Lubrication Moves The WorldMaintenance & Lubrication For Water & Wastewater Personnel

Oil•Greasy, usually liquid, substances from plant, animal, or mineral sources that do not dissolve in water and are used as lubricants.

• Webster’s Dictionary

Oil

•Viscosity – Volatility - Toxicity

Oil•Viscosity

•Flow

•Temperature

•SAE•Multi-Grade

Cannon FenskeViscometer

Oil•Volatility

Oil•Toxicity

Oil•Mineral Based•Dinosaurs

•Synthetic•Laboratories

The Practical Handbook of Machinery Lubrication:http://store.noria.com/products/the-practical-handbook-of-machinery-lubrication-4th-edition

Oil•Mineral Based•Refined Crude•Additives

Fundamentals of oil refining:

http://www.machinerylubrication.com/Read/28960/mineral-oil-refining

Oil•Myth: All lubricating oils are the same.

• From hydraulic fluids to gear lubricants to motor oils, each lubricant, be it synthetic or mineral-based, is uniquely formulated for its application with a specific viscosity; additive package; physical, chemical, and performance properties; and regulatory requirements. Various products may or may not be compatible with each other

• Chris Kniestedt, Motion Industries

Oil•Myth: Tacky and stringy greases and oils offer better protection than non-tacky products.

• It’s important to understand that lubricants are only 20-microns thick (or less) at the point of contact.

• Film thickness is a function of the rated oil viscosity at operating temperature and speed,

• load has only a small effect.

• Tacky lubricants with higher percentages of thickener can actually cause problems at high operating speeds.

Oil•Mineral Based•Additives

Common Additives by Type of Machinery

Oil

•Synthetic•Polyalphaolefins (PAOs)•Polyalkaline glycols (PAGs or PGs)•Dibasic Acid Ester (Diester) •Polyol Ester

OilSynthetic Vs Conventional

•Viscosity•Lifespan•Cost

Oil•Changing

•Mixing

•Testing

Non-Engine, oil analysis kit, $22.53:

http://www.stainlesssteelfittings.com/Oil_Analysis_Basic_Industrial_p/pol-bia.htm?gclid=CKDUoZnQn8oCFQMMaQodJxsKrg

Example:Oil Analysis Report

Example:Oil Analysis Report

Filtering

•Change filters OFTEN

•Filter oil before use

Filtering•Filter oil before use

Filtering•Filter oil before use

•http://www.machinerylubrication.com/Read/28847/when-oil-filtered

Grease

Grease

•Mineral Based•Dinosaurs

•Synthetic•Laboratories

GreasePhysical Properties:

•Grease is expected to:

•Reduce friction and therefore wear.

•Provide corrosion protection.

•Seal bearings from water and contaminants.

•Resist leakage, dripping and throw-off.

GreasePhysical Properties:

•Grease is expected to:

•Resist change in structure or consistency during service.

•Maintain mobility under conditions of application.

•Be compatible with seals.

•Tolerate or repel moisture.• www.boucherandjones.com/grease.h

tm (Page saved as pdf in info pack)

GreaseWhat is extreme pressure grease?

•EP LITHIUM GREASE is multi-purpose extreme pressure grease made from lithium soap stock which imparts good high and low temperature characteristics and chemical stability.

GreaseWhat is extreme pressure grease?

“EP” refers to load capability, not pressure like in a canister or tank.

•The load carrying additives contain no environmentally undesirable lead or metals.

•www.lsc-online.com/extreme-pressure-lithium-grease/

Grease

•Mineral Based•Oil + Thickener•“Soap”

Grease

•Myth: If a little is good, more is better.

• Over-greasing of bearings is a major cause of failure. Seal failures and overheating are commonly caused by too much grease.

• Always check the O&M manual and err on the side of caution.

