LUBRICATION

MANAGEMENT
LUBRICTION DELIVERY
SYSTEM
LUBRICANT RECONDITIONING
CONDITION MONITORING
ULTRASONIC TECHNIQUE
1: What is Lubrication Management
system?

ANSWER :
Definition: a number work performed in order to make sure that lubrication is supplied in right amount/ right
portion to the right point at the perfect time with the right technique. Lubrication Management Program
consists of five main steps:
1. Client needs analysis
2. Lubrication audit
3. Improvement proposal
4. Design and implementation
5. Optimization
References :
http://www.skf.com/group/services/lubrication-services/lubrication-management-services/index.html
http://www.maintenancetechnology.com/2013/08/developing-an-effective-lubrication-management-
program/
QUESTION 2 : LIST 5 ADVANTAGES OF OIL SUPPLY SYSTEM.

Extend the period of time of changing oil lubricant. By

replacement of used oil by fresh oil.

Contaminant is removed. The harmful wear debris,

contaminant that can harm surface, abrasive particles. Eg :
remove any water and products of combustion plus any
foreign particles which may be in the oil.

Reduces heat / as a cooling medium. Removing hot oil and

supplying cool oil help reduce surface temperature.

Measured lubrication amounts means no wasted lubricant.

Safety - no climbing around machinery or inaccessible areas

(gases, exhaust, confined spaces, etc.)

Refferences :
Slide Chapter 3 Lubrication Formulation and Lubrication Selection
WIKIPEDIA. (2016). https://en.wikipedia.org/wiki/Automatic_lubrication_system [ Available from : 19 May 2016]
3 : Name 4 major types of oil supply system

RING, DISC
AND SPLASH

TYPE OF OIL TOTAL LOSS

CIRCULATION SUPPLY
SYSTEM
SYSTEM

MIST AND
FOG

References:
https://books.google.com.my/books?id=HxMSBQAAQBAJ&pg=PA57&lpg=PA57&dq=different%20
oil%20feed%20system&source=bl&ots=5OIDPQA6jX&sig=ZP6RsUeJRMOeUiInjVlGobnAB3c&hl=e
n&sa=X&redir_esc=y#v=onepage&q=different%20oil%20feed%20system&f=false
QUESTION 4 : ADVANTAGE AND DISADVANTAGE OF RING, DISC AND SPLASH OIL SUPPLY SYSTEM

Advantages Disadvantages

Low labour cost Fairly high initial cost

Generally reliable Limited speed range
Some cooling
Recovery of used oil

Reference:
Lubrication: A Practical Guide to Lubricant
Selection
By A. R. Lansdown
 NO 6: Advantage and disadvantage of total
loss feed system

DISADVANTAGE
ADVANTAGE
High initial cost
Low labour cost
High maintenance cost
High reliability
No cooling
Little risk of wrong oil
No recovery of used oil

References: https://books.google.com.my/books
(LUBRICATION: A PRACTICAL GUIDE TO LUBRICANT SELECTION)
 Oil Supply System :
Oil Mist or Fog System
Advantages Disadvantages

Effective cooling and Oil can escape with air

suitable for high into atmosphere
speed bearing

Less wasteful, cleaner Hard to use with plain

and more reliable bearings because of
than pumped system difficult to feed the oil

Reference:
A R Lansdown, Lubrication A Practical Guide To
Lubricant Selection (Pegamon Press),pp. 62 - 63
8 : Describe different types of Total Loss System
Answer:
Two types of total loss system
Direct system
Indirect system
Direct System
the oil passes directly from the pumping device
For example
1. a single piston pump with a number of separate outlet ports.
2. Multi piston pumps are used in which a separate piston supplies each outlet.
Indirect Systems
the pump supplies pressurized oil to a complex system or manifold and to individual lubrication point is
controlled by separated metering valves

