2. • Introduction
• Base Oil
• Additives
• Grease
• Lubricants Failures
• Viscosity
• Grease Application Method
• Oil Application Method
• Handling, Storage and Management of Lubricants
• Basics of Oil Analysis
CONTENT
3. Introduction
• Tr i b o l o g y.
• L u b r i c a t i o n
f u n c t i o n .
• L u b r i c a t i o n f i l m
a n d r e g i m e .
• Fa c t o r s e f fe c t i n g
o i l re g i m e .
4. Tribology
Tribology: A study of friction, wear and lubrication.
• Friction: the resistance force between two bodies
where one body moves to the surface of the other.
• Wear: rubbing away of the material surface.
• Abrasive wear (cutting wear): wear due to
embedded of hard material into soft surface.
• Adhesive wear (Galling or scuffing): wear
due to sliding surfaces contact of one into another.
• Fatigue wear: wear due to cyclic loading of a
surface.
• Lubrication: application of some oily or greasy
substance in order to minimize friction.
According to tribologist Ernest Rabinowicz (MIT)
5. Lubrication functions
Friction control
Wear control
Corrosion
control
Contamination
control
Temperature
control
Reduce heat generation
and power consumption
Reduce mechanical and
corrosive wear
Protects surfaces from
corrosive substances
Transports contaminants
to filters
Absorbs and transfer
heat
6. Lubrication Films and Lubrication Regime
Viscosity Oil Film Suspended Oil Film Chemical Oil FilmLubrication Film
Hydrodynamic Mixed BoundaryLubrication Regime
Full speed condition Start, stop and shock load
condition
metal
lubricant
Anti-wear additive
Film thickness > 5 & < 200 microns Film thickness < 1 micron
8. Base Oil
• H o w l u b r i c a n t s a r e
fo r m u l a t e d .
• C o m m o n l u b r i c a n t
t y p e s .
• B a s e o i l .
• M i n e ra l o i l
p ro p e r t i e s .
• S y n t h e t i c
l u b r i c a n t s a n d i t s
p r o p e r t i e s .
• W h e n t o s e l e c t
s y n t h e t i c o i l ?
9. How Lubricants are Formulated B a s e O i l
Mineral
Synthetic
Vegetable
Enhance base
oil properties
10. Common Lubricants Types B a s e O i l
Lubricant Description Application
R&O Rust and oxidation inhibited oil Bearing oils
AW Lubricating oil with anti-wear (AW) additive Hydraulic fluids
EP Lubricating oil with extreme pressure (EP) additive Gear oils
COMP Compounded oils containing synthetic fatty-acid agents Worm gear oils
Motor Oil Anti-wear with detergents and dispersants
Internal
combustion
engine oils
• AW lubricant: lubricants that improve service life of elements operating in boundary lubricant regime.
• EP lubricant: lubricants that impart to rubbing surfaces to carry greater loads to prevent excessive wear and damage.
• Detergents and dispersant: additive that keeps insoluble materials in homogenous solution to prevent settle out and accumulate.
11. Base Oil B a s e O i l
Derived
from
vegetable
oils
Man-
made
fluid
Crude oil
derivative
Most lubricating oils come from
petroleum (95%) Types of Base Oil
12. Common mineral oil:
1) Paraffinic 2) Naphthenic 3) Aromatic
Mineral Oil Properties B a s e O i l
PARAFFINIC NAPHTHENIC
VISCOSITY INDEX 95-105 30-70
POUR POINT Wax pour point Lower than paraffinic
FLASH POINT Higher than Naphthenic Lower than Paraffinic
ADDITIVE SOLVENCY Poor to fail Good
APPLICATION
Crankcase oil, hydraulic
oil, gear oil, and
Bearings oil
Refrigerant oils
Compressor oils
13. Synthetic Lubricants B a s e O i l
Synthetic lubricants are man made lubricants
using mineral oil or other raw materials as base
fluid.
• provides superior mechanical and chemical
properties.