Examples of Over-greasing

Examples of Over-greasing

Grease

•Synthetic•Water

•Heat

•Pressure•Corrosion

Grease

•Synthetic grease advantages:•http://www.ehow.com/list_7434581_advantages-synthetic-grease.html

Mixing•Brands•Grades •Types

Myth:•Food Grade lubricants are never as good as Non-Food Grade lubricants.• Advances in base-oil technology and

additive chemistry have made Food Grade H1 products stronger than ever, particularly with synthetics. There are many applications where a correct, strong Food Grade H1 product will work as well as a non-Food Grade H2 mineral-oil-based equivalent.

Myth:• All products are compatible.

• Grease is formulated with various thickeners (lithium, lithium complex, aluminum complex, calcium, polyurea, bentone, and silica gel), which may or may not be compatible with each other.

• When changing grease, laboratory compatibility testing MUST be done.

• If incompatibility exists between old and new products, purge bearings before changing to the new one.

Scheduling Grease & Oil Maintenance

•O&M Manuals

Scheduling Grease & Oil Maintenance•Manufacturers Recommendations (Warranty)

Scheduling Grease & Oil Maintenance

•Lubrication Survey

Scheduling Grease & Oil Maintenance•Lubrication Survey

• Every piece of Equipment that gets lubrication

• Frequency of Lubrication for each asset

• Every type & quantity of lubrication used

• And more…

Scheduling Grease & Oil Maintenance•Observation & Experience

•Location•Temperature•Moisture•Calendar VS Hour Meter

The Missing Link in Reliability Lubrication Maintenance

http://www.machinerylubrication.com/Read/1126/reliability-lubrication-

maintenance

Observation & Experience

•Water

•Dust & Rust

•Paint

•Chemicals

•Other Stuff

CMMS•Computerized Maintenance Management System

• Documentation of work performed• Documents repairs & preventive maintenance• Excellent Planning Tool

•Database system tied to all equipment• Perfect tool for PM Work Orders• Perfect Tool for Lubrication Survey

Bearings

•Plain Bearings

•Rolling Element Bearings

Bearings•Plain

Bearings•Plain Bearings

Plain Bearings: Split Journal

Plain Bearings: Babbitted Bore

Bearings•Babbitt

• Like a lot of stuff, named after the guy who invented it…

Bearings•Rolling Element Bearings

Bearings•Conventional Ball Bearings

Bearings•Conventional Spherical Roller Bearings

•Thrust

Bearings

•ThrustBearings

Thrust

Bearings•Fluid Bearings• Hydrostatic• Hydrodynamic

•Fluid Bearings•Hydrostatic

•Fluid Bearings•Hydrodynamic

Bearings•Magnetic Bearings•Passive•Active

Earnshaw’s Theorem:

• Earnshaw's theorem states that a collection of point charges cannot be maintained in a stable stationary equilibrium configuration solely by the electrostatic interaction of the charges.

• Point charges – Magic electro-physics

• The hole in Earnshaw’s Theorem is the word “Stationary”

Active Magnetic Bearings

Bearings•Bearing failure causes and distribution

• Graphic Courtesy of LUBCON, GmBH

BearingGrease

•Adding•Mixing

BearingGrease

Adding:

•StoppedVs

•Moving

Automatic Grease Systems

Bearing

Grease

What are advantages of Automatic Lubrication?Reduces Repairs by increasing bearing life.

Prevents Waste of Lubricant by dispensing precise amounts.

Reduces Man-Hours by eliminating manual lubrication.

Eliminates Machine Downtime thereby increasing production.

Eliminates Product Spillage by controlling amount of lubricant to the bearing.

Reduces Energy requirements by increasing machine efficiency (lowers bearing friction).

Increases Machine Output by allowing faster speed in operation at machine.

Safety No climbing on or over the machinery. Also safe lubrication of bearings inaccessible due to

gas, fumes, or height.

Machine Tolerances are maintained longer by consistent automatic lubrication.

Better Housekeeping - A closed, sealed system eliminates spillage. Machines remain cleaner. No

spillage promotes safer environments for workers.

Reduces Rejects by maintaining closer bearing tolerances, which allow for closer product

tolerances.

