P-38, P-55, P-54 and P-57 ● Solar Turbines ES9-224 ● AIST 125 ● ISO 8068 ● AGMA 9005 E02-RO ● Parker Denison HF-0 Bench Tests ● MAG P-38, P-55, P-54 and P-57
PHOENIX TURBINE OIL PERFORMANCE
Sugar Mill in Mindanao 36 ■ Sugar mill has a 5-mills in tandem design capable of processing 4,000 tons of cane per day ■ Steam power generation of around 7000 kW - 4 Turbine Alternators ■ All 5 Steam Turbines (Peter Brotherhood, Shinko Seisa) and 4 Turbine Alternators (Peter Brotherhood & Hirozoki) are lubricated by Phoenix Turbine Oil 68 with around 8,000 liters volume ■ Complemented with oil analysis program to check oil viscosity, water content, acid number, and wear metals of the turbine oil after every milling season ends
Turbine Oil 68 Performance 37 Brand: Peter Brotherhood Speed: 1800 rpm Capacity: 2000 kW Sump Volume: 2000 liters Parameters Limits Aug ‘19 Feb ‘20 Mar ‘20 Sep ‘20 Jun ‘21 OIL RUNNING HOURS 0 706 1425 4033 4476 Viscosity @40 C >57.8, <78.2 64.54 67.2 68.06 68.22 69.42 Viscosity @100 C >7.31, <9.89 8/967 8.797 9.465 9.134 9.186 Water Content 0.05 - 0.05 0.05 0.05 - Flash Point 190 C No Flash No Flash No Flash No Flash No Flash Acid Number <2.0 0.05 0.09 0.17 0.11 0.1 Wear Metals Iron <100 0.1 4 3 0.4 1 Copper <50 0 <1 <1 0 <1 Nickel <150 0 <1 <1 0.2 <1
Steam Power Plant in Mindanao 38 ■ FDC Misamis Power Corporation, a 405 MW Coal-Fired Power Plant in Villanueva, Misamis Oriental. ■ The power plant consists of 3 units of 135 MW Alstom Turbines and 2 out of 3 units are currently lubricated by Phoenix Turbine Oil ISO VG 46 ■ In 2018, FDC approved the use of Phoenix Turbine 46 after warranty period has ended for its Alstom Turbines. After a series of performance test were carried out for 1 turbine with satisfied results, another turbine was converted to Phoenix in 2020. ■ Oil performance monitoring are checked semi-annually to evaluate the condition of oils
Turbine Oil 46 Performance 39 Brand: Alstom Turbine Ltd. Speed: 3,600 Rpm Capacity: 125 MW Sump Volume: 17,000 Liters Parameters Limits Results Date 4/2/19 10/23/19 9/29/20 2/17/21 Viscosity @40 C >36.8, <56.8 45.3 43.3 46.72 46.86 Water Content 0.05 0.05 0.05 0.05 0.05 Flash Point 190 C No Flash No Flash No Flash No Flash Acid Number <2.0 0.07 0.23 0.4 0.2 Wear Metals Iron <100 - <4.8 0.5 1 Copper <50 - <0.47 0.0 <1 Nickel <150 - <0.35 0.2 <1
Turbine Oil Top-up Procedure 40 1. Phoenix to evaluate the existing oil used by CADPI and Roxol Bioenergy for checking on oil compatibility vs Phoenix Turbine Oil 2. All equipment should be checked for oil condition before topping-up. 3. After topping-up, Phoenix technical services will facilitate oil performance testing with the agreed frequency of the customer and tested via 3rd party laboratory ( SGS/ITS).
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