• Made by polymerization.
Common Synthetic Lubricants :
Fluid Application
Polyalphaolefins (PAO) Engine oil, gear oils, bearing oils and
lube-for-life application
Diesters and Polyol
Easters
Compressor oils, co-base stock with
PAO, oil mist and jet engine oil.
Phosphate Easters Fire resistance fluid used in: power
plant, mining and aircraft.
Polyalkylene Glycols Refrigeration compressor, H1 food
grade etc.
Silicones High temp fluid and lubricant
contacting chemicals
14. Properties What does it mean?
Advantages
Higher flash point Improved fire resistance and thermal stability
Lower pour point Improved low temp pumpability
Fire resistance Safe for high-risk hydraulic applications
Thermal stability Oil doesn’t degrade at high temperatures
Oxidation stability Resist sever application
High viscosity index Function like multi-grade oil
Lower friction Reduce energy consumption
Natural detergency Keeps surface clean of deposits
High shear strength No viscosity thinning
Disadvantages
High cost Synthetic lubricant costs 04 to 15 times more than mineral oil
Toxicity Phosphate Easter may be a toxicity risk
Seal compatibility Some seals may shrink or swell with synthetic oils and some
incompatible with coating (paint)
Hydrolytic stability Easter based synthetics may degrade in presence of water
Mix ability Some are unmixable in other fluids
Synthetic Lubricants Properties B a s e O i l
15. When to Select Synthetic Oil B a s e O i l
1. When equipment performance
demands exceed the capabilities of
mineral oil.
2. Cost reduction.
3. Safety and environmental
enhancement.
High Oxidation
Stability
• High temperature application.
• Longer lubricant life.
• Low deposit forming
Improved Lubricity
• Reduce equipment wear.
• Longer equipment life.
• Lower maintenance cost.
• Energy saving by reducing friction.
High Viscosity
Index and Low
Pour Point
• High temperature range operation.
• Satisfy low temperature application
Other Factors
• Low volatility.
• Anti-foaming.
• Excellent demulsibility.
16. Additives
• A d d i t i v e s
d e f i n i t i o n .
• Ro l e o f a d d i t i v e s .
• A d d i t i v e s p o l a r i t y.
• Ty p e s o f a d d i t i v e s .
17. Additives Definition A d d i t i v e s
0.1% 30%
Additives percentage in base oil
1% 5% 10%
Gears & Hydraulic Oils Engine Oil
Additive: a compound that added to base oil to enhance some properties.
19. Additives Polarity
Additive polarity: The tendency of additive's molecules to react with other polar materials in contact with oil.
A d d i t i v e s
Polarmaterial
Water
Glass
Metal
Wood
Non-Polarmaterial
Teflon
Mineral oil
Wax
Polar mechanism What happen? Additives
Particle enveloping
Additive clings to particle
surface
Metal deactivators,
detergents and dispersant
Water emulsifying
Polar head of additive to
droplets of moisture
Emulsifying agent
Metal wetting
Additive anchors to metal
surface
Rust inhibitors, AW&EP
additives, oiliness agent
and corrosion inhibitors
20. Types of additives
Additive type Function Compound used
Antioxidant/oxidation
inhibitors
Prevent the formation of acids, varnish,
and sludge by Attacking oxidants like
heat, water and air
Zinc Dialkyldithiophosphate (ZDDP), Peroxide
Decomposer
Rust & corrosion
inhibitors
Protects surface from rust and
corrosion
Sulfonates, phosphoric, succinic acid and calcium
phenol sulfides
Dispersant Disperses engine soot particles in oil Succinimides and other organic compounds
Detergents Scrubs engine surface of deposits and
neutralize acids
Organometallic soaps of barium, calcium and
magnesium
Anti-Wear & Extreme
Pressure agents
Protects surface from wear Zinc Dialkyldithiophosphate (ZDDP) AW
Sulfur phosphorus EP
VI improvers Improve VI of oil Radial Polyisoprene, Polyisobutylene,
Polymethacrylates and Olefin co-polymer
Defoamants/antifoam
agents
Retard the formation of stable foam on
the surface of the oil
Methyl silicone and organic polymers
(polymethacrylate)
Demulsifying agents Separate water from oil salt of an amphiphilic amine and an amphiphilic acid
Pour point depressants
(PPD)
Control wax crystal formation poly alkyl methacrylates, Chlorinated wax
polymethacrylates, polyacrylates
A d d i t i v e s
21. Grease
• L u b r i c a t i n g
g r e a s e .