Eliminates Bearing Contamination by supplying lubricant from a closed circuit. Most oilers do not

clean grease fittings before manually lubricating them.

Purges Bearings in intense dirty work environments. Automatic lubrication systems will purge or

flush bearings thus reducing bearing failures due to contamination.

Bottom Line Automatic Lubrication reduces manufacturing costs thereby allowing companies to

increase profits and remain competitive in the marketplace.

Promotes More Efficient Lubrication A). Lubricates while machine is running. B). Delivers the right

lubricant, in the right amount, at the right time.

To Bearing

To Bearing

To Bearing

PARALLEL

SYSTEM

Injector System

Orifice System

Filter

Check Valve

Fixed Orifice

Dual Line

System

To Bearing

To Bearing

To Bearing

SERIES

SYSTEM

Automatic Grease Systems

Manual Grease Systems

Bearing

Grease

Bearing

Grease

Manual Grease Systems

Zerk Fittings•What to look for:

Zerk Fittings•What to look for:

Zerk FittingsOscar U. Zerk applied for and was granted a patent in January 1929. As an employee of the AlemiteManufacturing Corporation, the patent was assigned to them. If you have ever heard them called “AlemiteFittings”, now you know why. Alemite already sold a form of ball check valves which would screw in as replacements for O.E.M. grease cups and marketed as upgrades.

Zerk's fitting was a big improvement, more forgiving of misaligned attachment and less vulnerable to dirt.

Many companies make these grease fittings in both Metric and English sizes.

Quantity isImportant

Bearing

Grease

The Formula:

•G = 0.114 x D x B

•Where G = the amount of grease in ounces

•D = the outer race diameter in inches

•B = the bearing width in inches

•Next, calibrate all grease guns and train the technicians on the proper procedures.

Get your grease gun(s) and a scale. Determine the weight in ounces per full stroke (shot).

Calculate the number of shots it takes to equal 1 ounce of grease. Permanently mark the grease gun(s).

Re-calibrate annually.

Calibration

Multiply the number of strokes per ounce times the number of ounces

required

Calculate

Discontinue greasing if you feel abnormal back pressure.

Always make sure exhaust ports are cleaned out from any debris or old, hard crust that could be blocking the passageway.

Tips to Control Overgreasing

Tips to Control Over-greasing:

Consider installing grease guns with pressure gauges, shut-off grease fittings or relief-type vent plugs.

Slowly pump grease into bearings every few seconds. Using a quick-lever action could cause seal damage and not allow the grease to distribute throughout the bearing correctly.

Check the O&M Manual to

confirm the bearings are re-greasable & due

for service.

Whenever possible, stop the

motor and lock out the

machine.

Find the Grease Zerkdesigned to accept the grease & clean it.

Find the vent point to allow the old grease

easy escape and remove

the plug.

Attach the grease gun and slowly

add the calculated volume.

Plug the vent, clean up, & return the machine to

service.

Procedure

Myth: Add Grease to a Noisy Bearing

Adding grease to a bearing that’s making

noise only provides temporary relief.

Noisy bearings should be closely monitored

and replaced as quickly as possible.

When a bearing is making noise, internal

damage has already occurred.

If the bearing continues to run

without being replaced, more internal

damage will occur and the potential

for failure is greatly increased.

Possible causes of noise are

spalling, false brinelling, frosting and

excessive thrust load.

Myth: Add Grease to a Noisy Bearing

Oil Bath Bearings

•Oil is generally used to lubricate rolling bearings when:• high speeds or operating temperatures

preclude the use of grease.• excessive heat has to be removed from

the bearing position.• adjacent components (gears etc.) are

lubricated with oil.

Oil Bath Bearing System

•Bearings are not flooded• Normal level is halfway up

the diameter of the lower rolling elements.

• Spherical, Cylindrical, Tapered Cylinder, etc.

