Lubrication Oil & Grease

By Fayek Shakran

Course Content
Principles of Lubrication

Oil & Grease Lubrication Oil Analysis Lubricant storage and handling Task-Lubricant selection

Right lubricant to the right place, on the right machine, in the right amount, at the right time.

Principles of Lubrication

Our Industrial Requirement

Improving productivity & Minimizing waste . Reducing costs of Operation .

How ?

Ex-Bearing Failure analysis

Friction
Force that opposes motion between two surfaces in contact.
When one body slides across another a resistive force must be overcome.

Friction
Friction is Caused by Micro welds

Types of friction:
a. Static (usually the greatest) b. Sliding c. Rolling (usually the least)

Friction
Causes of Solid Friction

Surface roughness

Flatter areas

Factors Influencing Friction It is independent of both: - Speed - Area of contact

Friction

Lubrication

Lubrication
1 prevention of metal-to-metal contact by means of an intervening layer of fluid

The principle of supporting a sliding load on a friction-reducing film is known as lubrication

These lubricants are used to a large extent in the lubrication of aircraft internal combustion engines & moving parts.

World Organizations

World Organizations

Lubrication
Type of lubricants
Solid- Semisolid Fluid

Classification of Lubricants
Animal Vegetable Mineral Synthetic
These are highly stable at normal temperatures Animal lubricants may not be used for internal combustion because they produce fatty acids Examples of vegetable lubricants are: Castor oil Olive oil Cottonseed oil
Animal and vegetable oils have a lower coefficient of friction than most mineral oils but they rapidly wear away steel

Lubricating oils
Lubricants
All liquids will provide lubrication of a sort, but some do it a great deal bettor than others.

Oil Requirement :
Provide high quality products, supported by successful field experience. Work to lower maintenance. - Work to Lower cost of operation through value added services. Provide products to help Machine for long operation.

Lubricating oils
The advantages of a lubricating oil .
are improved heat dissipation from the friction point its excellent penetrating and wetting properties.

main disadvantage
Complex design is required to keep the oil at the friction point and prevent the danger of leakage.
gears

Lubricating oils are used in

chains
sliding bearings hydraulic systems

Oil Lubrication Purpose of Oils Oil reduces friction between moving parts
Lubrication slippery surface between moving parts Seal between piston rings and cylinder surface Cool especially bearings (dissipate heat) Clean contaminates held in suspension (wear particles)

Change oil before winter lay-up so contaminates are removed and do not damage the machine during storage
Different lubricants show different behavior regarding these requirements.

Purpose of Oils

Lubricating oils
Lubricating oils consist of a base oil and additives which determine their performance characteristics. The additives, however, determine its actual performance by influencing the base oils.
The additives to oxidation stability. anticorrosion properties. wear protection. emergency lubrication properties. wetting behavior. emulsibility. stick-slip behavior. viscosity-temperature behavior.
Main tasks, remain lubrication and protection against friction and wear.

Mineral & synthetic Oil

These lubricants are used to a large extent in the lubrication. Synthetic oil Engine oil Transmission fluid. Refrigeration oil. Compressor oils. Metalworking fluids and oils. Laminating oils. Industrial hydraulic fluid. Copper and aluminum wire drawing solution. Electrical insulating oil. Industrial process oils. Oils used as buoyants. This list does not include all types of used oil.

Mineral & synthetic Oil

Oils are generally classified as refined and synthetic. Oils are refined from crude. Oil while synthetic oils are manufactured.

Petroleum (mineral) lubricants are produced from the refinement of existing petroleum -Synthetic lubricants are produced from chemical synthesis. -These oils are generally superior to petroleum (mineral) lubricants in most circumstances. -Synthetic oils perform better than mineral oils.

