A Suncor Energy business
LUBRICATION FUNDAMENTALS
2LUBRICATIONFUNDAMENTALS
FunctionsofaLubricant LubricatingOilProperties BaseOils LubricatingOilFilms OilAdditives
3API AmericanPetroleumInstitute
ASTM AmericanSocietyforTestingMaterials
SAE SocietyofAutomotiveEngineers
NLGI NationalLubricatingGreaseInstitute
STLE SocietyofTribologists&LubricationEngineers
AGMA AmericanGearManufacturersAssociation
ISO InternationalOrganizationforStandardization
LUBRICATIONINDUSTRY
4TRIBOLOGY
Isthescienceandtechnologydealingwiththedesign,lubrication,friction,andwear ofinteractingsurfacesinrelativemotion
5FUNCTIONSOFALUBRICANT
ReduceFriction
MinimizeWear(KeepMovingSurfacesApart)
CoolParts(CarryAwayHeat)
PreventCorrosion
DisperseCombustionProducts(e.g.,Soot)
ActasaSealant
TransmitPower
6 Lubricationiskeywhensliding(area)contactispresent. Lubricantsareusedtoreducefriction and wear bypreventingmetaltometalcontact.
No Lubricant: High Friction
Full Film (Hydrodynamic) Lubrication: Low Friction
Thin Film (Boundary) Lubrication: Moderate Friction
Steel
Steel
Steel
Steel
Steel
Steel
Air
Oil Film
WHYLUBRICATE?
7LUBRICATIONFUNDAMENTALS
FunctionsofaLubricant LubricatingOilProperties BaseOils LubricatingOilFilms OilAdditives
8LUBRICATINGOILPROPERTIES
Viscosity ViscosityIndex Density/SpecificGravity FlashPoint FirePoint PourPoint CloudPoint
9LUBRICATINGOILPROPERTIES
Whatisthemostimportantcharacteristicofalubricatingoil?
10
LUBRICATINGOILPROPERTIES
Whatisthemostimportantcharacteristicofalubricatingoil?
11
VISCOSITY
Measurementoftheoilsinternalresistancetomotion
12
VISCOSITY
Measureofresistancetoflowatagiventemperature (Typically40oC&100oC)
Viscositychangesinversely withtemperature* i.e.,Astemperatureincreases,oilbecomesthinner
ChangeinViscosityisNOTlinear
13
VISCOSITYANDTEMPERATURE
LubricantViscosityDecreasesDramaticallyWithIncreasingTemperature(LogLogRelationship)
ViscosityIndex(V.I.)isaMeasureoftheViscosityTemperatureRelationshipforanOil
MultigradeOilsHaveHigherV.I.sThanSingleGradesViscosityChangesLessWithTemperature
Honey
0
100
1,000,000
K
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m
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V
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,
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t
100,00010,000
1,000
10
5
Temperature, C
Tar
Olive Oil
Cream
Water
3002602201801401006020-20 0 40 80
14
Loadcarryingcapacityincreaseswithviscosity
LOADCARRYINGCAPACITY
V
I
S
C
O
S
I
T
Y
VISCOSITY
15
VISCOSITYEXAMPLE
Usingtheviscositychartpaperprovided,[email protected]@100oC
This image cannot currently be displayed.
This image cannot currently be displayed.