Simple Multi outlet Direct Single line Progressive Indirect

References:
A.R.LANSDOWN LUBRICATION A Practical Guide to Lubricant Selection Pergamon Press
ISBN 0-08-026728-9
9.Discuss why sometimes it is not wise to completely
immerse the moving parts of machine in a lubricant bath or
reservoir.
Factors/Reasons :
The main reason : if the moving parts are completely immersed the oil
becomes continuously stirred.
If the oil completely fills the enclosed space then as its gets hot in
operation it will need to expand, thus lead to high pressure and
leakage.
The shaft seals are less effective when fully immersed than they are
when simply splashed with oil, so that leakage can become even more
of a problem.
References :
-A R Landsdown, Lubrication and Lubricant Selection, A Practical Guide,
Third Edition.
-Boris M.Klebanov, Morel Groper, Power Mechanisms of Rotational and
Cyclic Motion.
10 : An alternative solution to problems discuss earlier is to only partly
submerged part in lubricant bath or reservoir. Discuss some important
guidelines to ensure proper implementation of this alternative solution.

Using the right amount of oil to establish

the optimum usage of oil to the
component.
Make sure to use the best type of lubricant
and good quality lubricant to the system.
Always change the oil filter to get rid the
debris in the system.
Use proper equipment to replace the
lubricant oil.

Reference :
https://en.wikipedia.org/wiki/Motor_oil
http://www.maintenancetechnology.com/2012/06/lubricating-and-troubleshooting-
centrifugal-pumps/
11) Describe an oil mist or fog lubrication systems.
Mixture of one part oil to 200,000 equal parts of air

Only limited oil feed supply is required

Bearings, gears, cams, chains and sliding surfaces of machines

Alternative both to grease at low-to-moderate speeds and to

circulating oil systems for high speeds and high temperatures

http://www.machinerylubrication.com/Read/799/oil-mist-lubrication
12. What are the advantages & disadvantages of oil mist of fog system
ADVANTAGES
No oil changes and reduced
maintenance requirements. Maintenance
normally consists of changing filters and
doing walk-down inspections to look for
broken or leaking lines.
Reduce energy consumption (bearings
operate in a thin film of oil instead of a pool
of oil, typically 3 percent)
Increases safety because it eliminates
hand labor next to moving machines
http://www.machinerylubrication.com/Read/799/oil-mist-lubrication
DISADVANTAGES
The air stream in feed lines must be kept
laminar, below approximately 24 ft/sec, because
turbulence causes oil particles to impact the pipe
wall and be removed from the air stream before
reaching delivery points. At abnormally low
velocities, on the other hand, oil droplets may
also settle out prematurely.
Performance is sensitive to temperature.
Even when not required by viscosity
considerations, heaters are often employed to
stabilize the oil/air ratio under widely varying
ambient temperatures. When used, air heaters
are usually accompanied by oil reservoir heaters.
Spray mist involves environmental hazards.
Vent lines are needed at lubrication points for
collecting stray mist which has not been
classified. OSHA requirements state that in an
eight-hour period, a person can be exposed to no
more than five milligrams of oil per cubic meter
of air.
DAUS
13. Describe oil circulation system and how it is different from the previous
systems

Oil circulatory system is the system that permits oil to circulate. After the oil passes through the
point requiring lubrication, it is fed back through the return line for reuse.
This function can stabilizes the lubricant point to the proper temperature, remove and filter out
wear particles, prevent corrosion damage and remove water condensation. Modern type of this
system delivered lubricant by a pump is split up by hydraulic resistor.
The previous system is a total-loss oiling system is an engine lubrication system whereby oil is
introduced into the engine, and then either burned or ejected overboard.

Oil circulating system Total-loss oiling system

Engine became faster & more powerful Amount oil required is high
Oil is reused from the reservoir New oil is used/supply
Efficient cooling/lubrication system Impractical either in costing or cost

Reference : https://en.wikipedia.org/wiki/Total-loss_oiling_system
 14. In a self-contained arrangement, discuss the
typical components of the oil circulation system.

Pressure relief valve system. Full flow system.

