Escolar Documentos
Profissional Documentos
Cultura Documentos
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
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
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
2
The principle of supporting a sliding load on a
friction-reducing film is known as lubrication
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
Lubricating
Complex design is required to keep oils are used
the oil at the friction point and in
prevent the danger of leakage.
gears
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)
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 Synthetic oil
are used to a Engine oil
large extent in Transmission fluid.
Refrigeration oil.
the lubrication. 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
Gravity
Flash Point
Viscosity
Cloud Point
Pour Point
Carbon-
Residue Test
Ash Test
Precipitation-
number
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 carbon-
forming 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
Cooling
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.
Refilling Lubri-
Cup 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
Petrochemical
companies will Company policy
usually develop must ensure that all its products in their
their standards prescribed use and subsequent disposal
to take these shall not create a significant hazard to the
criteria. public health or environment.
Audit Checklist
Audit Checklist
selecting the suitable Lubricant
90% by greases
revolution or DN - factor
D+d
DN =
2
n
C Lubrication interval
l above 70C the factor 0,5 applies
100 for each temperature rise of 15C
70
55
l below 70C the factor 2 applies
for each temperature drop of 15C
40
i.e. with a temperature drop from
e.g.
70C down to 55 C the service life
Temperature at the outer ring of the grease is doubled.
Lubrication with Solid Lubricants
Deep groove ball bearings with increased clearance
required at:
l low speed
Desiccant Breather Function
Hydrophilic agent
adsorbs water, Durable, shock
indicates condition by absorbing housing.
color change.
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 tool-
predictive maintenance
Methods of Analysis
Spectrometric
Viscomentry
Crackle Test
Ferrography
Infrared
Spectrosopy
Methods of Analysis
Contamination
Wear metals Water color Particular matter
80
83
78
70
60
50
48
40
30
20
10
Valve
Pump
Drain
Acceptable Contamination Levels
Particle Range of Sensitivity: Main protection
sizes counts ISO Type of system: Low pressure systems
with large clearances
> 5 m 1,000,000 21 /17
Typical components Ram pumps
> 15 m 64,000
Sensitivity: Average
Type of system: Low pressure heavy industrial
systems
> 5 m 250,000 19/15 Typical components Gear pumps, manual and poppet
valves cylinders
> 15 m 16,000
Sensitivity: Important
Type of system: General machinery & mobile
systems. Medium pressure,
> 5 m 130,000 18/14 medium capacity
> 15 m 8,000 Typical components Vane pumps, spool valves
Sensitivity: Critical
Type of system: High performance and high
pressure long life systems,
> 5 m 16,000 15/11 i.e., aircraft, machine tool
> 15 m 1,000 Typical components Industrial servo valves
reducing its heat transfer coefficient and reducing its film strength
ISO
22/19 Component Life
C
o
n
21/17
---- 2,500
t
a
20/15 -----
157.7 lb/yr
m 19/16
i 10,000
n
a
18/15
------------
78.9 lb/yr
25,000
t 17/14
i
19.7 lb/yr
o 16/13
n Clean New Oil
15/12
14/11
13/10
12/09
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 Z*N/P
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.
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.
1 u = * d * n 2 = w/I*d
Where
where = pressure, kN/m2
u = surface speed
d = bore diameter, meters l = bearing width
n = shaft speed, revolutions per second d = shaft diameter
= 3.1415 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
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
1 Calcium grease.
manufacturing cost is
relatively low