Spalling•Spalling is when pieces break off of the bearing metal. The noise from spalling is a random, high-pitched sound. (Not Enough Lubricant)

False Brinelling

•False brinelling -elliptical wear marks in an axial direction at each ball position with a bright finish and sharp demarcation, often surrounded by a ring. (Vibration)

True Brinelling

•Dents in the race(s)

Frosting•Electrical discharges at 60Hz (millions per hour) arc between the internal surfaces and the bearing race becomes marked with pits known as frosting. (Bad Ground, VFD)

What to look for:

•O&M Manual•Sealed Bearings?•Grease Type?•Quantity

•Supply fitting

•Vent fitting

Power Transmission Devices

•Gearboxes

•Sprocket & Chain

•Sheaves & Belts

Gears & Gearboxes:

Spur Gears

Bevel Gears

Helical Gears

Hypoid Gears

Worm Gears

Gearboxes:

•Oil Level•Sight Glass•Reversing

Gearboxes:

•Oil Level• Ports top, middle, & bottom

• Fill through the top port until level reaches middle port

Gearboxes:

•Reversing• Input shaft can usually rotate

in either direction• Output shaft cannot be used

to drive worm shaft.Input

Gearboxes:

•Sight Glass•Many Designs•Potential Problems

Gearboxes:

•Sight Glass•Many Designs•Expensive Solutions

Gearboxes:

•Sight Glass•Many Designs•Potential Problems

Gearboxes:

•Sight Glass•Low Cost Solution

Gearboxes:•Myth: If a little is good,

more is better.• Overfilling gearboxes will also lead to

problems, including failed shaft seals or increased operating temperatures.

• A gearbox that has too much oil will have to work harder to move through the lubricant, subsequently generating more heat or churning the oil into foam.

Gearboxes:•Change Direction

• Right Angle Drives• Forward & Reverse• Input & Output Shafts

•Change Speed• Slower Output – Greater Torque• Faster Output – Reduced Torque• Gear Ratios

Gear Ratios•Big / Little = Fast / Slow

Chain & Sprockets

•Roller Chain

•Sprockets

•Lubrication

•Tension Adjustment

Chain & Sprockets

•1. Outer plate

•2. Inner plate

•3. Pin

•4. Bushing

•5. Roller

Chain & Sprockets

•Sprocket Wear

Chain & Sprockets

•Lubrication

Chain

•Proper Tension

Belts & Sheaves•Alignment

•Tension Adjustment

•Sheave Bearings

Motors & Couplings

•VFD Motors & Components

•Couplings

Motors & Couplings

•VFD Motors & Components

Motors & Couplings

•Couplings

Alignment•Wear•Vibration•Alignment Tools & Procedures

Alignment•Wear

Remember, all these types ofmisalignment are 3 dimensional,each illustration can be consideredeither a plan view or an elevation.

This represents misalignment in 3 dimensions. Both of these illustrations could be from the same situation

Elevation

Plan View

The shafts of the components will run along the “X” axis, parallel misalignment means shaft centerlines are parallel, but in different planes.

Parallel Centerlines, Different Planes

Angular misalignment means shaft centerlines are not parallel, and therefore coupling faces are not parallel.

Alignment•Wear

Alignment•Vibration

Soft Foot•When the foundation is out of plane OR the plane of all four motor feet do not match.

•Effects alignment process because vertical positions change each time bolts are tightened after corrections.

•Motor frame distorts each time bolts are tightened.

•Result is bearing misalignment – Vibration & Heat.

Soft Foot

Soft Foot•Check for & correct “Gross” Soft Foot

•Start with all the bolts loose

•If there are no shims under any feet, try to slip a 0.005” shim under each foot.

•If there are shims under the feet, check to see if any are loose.

Alignment

•Alignment Tools

Alignment•Alignment Tools

Review• Mineral Vs Synthetic, Mixing is bad

• Testing before changing is good, Contaminants bad

• PM Scheduling & CMMS

• Bearings & Drive Components

• Adding grease & Oil to rotating Equipment

• Alignment

Questions?Thank you for your participation!!!

www.mi-wea.org