Reference: http://www.bsaeronautics.com/2015/05/04/engine-lubrication-and-
fuel-systems/
 15: Summarize the advantages and disadvantages
of different oil feed systems: Oil can

Advantages:

Disadvantages:

Reference: A R Landsdown. (2004). Lubrication and Lubricant Selection:

A Practical Guide. London, UK: Professional Engineering Publishing Limited.
 Drip Oil Feed System

Advantages
Reduces labour involve because less
frequent filling (compare to hand held oil
can)
Possible to reach a point that inaccessible
to oil can
Disadvantages
o Difficult to control and judge the oil flow
rate
o Difficult to detect blockage in feed pipe
(installation of sight glass to the reservoir
is recommended to see oil level)

Reference: Lubrication: A Practical Guide to Lubricant Selection By A. R. Lansdown

 17:Summarize the advantages and disadvantages of different oil feed system:
centralized total loss
advantages disadvantages

Simple because no need return line Wasteful of oil, and leads to a

or any of the components which are general oiliness of the equipment
used to control and clean the and surrounding floors unless care is
recycled oil. taken

Individual can control of the amount Use almost entirely human skills,
of oil feed to each bearing, and with
care it can be highly reliable.

Large number of bearing using the Use manual labour may not be
same oil economical

Oil life short, so that frequent oiling

is needed

Reference= lubrication: a Practical guide to Lubricant Selection by A.R.Lansdown

18. Summarize the advantages and disadvantages of different oil feed system:
oil mist/fog

Application: Bearings of electric motors, pumps and compressors

Advantage
- The oil mist system are generally less
wasteful, cleaner and more reliable
- Give very effective cooling
- Tend to be used for high-speed rolling
bearings or for chains in hot environment
- Lower friction and reduced bearing
temperatures
Disadvantage
- The amount of oil which can escape with
the air into the factory atmosphere (it can
be controlled by choosing the right nozzle
diameter, properly positioning the nozzle
and especially by choosing a suitable oil.
- Difficult to use with plain bearing because
of the difficulty of feeding the reclassified
oil from the nozzle into the bearing
clearance.

Reference: Books Lubrication: A Practical Guide to Lubricant Selection. A.R.

Lansdown 2013. Swansea Tribology Center, UK.
Advantages:
Viscous friction is minimize
Act likes a filter and supplies only clean oil to the
bearing
Operates at high speed
No resistance to the motion of rolling elements
Reuse system without losses

Disadvantages:
Need to be properly maintained

Reference: Bearing Design in Machinery (Engineering Tribolgy

and Lubrication) by Avraham Harnoy
 The Advantages & Disadvantages of Different Oil
Feed System : Ring or Disc

ADVANTAGES DISADVANTAGES

Low Labour Cost Fairly High Initial Cost

Generally Reliable Limited Speed Range
Some Cooling
Recovery of Used Oil

Lansdown, A. (1982). Lubrication, a practical guide to lubricant selection. Oxford [Oxfordshire]:

Pergamon Press. Pg 71.
21: Advantages and disadvantages of different oil feed system : Splash

Splash type oil feed system

ADVANTAGES DISADVANTAGES

Low cost Limited speed range

Simple to implement Helps regulate the temperature.

References : A. Lansdown, Lubrication, a practical guide to lubricant selection.

Oxford [Oxfordshire]: Pergamon Press, 1982.
 22: Summarize the advantages and disadvantages of different oil feed system:
Oil Circulation
Answer: The oil is fed into the bearings, gears , other mechanical parts and
then the oil is returned to a separate reservoir for-reuse.

Advantages Disadvantages

Possible to feed much High cost of installation

quantities of oil without waste High maintenance cost
Wide range of use
Generally Reliable
Effective cooling
Recovery of used oil

Reference: Google Book; Lubrication: A Practical Guide to Lubricant Selection

23. What is the purpose of lubricant
monitoring?

Answer : The purpose of lubrication oil condition monitoring and degradation detection is to

determine whether the oil has deteriorated to such a degree that it no longer fulfills its protective

function and to provide early warning of the possibility of total failure.