Synthetic Lubricants
Because of the high operating temperatures of gas-turbine engines, it became necessary to develop lubricants which would retain their characteristics at temperatures that cause petroleum lubricants to evaporate and break down.
Synthetic lubricants do not break down easily and do not produce coke or other deposits

Synthetic Oil
Advantages of synthetic Oil Disadvantage to synthetic oils

notable at either very low or very high temperatures. Good oxidation stability lower coefficient of friction permits operation at higher temperatures. The better viscosity index and lower pour points permit operation at lower temperatures

The major is the initial cost, which is approximately three times higher than mineralbased oils. However, the initial premium is usually recovered over the life of the product, which is about three times longer than conventional lubricants. The higher cost makes it inadvisable to use synthetics in oil systems experiencing leakage

Petroleum Lubricants
Petroleum lubricants stand high in metal-wetting ability, and they possess the body, or viscosity characteristics.

oils have many additional properties that are essential to modern lubrication, such as: -good water resistance. -Inherent rust-preventive characteristics. -Natural adhesiveness. -Relatively good thermal stability. -Ability to transfer frictional heat away from lubricated parts.

Characteristics of Lubricating Oils

Gravity Flash Point Viscosity Cloud Point Pour Point CarbonResidue Test Ash Test Precipitationnumber

Characteristics of Lubricating Oils

1 Gravity
The gravity of petroleum oil is a numerical value which serves as an index of the weight of a measured volume of this product

2 Flash Point
Temperature which the oil give off enough vapor to form a combustible mixture above the surface.

3 Viscosity
Viscosity a measure of a resistance to flow

Characteristics of Lubricating Oils

4 Cloud Point
The cloud point is the temperature at which the separation of wax becomes visible in certain oils under prescribed testing conditions.

5 Pour Point
The pour point of an oil is the temperature at which the oil will just flow without disturbance when chilled.

6 Carbon-Residue Test
The purpose of the carbon-residue test is to study the carbonforming properties of a lubricating oil.

Characteristics of Lubricating Oils

7 Ash Test
The ash test is an extension of the carbon-residue test - The ash content is a percentage (by weight)

8 Precipitation number
The precipitation number recommended by the ASTM (American Society for Testing and Materials) is the number of milliliters of precipitate formed when 10 mL of lubricating oil is mixed with 90 mL of petroleum naphtha under specific conditions and then centrifuged

Lubricant Additives
-Additives are most effective in overall performance of an oil . -A poor oil cannot be converted into a quality oil by additives. -There are limits to the amount of additives that can be added. additive may function in any of the following three ways:
Protecting lubricated surfaces. Additives coat the lubricated surfaces and prevent wear or rust Improving performance. Viscosity index improvers and antifoaming agents are examples. Protecting the lubricant itself. Antioxidants reduce the tendency of oil to oxidize and form sludge.

Oil Viscosity

Viscosity
viscosity a measure of a resistance to flow
With lubricating oils, viscosity is one of the most fundamental properties, and much of the story of lubrication is built around it.
Thick fluids, like molasses, have relatively high viscosities; they do not flow readily. Thinner fluids, such as water, flow very easily and have lower viscosities. Lubricating oils are available in a wide variety of viscosities

Viscosity

Multi grade oil

Viscosity

Viscosity

Typical Lubrication Systems

Circulatory oil lubrication
Cooling

Oil injection lubrication

Oil bath lubrication

pump

Oil Lubrication Methods

Splash Feed Lubrication Gravity Lubrication

Oil Lubrication Methods

Oil Bath Lubrication Vibrating pin Lubrication

Oil Lubrication Methods

Pressure Feed Lubrication

Oil Lubrication Methods

Wick Lubrication Ring Feed Lubrication

Oil Lubrication Methods

Stribeck Curve
Boundary Lubrication When a complete fluid film does not develop between potentially rubbing surfaces Mixed Film Hydrodynamic Lubrication

Hydrodynamic Lubrication
hydrodynamic film occurs when there is sufficient lubricant between the lubricated surfaces at the point of loading to form a fluid wedge that separates the sliding surfaces.

Elastohydrodynamic
Under even heavier loads and moderate to high sliding speeds, surfaces deform elastically and thin oil films are "trapped" between them

Hydrodynamic Lubrication
New device

Oil-Filter

Oil-Filter

Hydrodynamic Lubrication
New device

Components of Lubrication Systems

Plumbing for Lubrication Systems Temperature Regulator (Oil Cooler) Oil Viscosity Valve Oil Pressure Relief Valves Oil Separator Oil Pressure Gauge Oil Temperature Gauge Oil Pressure Pumps Scavenge Pumps Oil Dilution System

Lubricating Greases

Lubricating Greases
Lubricating greases consist of a lubricating oil, a thickening agents and one or more additives.

