Oil Mist Lubrication Training

7/22/2019 Oil Mist Lubrication Training

1/70

Lubrication Systems Company

Don Ehlert is currently Manager for EPC Sales at Lubrication Systems Co., a Colfax

Company, located in Houston, TX. His current responsibilities include providing technical

training and sales presentations. He is also responsible for quotation packages for

domestic and foreign engineering companies and end user projects.

Since joining LSC in 1984, Don has filled positions in equipment assembly, field

maintenance, field installation, field management, sales and sales management. His vast

experience allows him to provide technical support to oil mist users world wide. He has

been instrumental with the development of oil mist related products and accessories for

special applications. He has authored numerous articles related to lubrication systems

and their applications.

Prior to LSC Mr. Ehlert had spent time in the US Navy providing maintenance and

operation support for aircraft on the hydraulic and flight control systems.


2/70

Lubrication Systems CompanyPump Retrofit

Trico Oiler

Slinger

Rings

Plug on Top


3/70

Lubrication Systems CompanyTopics

Introduction & Evolution of Oil Mist

What is Oil Mist

Lubrication with Oil Mist

Applying Oil Mist To Equipment

Retrofitting Pure Oil Mist

Purge Oil Mist Applications

Justification of Oil Mist


4/70


Introduction & Evolutionof Oil Mist Lubrication


5/70

Lubrication Systems CompanyIntroduction to Oil Mist

Oil Mist can be applied to most rolling element bearings

Allows use of higher viscosity lubricants.

Pure Oil Mist eliminates oil sump issues.

Oil Mist is the ultimate oil filter.

Oil Mist is contamination control.

Wear particles are not re-circulated.

Cooling water in bearing jackets is eliminated.Oil Mist Generators are 99.9996% reliable.


6/70


Basic Oil Mist System

Introduction to Oil Mist

Air Controls

Mist GeneratorPiping System

Applications


7/70


Large Scale System

Serves 15 to 80 Pumps and Drivers

3 to 30 SCFM Air Flow Range

2 Gal. Maximum Oil Consumption



8/70


Vortex

Oil

Oil Mist


Instrumentation

Air In

Dry Mist

Out


9/70


OIL MIST PARTICLE SIZES 3 Microns

BELOW

DRY MIST

FOR

CONVEYING

ABOVE

WET MIST

FOR

LUBRICATION

Generation & Distribution

Application & Lubrication



10/70


Reclassifier Sizes

Bearing Inch SCFM

3 BI

6 BI

10 BI

15 BI20 BI

0.09

0.18

0.30

0.450.60

5

02



11/70


Standard reclassifier for singleor double row bearings.

Single Row Radial

Bearing on 3 Diameter

Shaft = 3 BI or .09 SCFM

Double Row Thrust

Bearing on 3 Diameter

Shaft = 6 BI or .18 SCFM

5

0

1

5

0

2



12/70


Dry Mist to Wet Mist

Velocity and Turbulence

Converts the Dry Mist to Wet Mist



13/70


Oil Mist

Generator


Mist

Manifold

Typical Pump ApplicationSpent Oil Collection

Container

Distribution HeaderReclassifier

502


14/70

Lubrication Systems CompanyEvolution of Oil Mist

Oil Mist was develop in Europe; 1930s.

Introduced to the US Market ; 1948 STLE Mtg.

First HPI system was in Amuay, Venezuela; 1960s.

First HPI paper on oil mist lubrication published byMr. Charlie Miannay; 1974 Hydrocarbon Processing.

System reliability improved; early 1980s.

Pure oil mist became the standard; 1990s

Closed loop system developed; early 2000.


15/70

Lubrication Systems Company1960s System Installation


16/70

Lubrication Systems Company1960s Pure Mist


17/70

Lubrication Systems Company1960s Purge Mist


18/70

Lubrication Systems CompanyOne Way System


19/70

Lubrication Systems CompanyPure Mist Per API 610


20/70

Lubrication Systems Company2010 Purge Mist

Oil Level

Is Visual


21/70

Lubrication Systems CompanyClosed Loop System

DemistingDevice

OMG

Return Header

Distribution

Header


22/70


What is Oil Mist?


23/70

Lubrication Systems CompanyWhat is Oil Mist?

Oil mist systems are centralizedlubrication systems

that continuouslyand efficiently atomizes oilinto small

particles and then conveys and delivers the correct

amountof thepressurized oil mist lubricantto

bearings and metal surfaces resulting in improved

lubrication, fewer failures/repairs, lower life cycle costs

and extended machinery life.