Reference: J Zhu, J M. Yoon , D He , Yongzhi Qu , E Bechhoefer, Lubrication Oil Condition Monitoring and Remaining Useful Life Prediction
with Particle Filtering, International Journal of Prognostics and Health Management, Department of Mechanical and Industrial Engineering,
The University of Illinois at Chicago, 2013.
 24. List the method of monitoring lubricants
Answer:
1. Monitoring the quality of the lubricant
Taking a sample of the oil from a system from time to time and examining it.
The choice of a suitable test depend on the way in which the lubricant likely to deteriorate
for example overheating & oxidation, depletion of additives and contamination.
2. Wear monitoring
The first systematic attempts to monitor wear followed the introduction of magnetic drain
plugs in oil systems.
Some important wear monitoring techniques are spectrographic oil analysis (SOA),
magnetic plug techniques, ferrography and the rotary particle depositor (RPD).
3. Field tests
In many situations simpler tests are needed which are cheaper and can be carried out on
the spot.
(blotting-paper test, viscosity tests, capacitance tests & appearance)
4. Investigating failures
Failure investigation requires an open-minded approach, and the use of all techniques
which may give useful information.
Example of lubricant tests for failure analysis (penetration test, infra-red examination,
examination with microscope and viscosity measurement)
Reference:
Lansdown, A. R. (2003). Lubrication and Lubricant Selection: A Practical Guide, 3rd
edition. ASME Press, pp. 230-252
 25. IDENTIFY THE ADVANTAGES OF EACH
METHOD IN (24)
Answer:
1. Monitoring the quality of the lubricant
Allow to use the oil (lubricant) more economically.
Able to plan maintenance more efficiently.
2. Wear monitoring
Remove ferromagnetic wear debris from oil system and thus prevent further
damage.
3. Field tests
Cheaper and test can be carried out on the spot.
4. Investigating failures
Able to know the properties of the material.
Able to have clear reason for component failure.
Reference:
Lansdown, A. R. (2003). Lubrication and Lubricant Selection: A Practical Guide, 3rd
edition. ASME Press, pp. 230-252
 26. Identify the disadvantages of each method (24)
1. Monitoring the quality of the lubricant
Need regular monitoring
2. Wear monitoring
Limited technique
3. Field tests
Can be used for small system only
4. Investigating failures
Need open mided approach

Reference:
Lansdown, A. R. (2003). Lubrication and Lubricant Selection: A Practical
Guide, 3rd edition. ASME Press, pp. 230-252
27: Discuss the quality of monitoring lubricant in term
of overheating and oxidation
If overheated lubricant :
-Oxidation products are present.

ANSWER
-Can be checked using infra red spectroscopy because oxidation products of oil or
addictives (eg organic aldehydes, acids) contain a carbonyl group, in which a carbon
atom is linked by a double bond to an oxygen atom. This group produces a
characteristics absorption band in the infra red spectrum.
-Ester based lubricants or any other lubricants cannot use infra red spectroscopy.
- Quantitative test for oxidation Analyse for organic acids by acid number test. At the
same time, the base number test can be used to show the amount of certain
addictives remaining.
- Severe Oxidation tarry or solid oxidation products. Can be check using pentane
insolubles because they are normally insoluble in pentane and other light
hydrocarbons. *other solid contaminants are also insoluble in pentane so caution
must be taken during interpretation.
- If anti oxidants are still present, and severe oxidation has not begun, it may be
useful to assess the amount of anti oxidant still present.

