lubrication - fundamentals -may 2012 draft ver3
DESCRIPTION
Lubrication FundamentalsTRANSCRIPT
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A Suncor Energy business
LUBRICATION FUNDAMENTALS
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2LUBRICATIONFUNDAMENTALS
FunctionsofaLubricant LubricatingOilProperties BaseOils LubricatingOilFilms OilAdditives
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3API AmericanPetroleumInstitute
ASTM AmericanSocietyforTestingMaterials
SAE SocietyofAutomotiveEngineers
NLGI NationalLubricatingGreaseInstitute
STLE SocietyofTribologists&LubricationEngineers
AGMA AmericanGearManufacturersAssociation
ISO InternationalOrganizationforStandardization
LUBRICATIONINDUSTRY
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4TRIBOLOGY
Isthescienceandtechnologydealingwiththedesign,lubrication,friction,andwear ofinteractingsurfacesinrelativemotion
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5FUNCTIONSOFALUBRICANT
ReduceFriction
MinimizeWear(KeepMovingSurfacesApart)
CoolParts(CarryAwayHeat)
PreventCorrosion
DisperseCombustionProducts(e.g.,Soot)
ActasaSealant
TransmitPower
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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?
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7LUBRICATIONFUNDAMENTALS
FunctionsofaLubricant LubricatingOilProperties BaseOils LubricatingOilFilms OilAdditives
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8LUBRICATINGOILPROPERTIES
Viscosity ViscosityIndex Density/SpecificGravity FlashPoint FirePoint PourPoint CloudPoint
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9LUBRICATINGOILPROPERTIES
Whatisthemostimportantcharacteristicofalubricatingoil?
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LUBRICATINGOILPROPERTIES
Whatisthemostimportantcharacteristicofalubricatingoil?
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VISCOSITY
Measurementoftheoilsinternalresistancetomotion
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VISCOSITY
Measureofresistancetoflowatagiventemperature (Typically40oC&100oC)
Viscositychangesinversely withtemperature* i.e.,Astemperatureincreases,oilbecomesthinner
ChangeinViscosityisNOTlinear
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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
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Loadcarryingcapacityincreaseswithviscosity
LOADCARRYINGCAPACITY
V
I
S
C
O
S
I
T
Y
VISCOSITY
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VISCOSITYEXAMPLE
Usingtheviscositychartpaperprovided,[email protected]@100oC
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This image cannot currently be displayed.
This image cannot currently be displayed.
Visc @ 40C
Visc @ 100C
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VISCOSITYMEASUREMENT
Viscosity Systems (most common)Kinematic (cSt) (metric)
American (SUS / SSU)
Absolute (cP)* Low temperature
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KINEMATICVISCOSITY
Measureoffluidsresistancetoflowduetogravity
Derivedfromthetimetakenforalubricanttotravelthroughacapillarytube
Measurement Stoke(St)=1cm2 /second
Typicallyreportedascentistoke (cSt)=1mm2 /second
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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
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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
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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
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Viscosity isameasurementofresistancetoflowatone temperature.
ViscosityIndex(VI)isameasurementoftherateofchangeofviscosityoverarange oftemperatures.Insimpleterms:itmeasureshowfasttheoilthickensupasitgetscolderorhowfastitthinsoutasitgetshotter.
WithMostlubricants,thehighertheVIthebetter
LUBRICANTPROPERTIES:VISCOSITYINDEX(VI)
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TheViscosityIndexiscalculatedfromviscositiesat40Cand100C
HighVIisatermwhichmeansthattheoilisusableoverawidertemperaturerange.
VHVI =VeryHighViscosityIndex
LUBRICANTPROPERTIES:VISCOSITYINDEX(VI)
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BaseStocksaretherefinedoils(derivedfromcrudeoil)whichareblendedtogetherwithadditivestoproduceafinishedlubricant.Theyaredescribedinaseparatesection.
Traditionalsolventrefined paraffinicbasestockshaveVIsintherange85to 95.ProcessimprovementssuchashydrofinishingcanimprovetheVItoover100.
OurHydroTreated basestockshaveViscosityIndicesintherange90110.
OurHydrocracked isodewaxedbasestocksareover120VI.