24/70

Lubrication Systems CompanyWhat is Oil Mist

Oil Mist

Oil Mist is an Aerosol; Not a VOC

1 Part Oil & 200,000 Equal Parts Air Will Not Support Combustion

Dry Mist is Generated for transportation

20 H2O Pressure

Oil


25/70


Per the American Conference of Governmental Hygienists

Long term threshold limit of 5 mg/m3 for 8 hours

Short term exposure limit of 10 mg/m3

The 5 mg/m3 is not commonly exceeded around equipment in outdoor

locations. Indoor applications use Closed-Loop Systems.

California Rule 1173 Exempts Lubricating Fluids from being a Fugitive Emission

or Volatile Organic Compound (VOC

Reference: Oil Mist Lubrication Handbook; Mr. Heinz Bloch

Toxicity Considerations of Oil Mist


26/70


The air-oil mixture is several orders of magnitude too lean to sustain combustion.

Experiments have shown the concentration of oil mist in the header ranges from

0.005 to as little as 0.001 of the concentration generally considered flammable.

The oil/air mixture is substantially below the sustainable burning point

Reference: Oil Mist Lubrication Handbook; Mr. Heinz Bloch

Flammability of Oil Mist


27/70


.65 in3 per Hour per SCFM

10 SCFM = 6.5 in3 per Hour

Typical Pump = 0.27 SCFM

10 SCFM = 27 Pumps

Max of 30 SCFM = 2 Gallons/Day

Oil Consumption with Oil Mist


28/70


Lubrication with Oil Mist


29/70

Lubrication Systems CompanyLubrication with Oil Mist

Generate Dry Oil Mist for Conveying; Below 3 microns

Lubricate with Wet Oil Mist;

Larger than 3 microns


30/70


Reclassifiers preferred location is on the mist manifold

Locate the reclassifier within 2 meters of bearings

Bearing isolators are preferred to help contain the oil mist in the

bearing housing Reclassifiers


31/70


Vent/Drain of bearing housing is very

important

Oil mist flow is required to apply mist to

bearings

Restricted flow exiting bearing housing

increases internal pressure reducing flow of

oil mist

Bearing housing vent/drain adequate to ventSCFM flow entering through reclassifiers


32/70

Lubrication Systems CompanySingle Row Bearings

Mist Flow for Bearing Lubrication

Vertical

Applications& Motor Brgs.

Radial Brgs.

Flow through is always preferred.

Always


33/70

Lubrication Systems CompanyDouble Row Bearings

Mist Flow for Bearing Lubrication

Recommended:

Brg. Isolators

150 Kw & Up

3000 RPM & Up

Flow through is always preferred.

Always

Vertical

Applications


34/70

Lubrication Systems CompanyTriple Row Bearings

Two

Points

Flow through is required.

Two

Points


35/70


Applying Oil Mist


36/70

Lubrication Systems CompanyApplying Oil Mist

Two methods of applying oil mist

Pure Oil Mist or Dry Sump

No Oil Level

Purge Oil Mist or Wet Sump

Oil Level is Maintained


37/70


Common on all rolling element bearings

Reduces bearing and mechanical seal failures

Eliminates manual lubrication tasks

Bearing temperature is reduced

Eliminates recirculation of hot

contaminated oil

Allows removal of cooling water

Pure Oil Mist or Dry Sump


38/70


Purge Oil Mist or Wet Sump

Oil level is maintained and

must be controlled; Oil mist

will increase the oil level.

Heavily thrust loaded bearings

may require the oil sump

Typical on sleeve bearings and gearing.

Positive pressure prevents intrusion

of air borne contaminates i.e.moisture & dust.


39/70


Reclassifiers For Purge Mist

Sleeve, Babbitt or Plain Bearings

are typically Purge Mist Applications

Purge Mist =

Light Service or

Low Flow Rate

Oil Mist is not Primary

Prevents Intrusion of Air Borne Contaminates


40/70


Sizing Reclassifiers For Pure Mist

Anti Friction Bearings are typically Dry Sump Applications

Formula Sf x D x N Sf = Service Factor

D = Shaft Diameter in Inches

N = Number of Rows

Sf = .009 for Light Loads i.e. Motors

.022 for Moderate Service

.045 for Heavy Service

Oil Mist is Primary Lubrication with NO Oil Sump

Lubricates and Prevents Intrusion of Air Borne Contaminates


41/70


Retrofitting Oil Mist

P R fi


42/70


Trico Oiler

Slinger

Rings

Plug on Top


43/70


3000 RPM and

Less than 150 Kw

Lip or Labyrinth Seals

Single Lube Point

Remove slingers, plug drain

back ports when pump is out

Remove

Trico and

convert to

pure mist


44/70


Single inlets and bearingisolators may require

additional vent to allow

flow through the multiple

row bearing

Single row

bearing

receives

adequatelubrication


45/70


Two points required with150 Kw and operating

at 3000 RPM

Bearing isolators often

require a second lube

point.