Lubricating Greases

Lubricating Greases
The function of grease is to remain in contact with and lubricate moving surfaces without leaking out under gravity or centrifugal action, or be squeezed out under pressure.

Todays new-generation greases are expected to do much more than lubricate. They must meet a wide range of demanding performance requirements. Long, trouble-free service life, even at high temperatures Rust and corrosion prevention Dependable, low-temperature start-up Resistance sling and water wash.

Lubricating Greases
Lubricating greases consist of a lubricating oil, a thickener and one or more additives. The thickener is responsible for the characteristics of the grease
Complex greases generally have a higher drop point. More resistant to oxidation. Synthetic thickeners are most resistant to temperature. Extensive testing is done to verify properties.

The advantage of a lubricating grease over an oil is that it Remains at the friction point for a longer time. less effort is required in terms of design. Its disadvantage is that grease neither dissipates heat nor removes wear particles from the friction point.

Lubricating Greases
WATER WASHOUT RESISTANCE

Grease Packed Bearings

Water, 80oC (175oF)

% Weight Loss of Grease Measured Typical Grease (Lithium) - 5% Water Resistant Grease <2% Exceptional < 0.5%
ASTM D1264 (DIN 51807)

Lubricating Greases - Uses

(1) Machinery that runs intermittently or is in storage for an extended period of time.
(2) Machinery that is not easily accessible for frequent lubrication.

(3) Machinery operating under extreme conditions such as high temperatures and pressures, shock loads, or slow speed under heavy load. (4) Worn components. Grease maintains thicker films in clearances enlarged by wear and can extend the life of worn parts that were previously oil lubricated.

Grease Characteristics
viscosity Dropping point penetration
Contaminants.

Evaporation Oxidation stability. Pump ability. Bleeding, migrationis Corrosion- and rust-resistance
High & Low temperature effects.

Grease Compatibility

Lubricating Greases - Added

How Much Grease Should be Added?

This is another area in which different manufacturers give differing recommendations. However, to provide guidance on the amount of grease to be added for different size motors, a grease weight versus shaft diameter curve was determined to provide the most useful information.

Grease Lubrication Method

Refilling LubriCup with 615

Ultra-Lube
Proper lubrication of bearings is a difficult problem to tackle. Unless the lubrication technician is able to hear the sound of the bearing during actual lubrication, it's a guessing game. Now the guesswork is over. The Ultra-Lube allows you to hear the voice of the bearing as it is being lubricated. It easily attaches to a grease gun, turning it into a sensitive listening device. The Ultra-Lube provides the user with feedback about the current lubrication status of components about to be lubricated. The Ultra-Lube is attached to and becomes an integral part of the grease-gun. Upon connecting the gun to the grease nipple the operator is able to listen to the electronically amplified noise through the headset and is able to discern problems associated with lack of lubricant or too much lubricant. No additional procedure is necessary other than to continue to grease components in the normal manner.

Brass Grease Nipples

Straight

90 Deg

45 Deg

Lubricant storage and handling study

Lubricant Handling/Storage
All lubricants are the end product of much careful research, refining, and testing. During storage after delivery, however, several things can happen to impair quality. -Careless handling. -Contamination. -Exposure to abnormal temperatures. -Confusion of stocks. all these factors can result in wastage, damage to machinery, deterioration of lubricants, higher maintenance costs, and loss of production.

Outdoor Storage
Outdoor storage should be avoided if possible
Keep bungs tight
Use drum covers
Lay drums on their sides

Before removing the bungs, dry the drum heads and wipe them clean of any contaminant

Indoor Storage
-Storage temperatures should remain moderate at all times. -Oil house should be located away from industrial contamination. -Should be kept clean at all times. -Regular cleaning schedules being maintained.