TYPICALVIOFDIFFERENTBASESTOCKS
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ViscosityIndexisaninherentpropertyofthebaseoil usedtoblendalubricant.
VIcanbeimproved significantlybyblendingsolubleadditivescalledVIImproversintotheoil.
Theseadditivesarelongpolymermoleculeswhichuncoilathightemperaturestoincreaseviscosity,whileatlowtemperaturestheyformtightballswhichnolongercontributemuchtoviscosity.
Onecaution:VIimproversdonotlastforever inablend.Theycanbechoppeduporsheareddownbyconstantmechanicalmotionintheoil.
VISCOSITYINDEX
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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
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VISCOSITY COMPARISON CHART
NOTE: Readacrosshorizontally. Assumes96Vlsinglegradeoils. Equivalenceisintermsofviscosity
at40Conly. Viscositylimitsareapproximate:
Forprecisedata,consultISO,AGMAand
SAEspecifications. Wgradesarerepresentedonlyin
termsofapproximate40Cviscosity.
Forlowtemperaturelimits,consultSAEspecifications.
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VISCOSITY RULES OF THUMB
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LUBRICATIONFUNDAMENTALS
Functions of a Lubricant Lubricating Oil Properties Base Oils Lubricating Oil Films Oil Additives
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Formulated Lubricant
Crude Oil
MineralBasestock Additives
Synthetic Basestocks
Natural Gas
LUBRICATINGOILS
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BaseOilCharacteristics
APIGroup Sulphurwt%Saturateswt
%ViscosityIndex
ManufacturingMethod
I >0.03
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HYDROTREATEDVS.SOLVENTREFINED
BENEFITS
Mayusepoorqualitycrude
Loweroperatingcosts
TypicallyhavehigherVIs
Improvedoxidationresistance
Improvedhightemperature
stability
DISADVANTAGES Highercapitalcosts Requireshydrogensupply Highpressureunits
skilledtechnicians Differentadditive
package
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DEFINITIONS
MINERALBASED Adistillate(physicalseparation)ofpetroleum
SYNTHETIC Oilderivedfromchemicalmanipulationresultinginsignificantmodificationfromoriginalsource
BIOBASED Formulatedwithrenewableandbiodegradablebasestocks.Itsworthnotingthatsomedefinitionsonlyconsiderbiodegradability.
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ANALOGY
Crudeoilisextractedfromground
GroupIoilismadefromsolventdistillation
GroupIIandIIIoilsaremadeusinghighpressurehydrogen
GroupIVoilsaremadebychemicallyselectingamodifyingmoleculesizes
Cowismilked
Milkandcreamareseparatedbygravityonly
Milkisseparatedbycentrifugeandthenpasteurizedwithhightemperatures
Butterismadebyforcingtinyfatmoleculesintolargergrouping
*Fluid Life Corp.
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SYNTHETICOILS
Polyalphaolefin(PAO) Diesters Polyglycols PhosphateEsters PolyolEsters Silicones
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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
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LUBRICATIONFUNDAMENTALS
FunctionsofaLubricant LubricatingOilProperties BaseOils LubricatingOilFilms OilAdditives
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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
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JournalBearings(CompactionSK09002)
Bearingatrest
Bearingathighspeed
Bearingatslowspeed
Oilwedgeproducespressure,highviscosity,andfullfilmhydrodynamiclubrication
HYDRODYNAMICLUBRICATION
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LUBRICATIONFUNDAMENTALS
FunctionsofaLubricant LubricatingOilProperties BaseOils LubricatingOilFilms OilAdditives
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ADDITIVES
GeneralpurposesDifferentadditives
SpecificpurposeHowtheywork
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WHYADDITIVES?
