Lubrication - Fundamentals -May 2012 DRAFT Ver3

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


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

i

n

e

m

a

t

i

c

V

i

s

c

o

s

i

t

y

,

c

S

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 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



38

LUBRICATINGOILFILMS

Hydrodynamic Elastohydrodynamic(EHD) Boundary Hydrostatic




SteelSteel

SteelSteel

SteelSteel

SteelSteel

SteelSteel

SteelSteel

Air

Oil Film




SteelSteel

SteelSteel

SteelSteel

SteelSteel

SteelSteel

SteelSteel

Air

Oil Film

39

JournalBearings(CompactionSK09002)

Bearingatrest

Bearingathighspeed

Bearingatslowspeed

Oilwedgeproducespressure,highviscosity,andfullfilmhydrodynamiclubrication

HYDRODYNAMICLUBRICATION

40



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

([email protected])

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 Rupture

Before After



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

([email protected])

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

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




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!!!!!




WrongLubricant

FITFORUSE?

Thiscontainerisguaranteedtohave

lubeoilinit.WhichOne????

AGENDA







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







Thesinglegreatestopportunityforincreasingcomponentlifeandloweringoperatingcostsistoeffectivelymanagefluid

cleanliness.

MANAGECONTAMINATION

HOUSEKEEPINGFAILURES

Sweepfloorsdaily Cleanupspillsimmediately Keepworkbenchesunclutteredandfreeofdebris

Limituseoffloorstorage

NOWTHATSBETTER!!

STORAGE

Takemeasurestoexcludecontaminantsfrombecomingpartofthelubricantorfluid

Thismusthappeninthemainwarehouseandattheindividualstoragestationsthroughoutyourplant.

OilRoomDesignContributingfactorsforoilroomdesign:

Location,location,location Firesafety Workerssafety Ergonomics Lubricantmixingcontrol Lubricantcontaminationingresscontrol Proceduresforbringingnewoilintoservice Abilitytodocumentactions(recordkeeping)

STORAGE

CourtesyProactiveLubeManagerInc.

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


HANDLING

Greaseismoresusceptibletoparticulatecontamination

Singleandmultipointautogreasershavegainedacceptanceforreducingparticulateingressrisk,andoverandundergreasingofcomponents.

HANDLING

Greasegunsarehandledimproperly

Transparentgreasingtoolseliminatetheageoldproblemofpickingupthewronggreasegunandmixingproducts.

HANDLING


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

Documents

Lubrication - Fundamentals -May 2012 DRAFT Ver3