Visc @ 40C
Visc @ 100C
17
VISCOSITYMEASUREMENT
Viscosity Systems (most common)Kinematic (cSt) (metric)
American (SUS / SSU)
Absolute (cP)* Low temperature
18
KINEMATICVISCOSITY
Measureoffluidsresistancetoflowduetogravity
Derivedfromthetimetakenforalubricanttotravelthroughacapillarytube
Measurement Stoke(St)=1cm2 /second
Typicallyreportedascentistoke (cSt)=1mm2 /second
19
ISOViscosityGrade Midpoint@40oc
(cSt)Minimum
(cSt) Maximum(cSt)
2 2.2 1.98 2.423 3.2 2.88 3.525 4.6 4.14 5.067 6.8 6.12 7.4810 10 9.0 11.015 15 13.5 16.522 22 19.8 24.232 32 28.8 35.246 46 41.4 50.668 68 61.2 74.8100 100 90 110150 150 135 165220 220 198 242320 320 288 352460 460 414 506680 680 612 7481000 1000 900 11001500 1500 1350 1650
ISO SYSTEM+/- 10%
ISOVISCOSITYSYSTEM
20
Equivalent ISOGrade
Viscosity Range(cSt @40oC)
AGMAR&O #
AGMAEP #
AGMASynthetic #
32 28.8 35.2 0 0 S46 41.4 50.6 1 1 S68 61.2 74.8 2 2 EP 2 S100 90 110 3 3 EP 3 S150 135 165 4 4 EP 4 S220 198 242 5 5 EP 5 S320 288 352 6 6 EP 6 S
460 414 506 7, 7 Comp 7 EP 7 S
680 612 748 8, 8 Comp 8 EP 8 S1000 900 1100 8A, 8A Comp 8A EP1500 1350 1650 9 9 EP 9 S
2880 3520 10 10 EP 10 S
4140 5060 11 11 EP 11 S
6120 7480 12 12 EP 12 S
190 220 (100oC) 13 13 EP 13 S
AGMA VISCOSITY SYSTEM
21
SAE Viscosity
Grade
Low Temperature Cranking Viscosity,
Max (cP @ oC)
Low Temperature Pumping Viscosity,
Max (cP @ oC)
Kinematic Viscosity @ 100oC, Min
(cSt)
Kinematic Viscosity @ 100oC, Max
(cSt)
High Shear Rate Absolute Viscosity @ 150oC, Max
(cP)
0W 6200 at -35 60 000 at -40 3.8 - -
5W 6600 at -30 60 000 at -35 3.8 - -
10W 7000 at -25 60 000 at -30 4.1 - -
15W 7000 at -20 60 000 at -25 5.6 - -
20W 9500 at -15 60 000 at -20 5.6 - -
25W 13000 at -10 60 000 at -15 9.3 - -
20 - - 5.6
22
Viscosity isameasurementofresistancetoflowatone temperature.
ViscosityIndex(VI)isameasurementoftherateofchangeofviscosityoverarange oftemperatures.Insimpleterms:itmeasureshowfasttheoilthickensupasitgetscolderorhowfastitthinsoutasitgetshotter.
WithMostlubricants,thehighertheVIthebetter
LUBRICANTPROPERTIES:VISCOSITYINDEX(VI)
23
TheViscosityIndexiscalculatedfromviscositiesat40Cand100C
HighVIisatermwhichmeansthattheoilisusableoverawidertemperaturerange.
VHVI =VeryHighViscosityIndex
LUBRICANTPROPERTIES:VISCOSITYINDEX(VI)
24
BaseStocksaretherefinedoils(derivedfromcrudeoil)whichareblendedtogetherwithadditivestoproduceafinishedlubricant.Theyaredescribedinaseparatesection.
Traditionalsolventrefined paraffinicbasestockshaveVIsintherange85to 95.ProcessimprovementssuchashydrofinishingcanimprovetheVItoover100.
OurHydroTreated basestockshaveViscosityIndicesintherange90110.
OurHydrocracked isodewaxedbasestocksareover120VI.
TYPICALVIOFDIFFERENTBASESTOCKS
25
ViscosityIndexisaninherentpropertyofthebaseoil usedtoblendalubricant.
VIcanbeimproved significantlybyblendingsolubleadditivescalledVIImproversintotheoil.
Theseadditivesarelongpolymermoleculeswhichuncoilathightemperaturestoincreaseviscosity,whileatlowtemperaturestheyformtightballswhichnolongercontributemuchtoviscosity.
Onecaution:VIimproversdonotlastforever inablend.Theycanbechoppeduporsheareddownbyconstantmechanicalmotionintheoil.
VISCOSITYINDEX
26
HOWAVIIMPROVERWORKS
Large"stringlike"moleculesthatexpand(unwind)athighertemperatures,therebypreventingtheoilfromthinningouttoorapidly.UnderShearStress(e.g.goingthroughsmallorificesinhydraulicvalves,orsqueezedbypistonringsoncylinderwalls)theVIimprovercanberupturedandloseitseffectiveness.
Effect of Temperature
Effect of Shear Stress
Effect of Rupture
Before After
Effect of Temperature
Effect of Shear Stress
Effect of Rupture
Before After
27
VISCOSITY COMPARISON CHART
NOTE: Readacrosshorizontally. Assumes96Vlsinglegradeoils. Equivalenceisintermsofviscosity
at40Conly. Viscositylimitsareapproximate:
Forprecisedata,consultISO,AGMAand
SAEspecifications. Wgradesarerepresentedonlyin
termsofapproximate40Cviscosity.
Forlowtemperaturelimits,consultSAEspecifications.