Oil & Grease Handling

preventive measures for personnel who regularly handle petroleum products

-Avoid all unnecessary contacts, use protective equipment to prevent contact. -Remove promptly any petroleum product that gets on the skin. -Do not use gasoline, naphtha, turpentine, or similar solvents to remove oil and grease from the skin. -Use waterless hand cleaner or mild soap with warm water and a soft brush. -Use only clean towels, not dirty rags. -Remove all contaminated clothing immediately. -Launder or dry-clean it thoroughly before reuse. -Use protective hand cream, and reapply it each time hands are washed. -After work hours, use simple cream to replace fats and oils removed from the skin by washing. -Wash hands and arms at the end of the work day and before eating. -Get first aid for every cut and scratch. -Avoid breathing oil mist or solvent vapors. -Keep work area clean. -Clean up spilled petroleum products immediately. Keep them out of sewers, streams, and waterways. -Contact the medical staff on all potential health-hazard problems.

Machinery Storage Protection

Storage Protection
Equipment amount of time required to store. -corrosion inhibiting of inactive process. -type of equipment. -expected length of inactivity. -Service time.

Petrochemical companies will usually develop their standards to take these criteria.

Company policy must ensure that all its products in their prescribed use and subsequent disposal shall not create a significant hazard to the public health or environment.

Audit Checklist

Audit Checklist

selecting the suitable Lubricant

90% by greases

9,5% by oils

0,5% by solid lubricants only

selecting the suitable Lubricant

revolution or DN - factor
D+d DN = n 2

D = external bearing diameter [mm] d = internal bearing diameter [mm] n = revolution per minute [rpm] D+d dm= medium bearing diameter [mm] =
2

selecting the suitable Lubricant

selecting the suitable Lubricant

selecting the suitable Lubricant

Dependance of Relubrication Intervals on Tempearture

C 100 Lubrication interval

l above 70C the factor 0,5 applies

for each temperature rise of 15C i.e. with a temperature rise from e.g. 70C up to 85C the service life of the grease is cut by half.

85

70

55

l below 70C the factor 2 applies

for each temperature drop of 15C

40

Temperature at the outer ring

i.e. with a temperature drop from e.g. 70C down to 55 C the service life of the grease is doubled.

Lubrication with Solid Lubricants

Deep groove ball bearings with increased clearance required at:

l high temperatures > + 200 C

l high temperature variations l low speed

Desiccant Breather Function

Second particulate filter element protects against migration of desiccant. Hydrophilic agent adsorbs water, indicates condition by color change.

Second foam filter stops oil mist during exhalation, evenly distributes air.

Durable, shock absorbing housing.

Particulate filter element. Air diffuser/oil mist foam filter.

In/out air vents. Press-in mounting, varying adapter options.

Design varies by manufacturer.

Keeps head space clean & dry

Oil Analysis & Contamination

Oil Analysis - why?

Contamination
Its the most frequent problem that affects sample integrity.
Wear metals Water Unusual color Particular matter

objective of Contamination Management

The primary objective of Contamination Management is optimal system cleanliness.
Optimal system cleanliness will give you:

1. Increased fluid usage life 2. Reduced component wear 3. Less machine down-time 4. Optimal machine performance

All this will result in significant cost savings for your plant.

Oil Analysis Purpose

To give an understanding of the oil analysis program and what is required to ensure that oil sampling from applicable equipment is successfully accomplished.

Objectives
-Condition Monitoring Program -Improve equipment reliability/readiness -Lower maintenance costs -Reduce resource usage -Maintenance diagnostic toolpredictive maintenance

Methods of Analysis

Spectrometric Viscomentry Crackle Test Ferrography Infrared Spectrosopy

Methods of Analysis
Contamination Wear metals Water color Particular matter Elements Tested For
Aluminum Antimony Barium Boron Calcium Chromium Copper Iron Lead Magnesium Molybdenum Nickel Phosphorus Potassium Silicon Silver Sodium Tin Titanium Zinc