• G r e a s e t h i c ke n e r
• G r e a s e a d v a n t a g e s
a n d
d i s a d v a n t a g e s .
• G re a s e
c o n s i s t e n c y.
• G r e a s e d r y - o u t .
22. Lubricating Grease
What is Grease:
Grease is a solid to semi-fluid product of thickening agent in a liquid
lubricant.
G r e a s e
Lubricating
Grease
Base oil
70 to 95%
Thickener
3 to 30%
Additive
0 to 10%
National Lubricating Grease
Institute
is an international trade
association that serves the
grease and gear lubricant
industry
23. Grease Thickener
What is Grease Thickener:
Grease thickener is a material that added to lubricant to produce the solid to semi-
fluid structure.
Types of grease thickener:
1. Simple soap thickener
2. Complex soap thickener
3. Non-Soap thickener
G r e a s e
Long-chain
Fatty Acid
Metal
Hydroxide
(Li,Na,Al,Ca)
Metal Soap
Long-chain
Fatty Acid
Short chain
Fatty Acid
Metal
Hydroxide
(Li,Na,Al,Ca)
Complex
Metal Salt
Soap
24. Grease Advantages and Disadvantages
Advantages Disadvantages
Better stop-start performance (lower risk of dry starts) Tends to hold heat in place (reduced cooling/heat transfer)
Less risk of leakage and starvation Limitation of bearing speed (to avoid heat generation of high
viscosity grease)
Seals out contaminants Poor compatibility of grease thickeners
Less risk of product contamination (Due to its resistance to
flow onto products)
Lower resistance to oxidation
Provide squeeze film under vertical loading Lower contamination control (particles in grease suspended
permanently)
Serves better in lubed-for-life applications Frequent occurrence of over and under greasing (difficult to
control quantity)
Insoluble solid additives remain suspended in grease Difficult to sample and analyze in-service grease
G r e a s e
25. Grease Consistency
Grease consistency is the ability of grease to resist the deformation under mechanical force.
Factors effecting grease consistency:
• Viscosity of base oil.
• Thickener type and concentration.
• Temperature.
• Agitation.
• Pressure.
• Contamination.
G r e a s e
Field condition
NLGI
#
ASTM
Worked
penetration
@ 25 ◦C
Appearance (@
room temp)
Food analogy
000 445-475 Fluid Cooking oil
00 400-430 Semi-fluid Apple sauce
0 355-385 Very soft Brown mustard
1 310-340 Soft Tomato paste
2 265-295 Normal Peanut butter
3 220-250 Firm
Vegetable
shortening
4 175-205 Very firm Frozen yogurt
5 130-160 Hard Smooth pate
6 85-115 Very hard
Cheddar
cheese
Cone Penetrometer
Used to measure grease consistency
NLGI Consistency Number
26. Grease Dry-Out G r e a s e
Contamination
• Dirt, dust, fly ash.
• Incompatible grease.
Oxidation
• Heat.
• Water.
• Metals.
Volatilization
• High temperature.
• Low flash point.
Bleed
• Vibration.
• High temperature.
• Low base oil viscosity.
Grease Dry-Out
27. Lubricants Failures
• H o w l u b r i c a n t
p r o p e r t i e s
c h a n g e ?
• H o w l u b r i c a n t s
fa i l ?
• C o n t a m i n a t i o n .
• O i l d e g ra d a t i o n .
• A d d i t i v e
d e p l e t i o n .