28
VISCOSITY RULES OF THUMB
29
LUBRICATIONFUNDAMENTALS
Functions of a Lubricant Lubricating Oil Properties Base Oils Lubricating Oil Films Oil Additives
30
Formulated Lubricant
Crude Oil
MineralBasestock Additives
Synthetic Basestocks
Natural Gas
LUBRICATINGOILS
31
BaseOilCharacteristics
APIGroup Sulphurwt%Saturateswt
%ViscosityIndex
ManufacturingMethod
I >0.03
32
HYDROTREATEDVS.SOLVENTREFINED
BENEFITS
Mayusepoorqualitycrude
Loweroperatingcosts
TypicallyhavehigherVIs
Improvedoxidationresistance
Improvedhightemperature
stability
DISADVANTAGES Highercapitalcosts Requireshydrogensupply Highpressureunits
skilledtechnicians Differentadditive
package
33
DEFINITIONS
MINERALBASED Adistillate(physicalseparation)ofpetroleum
SYNTHETIC Oilderivedfromchemicalmanipulationresultinginsignificantmodificationfromoriginalsource
BIOBASED Formulatedwithrenewableandbiodegradablebasestocks.Itsworthnotingthatsomedefinitionsonlyconsiderbiodegradability.
34
ANALOGY
Crudeoilisextractedfromground
GroupIoilismadefromsolventdistillation
GroupIIandIIIoilsaremadeusinghighpressurehydrogen
GroupIVoilsaremadebychemicallyselectingamodifyingmoleculesizes
Cowismilked
Milkandcreamareseparatedbygravityonly
Milkisseparatedbycentrifugeandthenpasteurizedwithhightemperatures
Butterismadebyforcingtinyfatmoleculesintolargergrouping
*Fluid Life Corp.
35
SYNTHETICOILS
Polyalphaolefin(PAO) Diesters Polyglycols PhosphateEsters PolyolEsters Silicones
36
P - Poor F - Fair G Good VG - Very Good E - Excellent
MineralOil
Polyalphaolefin Diester
PolyolEster
Polyglycol
PhosphateEster
SiliconeOil
ViscosityTemperature F G G G VG P E
LowTemperature P G G G G F G
OxidationStability F VG G E G F G
CompatiblewithMineralOil E E G F P P P
LowVolatility F E E E G G G
AntiRust E E F F G F G
AdditiveSolubility E G VG VG F G P
SealSwell E E F F G F E
BASEOILSCOMPARATIVECHARACTERISTICS
37
LUBRICATIONFUNDAMENTALS
FunctionsofaLubricant LubricatingOilProperties BaseOils LubricatingOilFilms OilAdditives
38
LUBRICATINGOILFILMS
Hydrodynamic Elastohydrodynamic(EHD) Boundary Hydrostatic
No Lubricant: High Friction
Full Film (Hydrodynamic) Lubrication: Low Friction
Thin Film (Boundary) Lubrication: Moderate Friction
SteelSteel
SteelSteel
SteelSteel
SteelSteel
SteelSteel
SteelSteel
Air
Oil Film
No Lubricant: High Friction
Full Film (Hydrodynamic) Lubrication: Low Friction
Thin Film (Boundary) Lubrication: Moderate Friction
SteelSteel
SteelSteel
SteelSteel
SteelSteel
SteelSteel
SteelSteel
Air
Oil Film
39
JournalBearings(CompactionSK09002)
Bearingatrest
Bearingathighspeed
Bearingatslowspeed
Oilwedgeproducespressure,highviscosity,andfullfilmhydrodynamiclubrication
HYDRODYNAMICLUBRICATION
40
LUBRICATIONFUNDAMENTALS
FunctionsofaLubricant LubricatingOilProperties BaseOils LubricatingOilFilms OilAdditives
41
ADDITIVES
GeneralpurposesDifferentadditives
SpecificpurposeHowtheywork
42
WHYADDITIVES?