TOPROTECT THEMETALSURFACES TOIMPROVE LUBRICANTPERFORMANCE TOEXTEND LUBRICANTSERVICELIFE
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ADDITIVES
SURFACEPROTECTRustinhibitorCorrosioninhibitorAntiwearExtremepressureDispersantDetergentTackifier
LUBE ENHANCERAnti-oxidantAnti-foamantPour Point depressantVi improverFriction modifierEmulsifierDe-emulsifier
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OXIDATIONINHIBITOR
WHATITDOESPreventsvarnish,sludge&acidprecursorsfromforming
HOWITWORKSReactsmorereadilywithO2 thandoesoil
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OXIDATIONINHIBITOR
Itwillbeusedup Every10oCincreaseintemperatureresultsinoxidationbeing2*faster
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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
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WATER+CATALYSTONOXIDATIONLIFE150SSU@100oFTurbineOil
Ref: Volume XXIII Proceedings of National Conference on Fluid Power, 1969, Weinschelbaum, M.
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ANTIWEAR(AW)
WHATITDOESMinimizeswearcausedbymetaltometalcontact
HOWITWORKSFormschemicalfilmonsurfaceFilmrubsoff
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ANTIWEAR(AW)
TypicallyZn/Pmaterial(ZDDP) SensitivetolongtermwatercontaminationWillresultinareddishdeposit
WillbeconsumedNottrackableinstandardoilanalysisbecausecannotdestroyZnorP
Needsbaremetalsurface
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EXTREMEPRESSURE(EP)
WHATITDOESPreventswelding&excessivewearundershockloading/highvibration
HOWITWORKSHeatatpointofshockloadcausesformationofnewcompound
Compoundwearsoff
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EXTREMEPRESSURE
TypicallyS Pmaterial Sulphurisreactivetoyellowmetals,especiallyabove75oC
Willbeconsumed InthepresenceofwaterandheatcanformS&Pacids
Needsbaremetalsurface
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TIMKENEPTEST
TypicalResultsReportedasthe
OKLoad
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4BALLEPTEST
TypicalResultsWeldPoint
LWI Loadwearindex
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VISCOSITYINDEX(VI)IMPROVER
WHATITDOESReducesrateofchangeofviscositywithtemperature
HOWITWORKSAdditiveactsasthickenerwithincreasingtemperature
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VIIMPROVER
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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
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DISPERSANT
WHATITDOESKeepsoxidationparticlesinsuspensioninoil
HOWITWORKSCombineswithsmallparticlestopreventformationoflargeparticles
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DISPERSANT Nonmetalliccocomponentwithdetergent
Willbeconsumed Notgenerallyusedinindustrialoils
SootDispersed LowViscosityIncrease
SootAgglomerates HighViscosityIncrease
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DETERGENT
WHATITDOESPreventsoxidationparticlesfromformingsludge,varnishorgum
HOWITWORKSReactswithmetalsurfacestominimizespaceforoxidationparticles
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DETERGENT
Typicallymetallicadditive(Ca/B/Mg) Willbeconsumed Nottypicallyfoundinindustrialoils Needsbaremetalsurface
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RUST&CORROSIONINHIBITORS
Protectsironandsteelpartsfromattackbyacidiccontaminantsandwater
Formsaprotectivefilmonmetal delicatebalance,caninterferewithothersurfaceactiveadditives
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RUST&CORROSIONINHIBITORS
RustTest ASTMD665
60oC 24hours Distilledor
Syntheticseawater PassorFail
CopperCorrosion Evaluatestheextentofdiscolourationortarnishingofacopperstripimmersedinthelubricant ASTMD130 2Hours@100oC Alphanumeric(1a..4c)
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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.
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POUR/CLOUDPOINTDEPRESSANTS
Inhibittheformationoflargewaxcrystals Enhancestheloweroperabilitytemperatureoftheoil
Highmolecularweightpolymers
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POUR/CLOUDPOINTDEPRESSANTS
Temperatureatwhichnomovementisobservedfor5seconds
Waxcomesoutofsolutioninsmallcrystalsastheoilnearspourpoint.Smallcrystalsformagelthatkeepstheoilfrommoving.
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FRICTIONMODIFIERS
Increaseoilfilmstrength Longchainmolecules Polarendadsorbstometalsurface Effectiveatlowtemperaturesandmildsliding
conditions Fattyacidorfattyoilderivatives AshcontainingcompoundssuchasMolybdenum
Disulphide(MoS2),graphite,Teflon(PTFE),arealsocalledFrictionModifiers
Sometimescalledantiseizeorsolidlubricants
Commonly found in Engine Oils to improve fuel economy.