Water Contamination Problem

% REDUCTION IN FATIGUE LIFE
90
80

70
60

78

83

50
40 48

30 20
10 0.002 3.0

6.0

% WATER IN OIL

Mobil Oil evaluation on bearing fatigue life 0.002% water reduces fatigue life 48% 6.0% water reduces fatigue life 83% 0.002% water is 1 drop of water in a quart of oil

Sampling Methods

Valve Pump Drain

Acceptable Contamination Levels

Particle sizes > 5 m > 15 m Range of counts 1,000,000 64,000
Sensitivity: Main protection Low pressure systems with large clearances Ram pumps

ISO 21 /17

Type of system: Typical components

Sensitivity: Type of system: systems

Average Low pressure heavy industrial

> 5 m > 15 m

250,000 16,000

19/15

Typical components valves cylinders

Gear pumps, manual and poppet

Sensitivity:

Important

Type of system:

> 5 m > 15 m

130,000 8,000

18/14
Typical components

General machinery & mobile systems. Medium pressure, medium capacity

Vane pumps, spool valves

Sensitivity: Type of system:

Critical High performance and high pressure long life systems, i.e., aircraft, machine tool Industrial servo valves Super critical Silt sensitive control system with very high reliability. Laboratory or aerospace High perf. servo valves

> 5 m > 15 m

16,000 1,000

15/11
Typical components Sensitivity: Type of system:

> 5 m > 15 m

4,000 250

13/9
Typical components

Air Contaminant
Air can exist in oil in three different states: dissolved. entrained . foam. Causes of Excessive Air Contamination
-When a lubricating oil becomes contaminated with water -loss of antifoam additives -suction leaks -poor reservoir design -using the wrong viscosity

Effects of Air Contamination Air contamination can have negative effects on the machine and the lubricant. Air can damage a lubricating oil by increasing the rate of oxidation reducing its heat transfer coefficient and reducing its film strength
Machine wear can be generated by air contamination by several mechanisms film thickness become compressible.

In hydraulics, entrained air can create other problems as well, such as spongy operations, loss of controls and an increased likelihood of surface deposits in valves.

Contamination Control
Keep it Clean-Cool-Dry
Storage solutions
ISO 22/19

Desiccant Breathers

Oil Safe System

Color Coding

Personnel training

Monitor/improve

Component Life

C o n t a m i n a t i o n

21/17 20/15
19/16 18/15 17/14

-------157.7 lb/yr
78.9 lb/yr -----------19.7 lb/yr

2,500

10,000

25,000

16/13 15/12
14/11 13/10 12/09

Clean New Oil

Component Life Over Time

Source Caterpillar Contamination Control Basic Training Program

Total Impact of Lubrication on Costs

Task-Lubricant selection for plain bearing

Plain bearings Plain bearings and bushings come in a wide variety of shapes, sizes, types of surface contact modes, material compositions and operating profiles, including: Single-sided Double-sided Vertical shaft Horizontal shaft Solid housing Split housing Thin wall Thick wall ..etc

Plain or journal bearings are used for high radial loads and low- to high speeds. Typical applications include turbines, large milling systems, engine cranks, compressors, gearboxes, shaft bearing supports, ...

Task-Lubricant selection for plain bearing

performs longer life by no metal contact with shaft to bearing Groove <= 5m
Fluid dynamic pressure support shaft floating

Oil flow Shaft Rotation

Task-Lubricant selection for plain bearing

Under normal operating conditions, the lubrication regime is a hydrodynamic full-fluid film. A hydrodynamic film occurs when there is sufficient lubricant between the lubricated surfaces at the point of loading to form a fluid wedge that separates the sliding surfaces. In this state, the lubricated components do not touch each another, reducing friction and wear.
Stribeck Curve. This is represented by Z*N/P where Z = viscosity, N = speed (rpm) P = load.

Z*N/P

Task-Lubricant selection for plain bearing

If the load or the speed changes, the lubricant viscosity must be adjusted to compensate for the change. the following approximation equation gives an estimate of what the final outcome should be.
The first step is to estimate the machines surface speed Second step -estimate the machines unit surface pressure.

u = * d * n where
u = surface speed d = bore diameter, meters n = shaft speed, revolutions per second = 3.1415

= w/I*d
Where
= pressure, kN/m2 l = bearing width d = shaft diameter w = load, kN

Task-Lubricant selection for plain bearing

Once known these values can be plotted on a table for a rough estimate of minimum allowable viscosity
Other considerations The final lubricant type decision should include considerations for oxidation stability, corrosion protection, wear protection, water and air separation properties, etc.