TOPROTECT THEMETALSURFACES TOIMPROVE LUBRICANTPERFORMANCE TOEXTEND LUBRICANTSERVICELIFE
43
ADDITIVES
SURFACEPROTECTRustinhibitorCorrosioninhibitorAntiwearExtremepressureDispersantDetergentTackifier
LUBE ENHANCERAnti-oxidantAnti-foamantPour Point depressantVi improverFriction modifierEmulsifierDe-emulsifier
44
OXIDATIONINHIBITOR
WHATITDOESPreventsvarnish,sludge&acidprecursorsfromforming
HOWITWORKSReactsmorereadilywithO2 thandoesoil
45
OXIDATIONINHIBITOR
Itwillbeusedup Every10oCincreaseintemperatureresultsinoxidationbeing2*faster
46
OXIDATIONINHIBITOR
Oxidationissignificantlyaccelerated by:Catalysts suchasmetals,dust,waterOxygen fromhighratesofairentrainmentHightemperature
TemperatureoC Hours Days80 10000 416
90 5000 208
100 2500 104
110 1250 52
120 625 26
130 313 13
Every10oC riseinsumptemperatureover80oCdecreasesthelifeoftheoilby
onehalf
Example Only Not real data
47
WATER+CATALYSTONOXIDATIONLIFE150SSU@100oFTurbineOil
Ref: Volume XXIII Proceedings of National Conference on Fluid Power, 1969, Weinschelbaum, M.
48
ANTIWEAR(AW)
WHATITDOESMinimizeswearcausedbymetaltometalcontact
HOWITWORKSFormschemicalfilmonsurfaceFilmrubsoff
49
ANTIWEAR(AW)
TypicallyZn/Pmaterial(ZDDP) SensitivetolongtermwatercontaminationWillresultinareddishdeposit
WillbeconsumedNottrackableinstandardoilanalysisbecausecannotdestroyZnorP
Needsbaremetalsurface
50
EXTREMEPRESSURE(EP)
WHATITDOESPreventswelding&excessivewearundershockloading/highvibration
HOWITWORKSHeatatpointofshockloadcausesformationofnewcompound
Compoundwearsoff
51
EXTREMEPRESSURE
TypicallyS Pmaterial Sulphurisreactivetoyellowmetals,especiallyabove75oC
Willbeconsumed InthepresenceofwaterandheatcanformS&Pacids
Needsbaremetalsurface
52
TIMKENEPTEST
TypicalResultsReportedasthe
OKLoad
53
4BALLEPTEST
TypicalResultsWeldPoint
LWI Loadwearindex
54
VISCOSITYINDEX(VI)IMPROVER
WHATITDOESReducesrateofchangeofviscositywithtemperature
HOWITWORKSAdditiveactsasthickenerwithincreasingtemperature
55
VIIMPROVER
56
VIIMPROVER
Canbepermanentlysheareddownundercertainhighload/highshearoperationsMayormaynotbeanissue
Filtrationat1mmayimpactthisadditive
Effect of Temperature
Effect of Shear Stress
Effect of Rupture
Before After
Effect of Temperature
Effect of Shear Stress
Effect of Rupture
Before After
57
DISPERSANT
WHATITDOESKeepsoxidationparticlesinsuspensioninoil
HOWITWORKSCombineswithsmallparticlestopreventformationoflargeparticles
58
DISPERSANT Nonmetalliccocomponentwithdetergent
Willbeconsumed Notgenerallyusedinindustrialoils
SootDispersed LowViscosityIncrease
SootAgglomerates HighViscosityIncrease
59
DETERGENT
WHATITDOESPreventsoxidationparticlesfromformingsludge,varnishorgum
HOWITWORKSReactswithmetalsurfacestominimizespaceforoxidationparticles
60
DETERGENT
Typicallymetallicadditive(Ca/B/Mg) Willbeconsumed Nottypicallyfoundinindustrialoils Needsbaremetalsurface
61
RUST&CORROSIONINHIBITORS
Protectsironandsteelpartsfromattackbyacidiccontaminantsandwater
Formsaprotectivefilmonmetal delicatebalance,caninterferewithothersurfaceactiveadditives
62
RUST&CORROSIONINHIBITORS
RustTest ASTMD665
60oC 24hours Distilledor
Syntheticseawater PassorFail
CopperCorrosion Evaluatestheextentofdiscolourationortarnishingofacopperstripimmersedinthelubricant ASTMD130 2Hours@100oC Alphanumeric(1a..4c)
63
ANTIFOAMAGENTS WHATITDOES
Veryimportantpartoflubricantformulation Helpsfoamtodissipatemorerapidly. Largesiliconmoleculesdispersedintheoil.
HOWITWORKS Promotescombinationofsmallbubblesintolargebubbleswhichbreakupmoreeasily.
Changessurfacetensionofoil Verylowconcentrationsarerequired
ASTMD892 Threetests,SequenceI,II,III Reportthevolumeoffoam(ml)after5minuteblowingperiodand10minuterestperiodateachtestsequence.(i.e.10/0)
SequenceI 24oCSequenceII 93.5oCSequenceIII1 24oC1. On same oil after Sequence II test.