Te x t B o o k L u b r i c a t i o n
 28. DISCUSS QUALITY OF LUBRICANT IN TERMS OF: DEPLETION OF ADDITIVE
Answer: Additives make up to 7% of a typical lubricant base. Commonly, they are
blended with lube oils to enhance specific features thereby improving their
qualities. Additives are organic or inorganic compounds dissolved or suspended as
solids in oil. There are three basic roles of additives such as:
Enhance existing base oil properties with antioxidants, corrosion inhibitors,
anti-foam agents and demulsifying agents.
Suppress undesirable base oil properties with pour-point depressants and
viscosity index improver.
Impart new properties to base oils with extreme pressure (EP) additive,
detergents, metal deactivators and tackiness agents.
Additive depletion is often used to estimate the aged of the oil or remaining used
for the life of the oil. Additive are sacrificial because they have to die to do their
job. There are 2 main types of additive depletion such as decomposition and mass
transfer. In additive decomposition, the additive literally die or change it state such
as oxidize, hydrolyze with water, expose to high temperature and neutralize. For
mass transfer, the mass of additive is leaving the body of the oil such as detergent
additive and depressant additive. In conclusion, depletion of additive is important
to save the oil and therefore know the oil should be change.
Reference: http://www.machinerylubrication.com/View/29858/additive-depletion-
truth
29 . DISCUSS THE QUALITY OF LUBRICATION IN TERM OF : CONTAMINATION
Contamination of lubricants is one of the most significant factors affecting the
storage stability and service life of bulk oils. The types of contamination is :

Condition of Storage and Handling Equipment :

- Contamination of newly commissioned storage and handling equipment include
preservatives .
- To avoid contamination of bulk lubricants.

Solid Contamination :
- Solid contamination includes the paint chips and rust particles.
- The weld splatter that may pre-exist within the tank when first commissioned.

Liquid Contamination :
-Lubricants in storage are most prone to become contaminated with water from
headspace condensation.
- Free water in bulk storage vessels provides a habitat for microbial contamination
which is corrosive and harmful to lubricant performance properties.

Refferences
https://www.finning.ca/Products/Parts/Maintenance_Products/Contamination_Cont
rol/_downloads/BulkLubricantandStoragehandling.pdf
 DISCUSS ON LUBRICANT HANDLING:
Lubricant is like metallic item which is can be degrade by heat, moisture and chemical attack

Deteriorations of a lubricant will be passed on to bearing, gears and other lubricated parts.

So, it very important to handle lubricant carefully before it has been used in the mechanical parts.

There are lubricant handling procedure that need to be considered :

1. Lubricant packaging and delivery suitable type of package depend on the quantity used and the
application
2. Lubricant storage
3. Dispensing and applying lubricant

Reference :
Lansdown, A. R. (2003). Lubrication and Lubricant Selection: A Practical Guide, 3rd edition. ASME Press, pp. 253-261
Number 31: lubrication packaging
Suitable type of packaging are depend on the quantity
used and application.
Standard Packaging
offers a variety of standard packaging options for oils and
greases such as glass bottles, plastics bottles, jars, tubes.
Specialty Packaging
To package lubricants in a variety of small, convenient,
application-specific dispensers such as:-
Oil Dispensers : Vials and bottles provide an economical way to apply
small amounts of synthetic oil.
Spray-On Applicators : usually in aerosol cans applications.

Specialty Packaging - Nye Lubricants", Nyelubricants.com, 2016. [Online].