Note:
This is intended only to be a rough approximation for the sake of illustrating the principles behind lubricant selection. Please consult with a lubrication engineering professional prior to attempting to make any change in the lubricant selection for any actual operating machines

Task 2 Causes of bearing failure

Improper Lubrication - 43%
How Much, How Often, What Type, What Thickness, What Properties are Important

Improper Mounting - 27%

Alignment, Work Area, General Practices, Inventory Control and Storage of Bearings

Other Lubrication Causes - 21%

Separation in Storage Temperature Limit Exceeded Moisture Contamination Other Contamination

Fatigue - 9% Ultimate L10 Life Expectancy

64% of Bearing Failures are Lubrication Related IS Not The Whole Story

In the Industry We Serve, Most Bearings Fail Due To Some Form of CORROSION

Task 3 - Gears Lubrication

Proper Lubrication with timely addition / replacement plays vital role in maintaining the gear boxes with efficiency and increasing its working life. Oil level should be checked in all the gear boxes oil indicators / dip sticks. Oil level should be in between the minimum and maximum limits of the dip stick (or indicator). Testing of the lubricating oils used to be carried out periodically. The following tests are to be done 1. Dirt contamination 2. Moisture 3. Volatile materials (Benzene, kerosene, spirit etc,) 4. Viscosity 5. Acidity 6. Alkalinity due to soda (Na2 Co3) etc.,

Synthetic Gear Oils for Worm Gear Lubrication

Worm gears are used to transmit power & motion between shafts at right angles Worm gears normally consist of a small diameter steel gear worm and a larger diameter bronze wheel Because of the high degree of sliding (520%), the efficiency of worm gears is lower than for spur or helical units ~ 75 - 85% To MINIMIZE WEAR & MAXIMIZE EFFICIENCY, synthetic Poly Alkylene Glycol (PAG)- based lubricants are used in these applications
Steel worm

Bronze wheel

Benefits in Using Synthetic Gear Oils

Mineral-based gear oils typically have a finite performance life determined by temperatures (low and high), loads, ambient conditions Synthetic gear oils typically provide the following benefits over mineral oils: Improved oxidative & thermal stability Improved viscosity-temperature behavior Extension of oil change intervals Reduced energy consumption Improved gear efficiency Reduced oil temperatures Savings on maintenance and waste disposal costs Reduced vibration

Troubleshooting
Symptom: Oil pressure decrease, oil temp. steady Cause:

Symptom: Slight drop in oil pressure, steady or slight rise in oil temp. Cause: Faulty air-induction systems Leaking cooling systems Loose cross-over fuel lines Abnormal wear rates of moving metal parts

Oil Recycling
Reprocessing is the most common method of recycling used oil in the U.S. Each year processors treat approximately 750 million gallons of used oil. Seventy-five percent of used oil is being reprocessed and marketed to: 43% asphalt plants; 14% industrial boilers (factories); 12% utility boilers (electric power plants, homes, etc.); 12% steel mills; 5% cement/lime kilns; 5 % marine boilers (tankers or bunker fuel); 4% pulp and paper mills; 6% other.

Saves Money
By Using Oil/lubricant products (Good One) Oil/lubricant filters Repairs by early detection

LUBRICATION

Right lubricant is applied to the right place, on the right machine, in the right amount, at the right time.

Types of Greases

Calcium grease.

Calcium or lime grease, the first of the modern production greases can lubricate satisfactorily to temperatures around 93 EC (200 EF).
lime grease does not emulsify in water and is excellent at resisting wash out.

manufacturing cost is relatively low maximum temperature of around 110 EC (230 EF).

Types of Greases

Calcium complex grease

Aluminum gre ase. Aluminum grease is normally clear and produced from high-viscosity oils.