The document provides an overview of an industrial lubrication training course. It discusses various machine types like electric motors, gearboxes, compressors, turbines, and engines. It then covers bearings, introduction to lubrication, lubricant types and properties, lubrication methods, and best practices for lubricant sampling and machine modifications to improve lubrication. The key topics covered include the functions and objectives of lubrication, lubricant composition and additives, lubrication failure causes, and pump selection factors like fluid, flow rate, temperature, pressure, and viscosity.

1. ‫لورد‬ ‫شركة‬ ‫الي‬ ‫اهداء‬
‫المهندس‬ ‫رعاية‬ ‫تحت‬:‫الخطيب‬ ‫هشام‬
(‫بالشركة‬ ‫التدريب‬ ‫مدير‬)

2. Industrial Lubrication fundmental
• Training course presentation
• Abdel Rahman Hassan
• Mohamed Sobhi
• Hazem Mohamed
• Omar Mohamed

3. • Machine types and the work they perform
1- Electric motor:
an electrical machine that converts electrical energy into mechanical energy.
The reverse of this is the conversion of mechanical energy into electrical
energy and is done by an electric generator, and generators and motors have
much in common.

4. 2-Gearbox:
to increase the engine torque.
to enable a free-wheel or neutral position.
to be able to reverse.
3-Compressors:
increase the pressure, and corresponding saturation temperature (boiling point)
of the refrigerant vapor to high enough level so the refrigerant can condense by
rejecting its heat through the condenser.

5. • 4-Turbine:
Turbines convert the kinetic energy of a moving fluid or gas into rotational
energy that can be used to drive a dynamo and generate electricity.Usually,
the source of the kinetic energy is steam, although it can sometimes be water
5- Engines:
The engine is the vehicle’s main source of power. The engine uses fuel and
burns it to produce mechanical power.
Chemical Energy converted into Mechanical Energy.

6. Bearings are used basically for performing three important tasks as mentioned
below
1-Reducing friction.
2-Supporting the load.
3-Providing the guide for moving components such as shafts or wheels.
6-bearing

7. Introduction to lubrication:
• What is Lubrication?!
Lubrication is the process, or technique employed to reduce wear on surfaces in
close proximity, and moving relative to each another.
• Composition of lubricants
• Typically contains 90% base oil(petroleum-mineral oils and less than 10%
additives
• Non liquid lubricants contains Grease, powder(dry graphite, Molibdenum
disulphite), Teflon tape used in plumbing etc.
• Those non liquid lubricants provide lubrication at higher temp(up to 350 °C)

8. Additives
The properties of a lubricant can be improved by adding certain chemicals
• Anti oxidants
• Foam depressants
• Corrosion inhibitors
• Detergent Dispersers e
• Oiliness improvers

9. Different Lubricating conditions
• Dry Lubrication
No lubricant present between the surfaces
• Boundary lubrication
this condition is found on machine slide ways(Lathe cross slide, milling machine
table).

10. Objectives of Lubrication
• To reduce frictional resistance.
• To reduce wear on the bearing surfaces.
• To protect the bearing surfaces from corrosion.
• To carry away heat from the bearing.
• To reduce noise from the moving components of the machine
Lubricating Methods
Oil can , Oil gun, Grease packing, Wick type, Bath type(Splash) and
Circulation(pressure).

11. Lubricants
Lubricants are those substances, which are Used to reduce the force of Friction
between two sliding surfaces.
Types of Lubricant
• Animal oils From animal fats
• Vegetable oils From plant seeds
• Mineral oils Hydrocarbons obtained from minerals
• Synthetic oils From various chemicals
• Grease Semi-fluid lubricant
• Dry Molybdenum disulphide, Graphite

12. Types of Lubricants
• Solid lubricants e.g Wax, Talc, Mica, Molibdenum disulphide e
• Semi solid lubricants e.g. Grease and Vaseline
• Liquid Lubricants e.g. Mineral oils, Vegetable oils, Animal oils
• Synthetic lubricants e.g. Polyglycols, Silicones, organic amines,
Imines, Amides.

13. Properties of Lubricant
• Viscosity- Resistance of a liquid to flow.
• Oiliness- Ability of the lubricant to stay in place between the bearing surfaces.
• Stability- Retention of properties as long as possible(Oxidization, Biological
degradation, Dilution).
• Volatility- It shows the evaporation behavior of lubricant at high temperature.
• A good lubricant should have low volatility
• Emulsification- It is the property of a lubricant due to which the lubricating oil
mixed with water to form an emulsion.
• A good lubricant should have low emulsion number.