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DEMULSIFIERADDITIVES
Addedtooilsinimprovetheabilityofwatertoshedfromtheoil.
Desirablefor: papermachines hydraulics turbines gears
Additivesthatareaddedtotheoilforotherreasonsoftenattractwater(i.e.detergents).
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DEMULSIBILITYTESTS
Determinestheabilityoftheoiltoshedwater. ASTMD1401,D2711(shouldbeusedforoilscontainingEPadditives)
Reportedas:Oil/Water/Emulsion(minutes)38438(20)
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SULPHATEDASH
Determinesthenoncombustibleresidueinalubricatingoil(ASTMD874)
Sometimesusedasanindicationoftheamountofdetergentinanewoil
Metallicadditivecomponents Calcium,Magnesium,Zinc
Newspecsarelimitingtheashcontent Primaryfunctionofthesulfatedashistominimizevalvewear(recession)inNGEO
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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
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ADDITIVESATWORK
Dispersant
VIImprover
AntiFoam
Pour/CloudPointDepressant
OxidationInhibitor
Someadditivesworkintheoil,someworkonthemetalsurfaceVERYDELICATEBALANCE
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OILCLEANLINESSandCONTAMINATIONCONTROL
CLEANLINESSANDCONTAMINATIONCONTROL
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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
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CLEANLINESSANDCONTAMINATIONCONTROL
Contaminationisthegreatestsinglecauseoflubricantdegradationandmalfunctionleadingtoabnormalwearandfailureofequipmentcomponents.
Because Contaminationsourcesareeverywhere Itcauseswearandsurfacedegradation Itcausesthelubricanttomalfunction Itcostsyoumoney!
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WHATISCONTAMINATION?
AnythinginafluidthatdoesnotbelongisaCONTAMINANT.
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SOURCESOFCONTAMINATION
BuiltincontaminationGeneratedcontaminants ExternalingressionMaintenanceintroducedcontaminants
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SOURCES(CONTD)
Builtincontaminantsfromcomponents: Cylinders,fluids,hoses,hydraulicmotors,linesandpipes,pumps,reservoirs,valves,etc.
Generatedcontaminants: Assemblyofsystem Breakinofsystem Operationofsystem Fluidbreakdown
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SOURCES(CONTD)
Externalingression Reservoirbreathing Cylinderrodseals Bearingseals
Contaminantsintroducedduringmaintenance Disassembly/assembly Makeupoil
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OILCONTAMINATION
80%ofconsequencescomefrom20%ofcauses.80/20RULE
PARETOPRINCIPLE
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WATER+CATALYSTONOXIDATIONLIFE150SSU@100oFTurbineOil
Ref: Volume XXIII Proceedings of National Conference on Fluid Power, 1969, Weinschelbaum, M.
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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
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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
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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
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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
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BEARINGFILMTHICKNESS
Theoperatingordynamicclearanceisnotequaltothemachineclearance,butdependsupontheload,speedandlubricant
viscosity.Alubricantfilmseparatesmovingsurfacestopreventmetaltometalcontact.