Field retrofit twopoints with tap in

bearing cap

Remove slingers, plug drain

back ports when pump is out

P R fi


46/70


No Trico Oiler

No Slinger Rings

No Oil Sump

API Specification

calls for two lube

points outboard

of bearings


47/70


Older model between bearing pumps

often require directional reclassifiers

P R t fit


48/70


Bearing arrangement did not allow mist to flow through

Oil mist would

not get to

inboard brg.


49/70


Oil mist is directed

into the rolling

elements and

passes through toinboard bearing

Directional's are

not required on

current API editionbetween bearing

pumps

1980 P Mi t


50/70

Lubrication Systems Company1980 Pure Mist

M t R t fit


51/70

Lubrication Systems CompanyMotor Retrofit

Not as easily retrofitted as pumps

No defined or sealed bearing housingGrease must be removed completely.

Seal inlet port to junction box

Oil Compatible lead wire insulation

Oil compatible epoxy coating

Case drain required on coupling

end; plug fan end drain port

Vent lines routed away from fan

Items of Concern

M t R t fit


52/70

Lubrication Systems CompanyMotor Retrofit

Oil mist must passthrough the bearings

from top to bottom

Low point case drain is

required on vertical motors

Sealed bearings arenot compatible with oil

mist lubrication

Pill Bl k


53/70

Lubrication Systems CompanyPillow Block

No re-greasing

No oil changesNo dirty oil

Bearings operate 3C to 10C cooler with oil mist

No more over or under lubrication

T bi R t fit


54/70

Lubrication Systems CompanyTurbine Retrofit

Mist flows

through bearings

top to bottom

Eliminates baking

of grease


55/70


Purge Oil Mist &Typical Applications

P A li ti


56/70

Lubrication Systems CompanyPurge Applications

Two Methods to Control the Oil Level

Oil Level Site Assy. Constant Level Oiler

T bi A li ti


57/70

Lubrication Systems CompanyTurbine Application

Prevents intrusion of

steam condensate

Helps with lubrication

when in slow roll mode

Little or no modifications required when retrofitting

purge oil mist to existing equipment.

L b i ti S t CG B A li ti


58/70

Lubrication Systems CompanyGear Box Applications

Gear box applications are always purge mist

applications. The oil mist prevents intrusion of

airborne contaminates, keeps internal components

coated with oil when equipment is sitting idle. Purge

mist housing must have oil mist vent and level

control.

L b i ti S t CGear Box Applications


59/70

Lubrication Systems CompanyGear Box Applications

Cooling Tower Fan Gear Box

L b i ti S t CP & P A li ti


60/70

Lubrication Systems CompanyPure & Purge Applications

Purge

Mist onGearing

Pure Mist

on

Bearings

L brication S stems Compan


61/70


Oil Mist Justification

Lubrication Systems CompanyOil Mist Justification


62/70


Pump Bearings

Mechanical Seals

Motors

Man Power

Oil Savings

Cooling Water

Operating Expense Items Reliability SavingsCost & Risk Avoidance

Fire Potential

Lost Production

Non-Spared Equip.



63/70


Pump Maintenance Experience



64/70


Mechanical Seal Experience



65/70


Motor Brg. Experience




66/70


Actual Experience

180 Oil Sumps

Oil Changes: 2 per year

Oil Fills/Checks: 4 per month

Time Per Sump: 4.5 hours/year

Cost: $67/hour

Manpower Credit: $55,000/year

.25 Hrs to re-grease mtrs. semi annual

Maintenance staff no

longer changes oil or re-greases motors.

Manpower Efficiencies


With 600 Pumps and Motors oil mist redirects 3000 man hours per year to

proactive failure avoidance and reliability improvement tasks.



67/70


Oil Savings




68/70


Potential Fire Damage




69/70


Published in Hydrocarbon Processing

August Issue 2008

Heinz Boch & Don Ehlert

Get the Facts on Oil Mist Lubrication

Lubrication Systems CompanyQuestions


70/70


Contact Info

Don EhlertLubrication Systems Co.

Houston, TX USA

Phone 1-713-464-6266

Email [email protected]

Questions

Oil Mist Lubrication Training

Documents

Transcript of Oil Mist Lubrication Training