14. Properties, continuous...
• Corrosion Stability It is properties of lubricant which represents its
resistance toward the metals.
• A good lubricant should not take part in corrosion
• Thermal Stability A good lubricant must be stable towards heat.
• It should not decompose during operation at high temperature.

15. Functions of Lubricants
• Keep moving parts apart
• Reduce friction
• Transfer heat
• Carry away contaminants& debris Transmit power
• Protect against wear
• Prevent corrosion

16. Lubrication failure
• It is important to note that lubricants do not automatically fail they do
so because of poor practices within the plant that strain them.
• The are three main reasons for lubrication failure:
1. Moisture.
2. Temperature.
3. Contaminants.

17. Moisture
• It is a result of excess moisture entering the lubricant, due to
rain, humidity, human error, or other equipment errors.
• Equipment errors include improper seals and wash down practices.
Human error in this case includes improper storage methods such
as lack of ventilation.
• The tiniest bit of moisture in oil lubricant can reduce its lifespan
by half. The less moisture in your oil lubricant, the better your
equipment will perform and the less chance of failures.

18. • Additives, which control oxidation, are also important in
extending the lifespan of lubricants. These will deplete
over time though, especially if other factors are
increasing the moisture in the lubricant. Fix this by
maintaining strong additive levels.
• To keep moisture failure away, do what you can to
reduce moisture levels in new lubricants, as well as
eliminating moisture in stored lubricants, equipment,
and wash down procedures.

19. Temperature
• This can be caused by limited air movement, lubricant overload (main cause), incorrect
cooling levels, an even using a high viscosity lubrication or the wrong viscosity.
• Temperature failure happens because higher temperatures result in faster oxidation. This
ultimately leads to more component wear.
• Although most lubricants have a long lifespan of about 30 years, rises in temperature will
majorly decrease their lifespan. Lubricants need to be kept at 70 degrees Fahrenheit. If this
temperature is raised by 20 degrees, it will cut the lubricant’s lifespan in half.
• You can reduce the risk of temperature failure by using coolant, and changing it more often.
Also, consider using synthetics, since they are better able to hold up to high temperatures.

20. Contaminants
• There are several ways contaminants can enter the lubricant. Depending
on how it is stored, transported, and filtered, foreign materials are
likely to get in with improper handling practices.
• It is harmful to machinery if there is a large amount of foreign particles
in the lube. There is only a very small amount of room for lube between
a bearing or gear. If foreign particles are present, they can grid and
scratch the machine’s gears.

21. Types Of Contaminants
• There is Two Major Sources of Lubricant Contamination:
1. Dirt.
2. Water.

22. Dirt
If the atmosphere is contaminated, oil will become
dirtier and
lubricant quality becomes compromised. Particulate
contamination, once inside an operating system, will
accelerate the generation of new contaminants. These
contaminants damage critical components and act as a
catalyst for oxidation, further degrading the condition
of
lubricants.

23. Water
• Water is the second most common contaminant that can cause equipment problems.
There are three forms of water: dissolved, emulsified and free.
• Dissolved water is usually benign except in extreme cases that require exceptionally
low moisture levels. This form of water generally enters the lubricant via humidity
or a similar process. The lubricant simply absorbs the water up to the saturation
point and does not exhibit any signs of water contamination .
• Emulsified water is the most damaging form of water contamination. It occurs when
the amount of water is beyond the saturation point and has likely entered the
lubricating stream.Emulsified water is the most damaging because it is free flowing
with all of the lubricant and will be in the load zone.

24. • Free water is somewhat less damaging than emulsified water but is
still problematic. Some lubricants will not hold water in suspension
past the saturation point, so it falls to the bottom of the sump.
Among the problems resulting from this type of contamination
include allowing water to become part of the lubricating stream,
impacting the lubricant’s ability to shed water and letting it
emulsify, initiating biological contamination that will further
degrade the oil, and plugging the filter.

25. Best Sampling Procedures
Proper oil sampling is critical to an effective oil analysis program. Without a
representative sample, further oil analysis endeavors are futile.
There are two primary goals in obtaining a representative oil sample:
• maximize data density, which is the information per milliliter of oil should be
maximized as possible, such as cleanliness and dryness of the oil, depletion of
additives, and the presence of wear particles being generated by the machine.
• The second goal is to minimize data disturbance. The sample should be
extracted so that the concentration of information is uniform, consistent and
representative, it is important that the sample dose not be contaminated during
the sampling process.