MachineClearanceMachine
ClearanceLoad,
No MotionLoad,
No Motion
5m5m
5m5m
10m10m
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BEARINGFILMTHICKNESS
Load & Motion& Lubricant
Load & Motion& Lubricant
JournalBearingJournalBearing
9m9m
1m1m
DynamicClearance
Rolling ElementBearing
Rolling ElementBearing
Cage LubricantFilm
Cage LubricantFilm
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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
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CylinderDrift JerkySteering SlowerPerformance ErraticOperation ShorterServiceIntervals HigherOperatingCosts LostProductivity
EFFECTSOFCONTAMINATION
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Corrosion(20%)
Obsolescence(15%)
Accidents(15%)
Loss of Usefulness
Mechanical Wear(50%)
Abrasion Fatigue Adhesion
Surface Degradation(70%)
Ref: Dr. E. Rabinowicz, 1981
LOSSOFEQUIPMENTLIFE
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CONTAMINATIONSOURCES
GeneratedCorrosionWearDebris
IngressAirborneMoistureDirtyOil
WrongLubricant
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CORROSIVEWEARCORROSIVEWEARCorrosionisachemicalattackonthematerialCausespittingProducesacorrosionproduct
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CORROSIVEWEAR
Acidsformedduringoiloxidation Internalcombustionengineswillgenerateacidsintheoil
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CORROSIVEWEAR CONDITIONSPROMOTINGWEAR
Corrosiveenvironment Corrodiblemetals Rustpromotingconditions Hightemperatures
CONTROL Eliminatecorrosivematerial Usemorecorrosionresistantmetal Reduceoperatingtemperature
LUBRICANT Removecorrosivematerialsuchastoochemicallyactiveadditiveandcontaminates
Corrosioninhibitor Usefreshoil
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GENERATED:WEARDEBRIS
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TYPESOFWEAR
1. AdhesiveWearMetaltometalcontact(lossoffluid)
2. AbrasiveWearParticlesbetweenadjacentmovingsurfaces
3. FatigueWearParticledamagedsurfacessubjectedto
repeatedstress
1. AdhesiveWearMetaltometalcontact(lossoffluid)
2. AbrasiveWearParticlesbetweenadjacentmovingsurfaces
3. FatigueWearParticledamagedsurfacessubjectedto
repeatedstress
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ADHESIVEWEAR
Metaltometalcontact
HeatisgeneratedSomediscoloration
Weldingormicrowelding
Metalbreakageortransfer
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ADHESIVEWEARADHESIVEWEAR
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CONTROLOFADHESIVEWEAR
Control: lubricationMetal-to-metal contact
Steel
Steel
Steel
Steel
control
PreventingAdhesivewearisprimarilycontrolledbyselectingtherightviscosity
andtherightadditivepackage.
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ABRASIVEWEAR
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ABRASIVEWEAR
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ABRASIVEWEAR
Piston Pump
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ABRASIVEWEAR
Control of Abrasive WearFiltration/Clean Handling/Good
Housekeeping
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FATIGUEWEAR
NORMALFATIGUE Whendesignedfatiguelifeismet. Whendesignedserviceconditionsarefollowed.
Ex:load100lbs,lifewillbe5years
PREMATUREFATIGUE Whendesignedlifeisnotmet Couldbeafunctionofloadormaterial
ex.Designedload=100lbsactualload=300lbs
InitialSurfaceDamage
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After"N"cycles,fatiguewearoccurscharacterizedbyspallingofsurface
Load
FATIGUEWEARFATIGUEWEAR
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FATIGUEWEAR
Cracks from surface propagating downwards
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FATIGUEWEAR
FactorsaffectingFatigueLife: LoadandhighstresspointsMaterial Temperature Timeorcycle
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CONTAMINATIONSOURCES
GeneratedCorrosionWearDebris
IngressAirborneMoistureDirtyOil
WrongLubricant
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DirtYouCanSee 40Microns&Larger WeldSplatter ShotBlast PaintChips MachineChips
DirtYouCantSee Under40Microns WearMetals Silica Coal Dirt Soot
TWOTYPESOFCONTAMINATION
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Exampleofaircontaminantsthatonlybecamevisiblewith
thecameraflash
AIRBORNECONTAMINANTS
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Theenvironmentmaybereality butwhatpreventsrealityfromgettingintothesystem?
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Sometimesthenormaljobfunctionopensthecomponenttotheenvironment!Isthereanotheroption?Whataboutasightglass?
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OEMbreathersmaynotbeadequateforprotectingyourequipmentfromtheworkingenvironment.
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INGRESSEDMOISTURE
Itsnotjustthewateritselfthatisanissue.ManyEPadditivescontainsulphurwhichmayreactwiththemoisturetocreateotherunwantedacids.
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DIRTYOIL
Didtheragdoitsjobandkeepthecontainerclean?
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Pickacontainer anycontainerwilldo?NO!!!!!
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CONTAMINATIONSOURCES
GeneratedCorrosionWearDebris
IngressAirborneMoistureDirtyOil
WrongLubricant
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FITFORUSE?
Thiscontainerisguaranteedtohave
lubeoilinit.WhichOne????
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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
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BUTFIRST WHATISAMICRON?