64
POUR/CLOUDPOINTDEPRESSANTS
Inhibittheformationoflargewaxcrystals Enhancestheloweroperabilitytemperatureoftheoil
Highmolecularweightpolymers
POUR/CLOUDPOINTDEPRESSANTS
Temperatureatwhichnomovementisobservedfor5seconds
Waxcomesoutofsolutioninsmallcrystalsastheoilnearspourpoint.Smallcrystalsformagelthatkeepstheoilfrommoving.
66
FRICTIONMODIFIERS
Increaseoilfilmstrength Longchainmolecules Polarendadsorbstometalsurface Effectiveatlowtemperaturesandmildsliding
conditions Fattyacidorfattyoilderivatives AshcontainingcompoundssuchasMolybdenum
Disulphide(MoS2),graphite,Teflon(PTFE),arealsocalledFrictionModifiers
Sometimescalledantiseizeorsolidlubricants
Commonly found in Engine Oils to improve fuel economy.
67
DEMULSIFIERADDITIVES
Addedtooilsinimprovetheabilityofwatertoshedfromtheoil.
Desirablefor: papermachines hydraulics turbines gears
Additivesthatareaddedtotheoilforotherreasonsoftenattractwater(i.e.detergents).
DEMULSIBILITYTESTS
Determinestheabilityoftheoiltoshedwater. ASTMD1401,D2711(shouldbeusedforoilscontainingEPadditives)
Reportedas:Oil/Water/Emulsion(minutes)38438(20)
69
SULPHATEDASH
Determinesthenoncombustibleresidueinalubricatingoil(ASTMD874)
Sometimesusedasanindicationoftheamountofdetergentinanewoil
Metallicadditivecomponents Calcium,Magnesium,Zinc
Newspecsarelimitingtheashcontent Primaryfunctionofthesulfatedashistominimizevalvewear(recession)inNGEO
70
DetergentsDispersants
Anti-OxidantsRust InhibitorsAnti-WearE.P. AgentsVI ImproversPour PointDepressantsAnti-Foam
EngineOils ATF
GeneralR&O Oil
AWHydraulic
IndustrialGear Oil
HVIHVI SomeSome
AutomotiveGear Oil
SomeSome
ADDITIVEADDITIVE
DyesFrictionModifiers
Grease
USEOFADDITIVES
71
ADDITIVESATWORK
Dispersant
VIImprover
AntiFoam
Pour/CloudPointDepressant
OxidationInhibitor
Someadditivesworkintheoil,someworkonthemetalsurfaceVERYDELICATEBALANCE
OILCLEANLINESSandCONTAMINATIONCONTROL
CLEANLINESSANDCONTAMINATIONCONTROL
AGENDA
INTRODUCTION CONTAMINATION SOURCES
Internal Corrosion Wear Debris
Ingress Airborne Contaminants Moisture Dirty Oil
Wrong Lubricant ISO PARTICLE COUNT SYSTEM PREVENTION
Storage Lube Rooms, Dispensing
Handling and Distribution
CLEANLINESSANDCONTAMINATIONCONTROL
Contaminationisthegreatestsinglecauseoflubricantdegradationandmalfunctionleadingtoabnormalwearandfailureofequipmentcomponents.
Because Contaminationsourcesareeverywhere Itcauseswearandsurfacedegradation Itcausesthelubricanttomalfunction Itcostsyoumoney!
WHATISCONTAMINATION?
AnythinginafluidthatdoesnotbelongisaCONTAMINANT.
SOURCESOFCONTAMINATION
BuiltincontaminationGeneratedcontaminants ExternalingressionMaintenanceintroducedcontaminants
SOURCES(CONTD)
Builtincontaminantsfromcomponents: Cylinders,fluids,hoses,hydraulicmotors,linesandpipes,pumps,reservoirs,valves,etc.
Generatedcontaminants: Assemblyofsystem Breakinofsystem Operationofsystem Fluidbreakdown
SOURCES(CONTD)
Externalingression Reservoirbreathing Cylinderrodseals Bearingseals
Contaminantsintroducedduringmaintenance Disassembly/assembly Makeupoil
OILCONTAMINATION
80%ofconsequencescomefrom20%ofcauses.80/20RULE
PARETOPRINCIPLE
WATER+CATALYSTONOXIDATIONLIFE150SSU@100oFTurbineOil
Ref: Volume XXIII Proceedings of National Conference on Fluid Power, 1969, Weinschelbaum, M.