26. Sampling on System Returns
There are several rules for properly locating oil sampling ports on circulating
systems.
• Turbulence The best sampling locations are highly turbulent areas where the
oil is not flowing in a straight line but is turning and rolling in the pipe, which
basically leads to a substantial reduction of the particle concentration
entering the sample bottle. This can be avoided by locating sampling valves
at elbows and sharp bends in the flow line

27. • Ingression Points sampling ports should be located downstream of the components that wear,
and away from areas where particles and moisture ingress. Return lines and drain lines heading
back to the tank offer the most representative levels of wear debris and contaminants. Once
the fluid reaches the tank, the information becomes diluted.
• Filtration Filters and separators are contaminant removers, therefore they can remove
valuable data from the oil sample. Sampling valves should be located upstream of filters,
separators, dehydrators and settling tanks unless the performance of the filter is being
specifically evaluated.

28. Sampling from Pressurized Lines
When samples need to be taken from pressurized feed lines leading to bearings, gears,
compressors, pistons, etc., the sampling method is simpler. Figure shows different
configurations.
Portable High-Pressure Tap Sampling The uppermost configuration on
Figure is a high-pressure zone where a ball valve or needle valve is
installed and the outlet is fitted with a piece of stainless steel helical
tubing. The purpose of the tubing is to reduce the pressure of the fluid
to a safe level before it enters the sampling bottle.
Ball Valve Tap Sampling. This configuration requires the installation of a
ball valve on an elbow. When sampling, the valve should be opened and
adequately flushed. Extra flushing is required if the exit extension from
the valve is uncapped. Once flushed, the sampling bottle’s cap is
removed and a sample is collected from the flow stream before closing
the valve. Care should be taken when removing the bottle cap to
prevent the entry of contamination. This technique is not suitable for
high- pressure applications.

29. Lubricant Contamination Control

33. Machine Modification for Excellence
• The ultimate goal of lubrication excellence is to increase machine
reliability and reduce operating costs. To achieve this objective,
changes must be made at different levels of the plant, including
the technology and hardware that are currently in use.
• Machines may require modifications for a variety of reasons, such
as to improve the accuracy of lubrication procedures, to enable
inspections of the in-service oil and the machinery, to ensure
precise oil analysis and consistent oil sampling, and to enhance
the effectiveness of the contamination control program.

34. It is critical that machines receive the right
lubricant in the right amount at the right
frequency. It is also essential that they are
lubricated using clean, ergonomic and safe
procedures. To ensure proper lubrication
practices, machines must have the
appropriate accessories installed. This
typically involves lubricant-delivery devices
like constant-level oilers, single-point
lubricators, grease fittings, grease purge
valves, centralized lube systems, spray
systems, etc. Temperature-management
systems, including heaters and coolers, may
also be needed, along with rolling-element
bearing seals and shields, and power-flush
quick-connects on reservoirs and sumps.

35. Inspections
Oil analysis that is supported by visual
inspections of the in-service oil offers
a powerful way to monitor the
condition of the oil and the machine.
Simple visual inspections can confirm
that the oil is in good condition or
indicate the presence of contaminants
or excessive degradation. Among the
devices that may be installed to
facilitate inspections of the oil include
bottom sediment and water (BS&W)
bowls, which enable quick inspection
of low-lying contaminants and sludge,
and level gauges, which should be
located near fill ports and be large
enough to easily determine the oil
level.
From time to time, machines should be
inspected internally to verify that the
lubrication system and machine
components are free of deposits and
excessive wear. External inspections
are also useful to identify the presence
of leaks or abnormal operating
conditions. A number of machine
modifications or accessories can be
employed for this. purpose

36. main points to pump selection
1). Fluid – This is the most important factor when selecting a pump in order to
avoid corrosion and unnecessary wear and tear on your pump. What’s the
chemical makeup of the fluid to be pumped? What’s the consistency? Is it a
slurry (thick suspension of solids in liquids), or is it a clean fluid?
2). Flow rate – You need to know the flow rate in order to select the proper
pump. This is measured in gallons per minute (GPM), although in day-to-day
speak, this translates into the pump diameter measurement. Remember: a
higher flow rate means a larger pump size is needed.