1MillionthofaMeter1ThousandthofaMillimeter
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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)
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ISOCLEANLINESSCODE
4m / 6m / 14m
11,000 4,000 500
IdentifiesquantityofcontaminantinonemLofFluid
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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
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Adjusttocleanerlevelsfordutycycleseverity,machinecriticality,fluidtype(forexample,water
base)andsafetyconcerns.
TYPICALHYDRAULICCLEANLINESSTARGETS
2,500psi
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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
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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
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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
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Thesinglegreatestopportunityforincreasingcomponentlifeandloweringoperatingcostsistoeffectivelymanagefluid
cleanliness.
MANAGECONTAMINATION
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HOUSEKEEPINGFAILURES
Sweepfloorsdaily Cleanupspillsimmediately Keepworkbenchesunclutteredandfreeofdebris
Limituseoffloorstorage
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NOWTHATSBETTER!!
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NOWTHATSBETTER!!
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STORAGE
Takemeasurestoexcludecontaminantsfrombecomingpartofthelubricantorfluid
Thismusthappeninthemainwarehouseandattheindividualstoragestationsthroughoutyourplant.
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OilRoomDesignContributingfactorsforoilroomdesign:
Location,location,location Firesafety Workerssafety Ergonomics Lubricantmixingcontrol Lubricantcontaminationingresscontrol Proceduresforbringingnewoilintoservice Abilitytodocumentactions(recordkeeping)
STORAGE
CourtesyProactiveLubeManagerInc.
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STORAGE
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STORAGE
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STORAGE
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HANDLING
Preservingtheintegrityofthefluidwhilegettingitfromstoragetousage
Bearinmindthatoftenthebestwaysarealsotheeasiestandmostefficientways
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Topup/smalloilchangeout,containers
HANDLING
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Containersthatreducethepotentialandriskofaddingunwantedcontamination.
HANDLING
Courtesy Proactive Lube Manager Inc.
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HANDLING
Dontbeafraidtogoonestepbetter. Considerretrofittingcontainerswithairbreathers,and
handpumpswithquickcouplers.
Courtesy Proactive Lube Manager Inc.
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HANDLING
CourtesyProactiveLubeManagerInc.
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HANDLING
Greaseismoresusceptibletoparticulatecontamination
Singleandmultipointautogreasershavegainedacceptanceforreducingparticulateingressrisk,andoverandundergreasingofcomponents.
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HANDLING
Greasegunsarehandledimproperly
Transparentgreasingtoolseliminatetheageoldproblemofpickingupthewronggreasegunandmixingproducts.
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HANDLING
CourtesyProactiveLubeManagerInc.
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DISTRIBUTION
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EXCLUSION
Thecostofcleaningdirtyoilis10Xhigherthankeepingitcleaninthefirstplace!
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BREATHERS
Therearebreathersthatwillexcludeparticlesassmallasmicron
Thesesamebreathersareratedat20CFMofairoranequivalentof150gpmchangeintankfluidlevel
Lookfordesiccantbreatherstoexcludemoisture
Courtesy Des-Case.
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BREATHERS
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PARTSHANDLINGANDSTORAGE
Keepcomponentspackageduntilreadytoinstall
Returnpartstostorageinpackaging Protectinprocesscomponents Washcomponentsbeforeassembly
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LIFEEXTENSION CLEANLINESS
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LIFEEXTENSION MOSITURE
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BENEFITSUMMARY
COMPONENT IMPROVEMENT
Pump/Motor 4 10xincreaseinpumpsandmotorlife
RollerBearing 50xextensionofrollerbearingfatiguelife
JournalBearing 10xextensionofjournalbearinglife
HydrostaticTransmission 4 10xincreaseinlife
Valves 5 300xincreaseinvalvelife
ValveSpool Eliminationofvalvestiction
Fluid Extensionoffluidlifethroughreducedoxidation
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StartwithCleanTanks Filtration
Priortobulktank Postbulktank Dispensingpoint(dropreels)
HighEfficiencyBreathers Properlabeling UseoilsafecontainersCLEANCLEANCLEAN
METHODSTOACHIEVETHESEBENEFITS
UsetheRIGHToilintheRIGHTcomponent