01
2
3
4
5
6
7
8
9
10
11
12
13
14
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
Absolute Filter Size in Microns
F
a
t
i
g
u
e
L
i
f
e
-
M
i
l
l
i
o
n
R
e
v
o
l
u
t
i
o
n
s
SMALLEST PARTICLE SIZE SEEN WITH THE NAKED EYE.
Improving cleanliness in this range
produces HUGE life extensions
BEARINGLIFEVS.PARTICLESIZE
Ref: SKF Ball Bearing Journal #242
Water Concentration (ppm)0 1 0 0 2 0 0 3 0 0 4 0 0 5 0 0 6 0 0 7 0 0 8 0 0 9 0 0 1 0 0 0
0 .0
0 .5
1 .0
R
e
l
a
t
i
v
e
L
i
f
e
*Cantley, R., The Effect of Water in Lubricating Oil on Bearing Fatigue Life
WATERONBEARINGLIFE
HOWCLEANISCLEAN?
TypicalOperatingDynamicFilmThickness
COMPONENT THICKNESS()RollerBearings 0.4 1
BallBearings 0.1 0.7
JournalBearings 0.5 100
VanePump 0.5 13
PistonPump 0.5 40
DieselEngine 5 45
Gears 0.1 1
BEARINGFILMTHICKNESS
Theoperatingordynamicclearanceisnotequaltothemachineclearance,butdependsupontheload,speedandlubricant
viscosity.Alubricantfilmseparatesmovingsurfacestopreventmetaltometalcontact.
MachineClearanceMachine
ClearanceLoad,
No MotionLoad,
No Motion
5m5m
5m5m
10m10m
BEARINGFILMTHICKNESS
Load & Motion& Lubricant
Load & Motion& Lubricant
JournalBearingJournalBearing
9m9m
1m1m
DynamicClearance
Rolling ElementBearing
Rolling ElementBearing
Cage LubricantFilm
Cage LubricantFilm
VALVEWEAR/STICTION
Valve Dynamic ClearancesServo valve 1 - 4 mProportional valve 1 - 6 mDirectional control valve 2 - 8 m
Valve Dynamic ClearancesServo valve 1 - 4 mProportional valve 1 - 6 mDirectional control valve 2 - 8 m
Clearance Size Particles Cause:Slow response, instabilitySpool jamming/stictionSurface erosionSolenoid burnout
CylinderDrift JerkySteering SlowerPerformance ErraticOperation ShorterServiceIntervals HigherOperatingCosts LostProductivity
EFFECTSOFCONTAMINATION
Corrosion(20%)
Obsolescence(15%)
Accidents(15%)
Loss of Usefulness
Mechanical Wear(50%)
Abrasion Fatigue Adhesion
Surface Degradation(70%)
Ref: Dr. E. Rabinowicz, 1981
LOSSOFEQUIPMENTLIFE
CONTAMINATIONSOURCES
GeneratedCorrosionWearDebris
IngressAirborneMoistureDirtyOil
WrongLubricant
CORROSIVEWEARCORROSIVEWEARCorrosionisachemicalattackonthematerialCausespittingProducesacorrosionproduct
CORROSIVEWEAR
Acidsformedduringoiloxidation Internalcombustionengineswillgenerateacidsintheoil
CORROSIVEWEAR CONDITIONSPROMOTINGWEAR
Corrosiveenvironment Corrodiblemetals Rustpromotingconditions Hightemperatures
CONTROL Eliminatecorrosivematerial Usemorecorrosionresistantmetal Reduceoperatingtemperature
LUBRICANT Removecorrosivematerialsuchastoochemicallyactiveadditiveandcontaminates
Corrosioninhibitor Usefreshoil
GENERATED:WEARDEBRIS
TYPESOFWEAR
1. AdhesiveWearMetaltometalcontact(lossoffluid)
2. AbrasiveWearParticlesbetweenadjacentmovingsurfaces
3. FatigueWearParticledamagedsurfacessubjectedto
repeatedstress
1. AdhesiveWearMetaltometalcontact(lossoffluid)
2. AbrasiveWearParticlesbetweenadjacentmovingsurfaces
3. FatigueWearParticledamagedsurfacessubjectedto
repeatedstress
ADHESIVEWEAR
Metaltometalcontact
HeatisgeneratedSomediscoloration
Weldingormicrowelding
Metalbreakageortransfer
ADHESIVEWEARADHESIVEWEAR
CONTROLOFADHESIVEWEAR
Control: lubricationMetal-to-metal contact
Steel
Steel
Steel
Steel
control
PreventingAdhesivewearisprimarilycontrolledbyselectingtherightviscosity
andtherightadditivepackage.