37. 3). Temperature – How hot will the fluid you are
pumping be? This will affect which pump materials are
best suited for your application.
4). Pressure – Another factor you should consider when
selecting your pump is what the pressure conditions on
the inlet and outlet of your pump will be. This
information will help you determine the right
equipment.
5). Viscosity – In order to select the right pump, you
need to know the viscosity of the fluid to be pumped.
High viscosity fluids require more robust pumping
equipment. Nine times out of 10, however, our
customers are pumping fluid with a viscosity less than
that of motor oil.

38. Viscosity
• “If you don’t account for the differing viscosity and density of
liquids, you may end up with too big a pump, which is overly
expensive to buy and run and takes up a lot of space,” says Søren
Mortensen, Grundfos Application Manager. “If the pump is too
small, you simply won’t be able to move the amount of liquid
required”.
• A fluid’s viscosity or “thickness” certainly affects how it will
behave in a pump, but it’s complicated because the viscosity of
fluids can change under different conditions. There are four main
groups of fluids – each group acts a certain way despite its specific
viscosity.

39. Continue…
• First, you have fluids like water, oil, alcohol and paint thinner. With these so-called “Newtonian fluids,” it
does not matter how fast they move or how much you agitate them, they flow the same.
• The second type is “dilatant fluids” like cream and butter, whose viscosity increases with agitation until
they become almost solid. “They are impossible to pump in standard centrifugal pumps and require special
measures to move them,” notes Søren Mortensen.
• Third, “plastic fluids” have a yield value (the point of resistance) that must be exceeded before they can
start flowing. After that point, viscosity decreases as agitation increases. “The best example of a plastic
fluid is ketchup,” says Søren Mortensen. “Think about how you have to shake it up in a bottle before it
starts to move, but once it is moving, it flows easily.”
• The fourth group, “thixotropic fluids,” is the hardest to explain… and to deal with in pumps. Glues, non-
drip paint, greases, cellulose compounds, soaps, starches and tar all fall into this category. These fluids
are viscous (thick) when standing still, but will become less viscous (thinner) over time with constant
agitation.

40. Types of pump (examples)
non-positive displacement pump
• Centrifugal pump
• The fluid enters the pump impeller along or near
to the rotating axis and is accelerated by the
impeller, flowing radially outward into a diffuser
or volute chamber (casing), from where it exits

41. ADVANTAGE : Best pump choice for lower viscosity
(thin) liquids and high flow rates. No pulsations that
may be found in some positive displacement pumps.
Applications Used : All sorts of liquids can be pumps
with centrifugal pumps. Highest flow rates of all pump
types. Handles clean or dirty liquids, and liquids with
low viscosity. Liquid should not contain air or vapors.
Recommended Media (Fluid) : Water and relatively
thin liquids (won't pump thicker oils). Can pump liquids
with or without solids if proper impeller type is chosen.

42. positive displacement pump
• Piston pump
• Piston pumps are a type of reciprocating positive displacement
pump that has, double acting reciprocating pistons

43. Applications Used : Used in oil production, in wash
down services, pressure washing, car washes, reverse
osmosis, and other applications where high pressure is
needed.
Recommended Media (Fluid) : Water and other thin
liquids, including liquids containing abrasives.

44. positive displacement pump (cont.)
• Gear pump
• Gear pumps are a type of rotary positive displacement
pump in which liquid is pumped by passing between two
meshing gears and the surrounding casing.

45. ADVANTAGE : Most widely used for clean oil services.
Few moving parts, simple construction.
Applications Used : Most common pump for clean oils
and other viscous liquids.
Recommended Media (Fluid) : Oils and other high
viscosity liquids. Usually only suited for clean liquids
(no solids).

46. positiVe displacement pump (cont.)
• Screw pump
• Screw pumps use two intermeshing screws, driven by
timing gears, move oils and other viscous liquids. Also
available with three screws, one driving the others.

47. ADVANTAGE : Highest flow rate of positive
displacement pumps.
Applications Used : Fuel transfer, elevators, and other
applications requiring relatively high flow rates of
viscous liquids.
Recommended Media (Fluid) : Oils, fuels, and other
high viscosity liquids. Also handles two-phase liquid/gas
mixtures.

49. ‫لورد‬ ‫شركة‬ ‫الي‬ ‫اهداء‬
‫المهندس‬ ‫رعاية‬ ‫تحت‬:‫الخطيب‬ ‫هشام‬
(‫بالشركة‬ ‫التدريب‬ ‫مدير‬)