Available: http://www.nyelubricants.com/lubricant-packaging. [Accessed: 08- Jun-
2016].
32. Discuss on lubricant delivery
Lubricant delivery controls for use in lubricating systems for internal combustion engines,
pumps, or the like, wherein lubricant is supplied to portions of the valve operating
mechanism through tappet reciprocated push rods.
A feeds system ensures that fresh oil is being continuously applied to the lubricated problem.
An automatic lubrication system (ALS), often referred to as a centralized lubrication system, is
a system that delivers controlled amounts of lubricant to multiple locations on a machine
while the machine is operating.
The lubricant delivery controls are embodied in the lash compensating tappets or valve
lifters of the valve operating mechanisms and are adapted to meter or control the delivery of
lubricating oil from supply passages, or from reservoir chambers in the tappets themselves,
through hollow push rods to remote bearing surfaces such as are found in the rocker arms of
valve linkages.
Basic component :
Controller/Timer activates the system to distribute lubrication
Pump with Reservoir stores and provides the lubricant to the system
Supply Line line that connects the pump to the metering valves or injectors. The lubricant is
pumped through this.
Metering Valves/Injectors component that measures/dispenses the lubricant to the application
points.
Feed lines - line that connects the metering valves or injectors to the application points. The
lubricant is pumped through this
References : 1. Mohawk College of Applied Arts and Technology: Reasons for Lube Systems; MATLLUB04. January 2007, FLO Components Ltd
2. LUBRICANT DELIVERY CONTROL Gerald D. Line, Royal Oak, Mich., assignor to Eaton Manufacturing Company, Cleveland, Ohio, a corporation of Ohio Filed
on. 23, 1958, Ser. No. 769,135
 33. Discussion On Lubrication Storage
STORING CONTAINER
o At least few inches above floor level to prevent o Unlabelled container should be discard.
bottom corroding.
o Date identification on labelling should be done.
o Large oil storage usually using rectangular
o Deterioration occur once the container opened.
container and drum.
o Cleanliness is important.
o Drum should be mounted horizontally and fitted
with non-trip tap to enable dispensing by gravity.
Rack o If unavoidable, can be stored vertically, but not if LOCATION
there is risk of water falling on top of them. o Corner of enclosed factory.
o If still unavoidable, the lids of containers should be o Basement or cellar.
cover with tarpaulin or plastic sheet and kegs need
to be tilted slightly. o Separate building.

o Small tins, cans, and bottles more convenient to be

stored on rack or shelves. SAFETY
Barrel rack storage
o Separate building with solvents and paints
with adequate fire precautions.
Buck oil o No smoking and naked flames in the area.
storage o Restricting access to lubricant stores.
tanks

Reference : Lansdown, A. R. (2003). Lubrication and Lubricant Selection: A Practical Guide, 3rd edition. ASME Press, pp. 253-258
 34. DISCUSS ON DISPENSING AND APPLYING LUBRICANTS

WHY?
Because improper handling can cause the lubricants to
deteriorate and becomes contaminated.

DISPENSING LUBRICANTS: APPLYING LUBRICANTS:

First-in, first-out storage principle
Clean drums and pails before opening
Use clean dispensing equipment
Do not mix products
Close lids and bungs properly after
opening
Inform of the hazards the lubricants pose so
workers can take extra care
Use of spouts or pumps with hoses would
eliminate the use of funnels which reduces
contact with lubricants
Use gloves or barrier cream to keep the
material from coming in contact with skin

References:
1. https://lubes.exxonmobil.com/MarineLubes-En/Files/storage-and-handling.pdf
2. http://www.machinerylubrication.com/Read/29101/handle-lubricants-problems
 Reconditioning of lubricants can be
categories as:-
a. remove contaminants,
b. refresh the additive system and
c. reconstruct the additive system.
Contaminant removal employs filters and other
separation technologies to remove contaminants
(such as solids, moisture, etc.) that the system has
ingested or generated.
Particles and moisture are the easiest common
contaminants to remove.
Acid, glycol, fuel and other chemical contaminants
are more difficult to extract.
Refreshing the additive system is typically
accomplished using a partial drain and fill
with the oil in service. By taking a
percentage of the old oil out of the system
and replacing it with fresh oil, the additive
system is simply refreshed.
 Reconstructing the lubricant's additive system,
sometimes called reclamation.
It is a trickier proposition than simply
decontaminating it or sweetening the additive
system with a partial drain of fresh oil.
Reconstructing the additive system essentially
involves reblending of the lubricant with an
additive system.
Blending additives to achieve proper bedding into
the base oil chemistry typically requires a
combination of heat and mechanical shear.
 Lansdown, A. R. (2004). Lubrication and lubricant selection: a
practical guide. ASME Press.
 Film thickness and viscosity measurement