ABRASIVEWEAR
ABRASIVEWEAR
ABRASIVEWEAR
Piston Pump
ABRASIVEWEAR
Control of Abrasive WearFiltration/Clean Handling/Good
Housekeeping
FATIGUEWEAR
NORMALFATIGUE Whendesignedfatiguelifeismet. Whendesignedserviceconditionsarefollowed.
Ex:load100lbs,lifewillbe5years
PREMATUREFATIGUE Whendesignedlifeisnotmet Couldbeafunctionofloadormaterial
ex.Designedload=100lbsactualload=300lbs
InitialSurfaceDamage
After"N"cycles,fatiguewearoccurscharacterizedbyspallingofsurface
Load
FATIGUEWEARFATIGUEWEAR
FATIGUEWEAR
Cracks from surface propagating downwards
FATIGUEWEAR
FactorsaffectingFatigueLife: LoadandhighstresspointsMaterial Temperature Timeorcycle
CONTAMINATIONSOURCES
GeneratedCorrosionWearDebris
IngressAirborneMoistureDirtyOil
WrongLubricant
DirtYouCanSee 40Microns&Larger WeldSplatter ShotBlast PaintChips MachineChips
DirtYouCantSee Under40Microns WearMetals Silica Coal Dirt Soot
TWOTYPESOFCONTAMINATION
Exampleofaircontaminantsthatonlybecamevisiblewith
thecameraflash
AIRBORNECONTAMINANTS
Theenvironmentmaybereality butwhatpreventsrealityfromgettingintothesystem?
Sometimesthenormaljobfunctionopensthecomponenttotheenvironment!Isthereanotheroption?Whataboutasightglass?
OEMbreathersmaynotbeadequateforprotectingyourequipmentfromtheworkingenvironment.
INGRESSEDMOISTURE
Itsnotjustthewateritselfthatisanissue.ManyEPadditivescontainsulphurwhichmayreactwiththemoisturetocreateotherunwantedacids.
DIRTYOIL
Didtheragdoitsjobandkeepthecontainerclean?
Pickacontainer anycontainerwilldo?NO!!!!!
CONTAMINATIONSOURCES
GeneratedCorrosionWearDebris
IngressAirborneMoistureDirtyOil
WrongLubricant
FITFORUSE?
Thiscontainerisguaranteedtohave
lubeoilinit.WhichOne????
AGENDA
INTRODUCTION CONTAMINATION SOURCES
Internal Corrosion Wear Debris
Ingress Airborne Contaminants Moisture Dirty Oil
Wrong Lubricant ISO PARTICLE COUNT SYSTEM PREVENTION
Storage Lube Rooms, Dispensing
Handling and Distribution
BUTFIRST WHATISAMICRON?
1MillionthofaMeter1ThousandthofaMillimeter
MEASURINGCONTAMINANTS
TheMicrometer(m)Smallestdotyoucanseewiththenakedeye=40m25m=1/1000ofaninch1m=0.00004inch
TheMicrometer(m)Smallestdotyoucanseewiththenakedeye=40m25m=1/1000ofaninch1m=0.00004inch
Humanhair(80m),particles(10m)at100x(14m/division)Humanhair(80m),particles(10m)at100x(14m/division)
ISOCLEANLINESSCODE
4m / 6m / 14m
11,000 4,000 500
IdentifiesquantityofcontaminantinonemLofFluid
TYPICALCLEANLINESSLEVELS
NewOilFromBarrel
23/20/18
NewOilFromBarrel
23/20/18
SystemWithTypical
HydraulicFiltration20/18/16
SystemWithTypical
HydraulicFiltration20/18/16
NewSystemw/BuiltinContaminants23/22/20
NewSystemw/BuiltinContaminants23/22/20
SystemwithB3 >200ClearanceProtectionFiltration16/13/11
SystemwithB3 >200ClearanceProtectionFiltration16/13/11
Adjusttocleanerlevelsfordutycycleseverity,machinecriticality,fluidtype(forexample,water
base)andsafetyconcerns.
TYPICALHYDRAULICCLEANLINESSTARGETS
2,500psi
TYPICALCELANLINESSTARGET
MACHINEELEMENT ISOTARGET
RollerBearing 16/14/12
JournalBearing 17/15/12
IndustrialGearbox 17/15/12
MobileGearbox 17/16/13
SteamTurbine 18/15/12
Guidelinesonly confirmwithOEM
Amount of Dirt FlowingAmount of Dirt in Oil Through Pump in One Year
630 lb/yr
79 lb/yr
20 lb/yr
ISO 21/18
ISO 18/15
ISO 16/13
CONTAMINATIONCONTROLEXAMPLE
AGENDA
INTRODUCTION CONTAMINATION SOURCES
Internal Corrosion Wear Debris
Ingress Airborne Contaminants Moisture Dirty Oil
Wrong Lubricant ISO PARTICLE COUNT SYSTEM PREVENTION
Storage Lube Rooms, Dispensing
Handling and Distribution
Thesinglegreatestopportunityforincreasingcomponentlifeandloweringoperatingcostsistoeffectivelymanagefluid
cleanliness.
MANAGECONTAMINATION
HOUSEKEEPINGFAILURES
Sweepfloorsdaily Cleanupspillsimmediately Keepworkbenchesunclutteredandfreeofdebris
Limituseoffloorstorage
NOWTHATSBETTER!!
NOWTHATSBETTER!!
STORAGE
Takemeasurestoexcludecontaminantsfrombecomingpartofthelubricantorfluid
Thismusthappeninthemainwarehouseandattheindividualstoragestationsthroughoutyourplant.
OilRoomDesignContributingfactorsforoilroomdesign:
Location,location,location Firesafety Workerssafety Ergonomics Lubricantmixingcontrol Lubricantcontaminationingresscontrol Proceduresforbringingnewoilintoservice Abilitytodocumentactions(recordkeeping)
STORAGE
CourtesyProactiveLubeManagerInc.
STORAGE
STORAGE
STORAGE
HANDLING
Preservingtheintegrityofthefluidwhilegettingitfromstoragetousage
Bearinmindthatoftenthebestwaysarealsotheeasiestandmostefficientways
Topup/smalloilchangeout,containers
HANDLING
Containersthatreducethepotentialandriskofaddingunwantedcontamination.
HANDLING
Courtesy Proactive Lube Manager Inc.
HANDLING
Dontbeafraidtogoonestepbetter. Considerretrofittingcontainerswithairbreathers,and
handpumpswithquickcouplers.
Courtesy Proactive Lube Manager Inc.
HANDLING
CourtesyProactiveLubeManagerInc.
HANDLING
Greaseismoresusceptibletoparticulatecontamination
Singleandmultipointautogreasershavegainedacceptanceforreducingparticulateingressrisk,andoverandundergreasingofcomponents.
HANDLING
Greasegunsarehandledimproperly
Transparentgreasingtoolseliminatetheageoldproblemofpickingupthewronggreasegunandmixingproducts.
HANDLING
CourtesyProactiveLubeManagerInc.
DISTRIBUTION
EXCLUSION
Thecostofcleaningdirtyoilis10Xhigherthankeepingitcleaninthefirstplace!
BREATHERS
Therearebreathersthatwillexcludeparticlesassmallasmicron
Thesesamebreathersareratedat20CFMofairoranequivalentof150gpmchangeintankfluidlevel
Lookfordesiccantbreatherstoexcludemoisture
Courtesy Des-Case.
BREATHERS
PARTSHANDLINGANDSTORAGE
Keepcomponentspackageduntilreadytoinstall
Returnpartstostorageinpackaging Protectinprocesscomponents Washcomponentsbeforeassembly
LIFEEXTENSION CLEANLINESS
LIFEEXTENSION MOSITURE
BENEFITSUMMARY
COMPONENT IMPROVEMENT
Pump/Motor 4 10xincreaseinpumpsandmotorlife
RollerBearing 50xextensionofrollerbearingfatiguelife
JournalBearing 10xextensionofjournalbearinglife
HydrostaticTransmission 4 10xincreaseinlife
Valves 5 300xincreaseinvalvelife
ValveSpool Eliminationofvalvestiction
Fluid Extensionoffluidlifethroughreducedoxidation
StartwithCleanTanks Filtration
Priortobulktank Postbulktank Dispensingpoint(dropreels)
HighEfficiencyBreathers Properlabeling UseoilsafecontainersCLEANCLEANCLEAN
METHODSTOACHIEVETHESEBENEFITS
UsetheRIGHToilintheRIGHTcomponent
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