28. How Lubricant Properties Change?
Base oil Additive Thickener
Mixed lubricant
Incompatibility:
• Sludge.
• Varnish.
• Viscosity change.
• Oxidation stability.
Incompatibility:
• Neutralizer.
• Sludge.
• Varnish.
Incompatibility:
• Consistency change.
• Separation.
Contamination
• Oxidation.
• Physical properties.
• Thermal degradation.
• Radiation.
• Oxidation.
• Accelerated depletion.
• Chemical reaction.
Incompatibility:
• Consistency change.
• Separation.
Mechanical shear
• Oxidation. • Shear out of VI
improver& depressant.
• Consistency change.
Storage -
• Separation.
• Insoluble additive.
• Separation.
In-Service
Environment
• Oxidation.
• Thermal degradation.
• Chemical reaction.
• Filtration.
• Separation.
• Evaporation.
• Centrifugal separation.
• Thermal separation.
L u b r i c a n t s Fa i l u r e
29. How lubricants Fail?
Contamination
External source such
as dirt, water and
material
Oil Degradation
Oxidation
High temperature
Additive
Depletion
Decomposition
Separation
Adsorptive
L u b r i c a n t s Fa i l u r e
30. Contamination
Contaminant
Change chemical
properties of oil
Change physical
properties of oil
Attacks machine surface
Solids dirt
• Oxidation.
• Additive depletion.
• Viscosity effected. • Varnish.
• Abrasion.
• Surface fatigue.
Water
• Oxidation.
• Additive depletion.
• Viscosity effected. • Acidity destruction.
• Rust.
• Cavitation.
• Scuffing.
Fuel
• Additive depletion.
• Sulfur.
• Lowers flash.
• Lowers viscosity.
• Increase vapor pressure.
• Sulfuric acid corrosively.
• Film strength loss.
Air
• Oxidation. • Oxidation.
• Viscosity increases.
• Foam.
• Rust & corrosion.
• Varnish.
• Cavitation.
Heat
• Thermal degradation.
• Oxidation.
• Volatility.
• Viscosity effected. • Varnish.
• Acidity.
• Film strength loss.
L u b r i c a n t s Fa i l u r e
31. Oil Degradation
Oxidation
Degradation of lubricant by
chemical reaction involving O2.
Oxidation indicators:
• Darkening.
• Foul odor.
• Acid no. increase.
• Viscosity increase.
• Oxidation.
Thermal Breakdown
High oil temperature accelerates
oil degradation (for every 10 ◦C
increases, oil life cut in half)
Oxidation and high oil
temperature leads to varnish and
sludge.
Varnish: film deposit occurring in
interior parts.
L u b r i c a n t s Fa i l u r e
On Field
On Lab
32. Additive Depletion
Additive depletion means change in additive’s molecules irreversibly.
L u b r i c a n t s Fa i l u r e
Decomposition
Neutralization
Hydrolysis
Oxidation
Thermal
degradation
Shear down
Separation
Condensation
setting
Filtration
Aggregate
adsorption
Evaporation
Centrifugation
Adsorptive
Surface
adsorption
Rubbing
contact
Particles
scrubbing
Water
wasting
33. Viscosity
• V i s c o s i t y a n d
v i s c o s i t y i n d ex .
• M e a s u r e m e n t o f
v i s c o s i t y.
• E n g i n e o i l
v i s c o s i t y
c l a s s i f i c a t i o n .
• G e a r o i l v i s c o s i t y
c l a s s i f i c a t i o n .
34. Viscosity
Viscosity: measurement of a fluid’s resistance to flow and shear.
Viscosity influenced by:
• Temperature.
• Water.
• Contaminants.
• Pressure.
• Chemical change.
• shear (large molecules breaks to small
pieces)
Viscosity selection application:
V i s c o s i t y
Low viscosity
application
High viscosity
application
High speed Low speed
Smooth surfaces High load
EP additives Shock load
Cold temperature Hot temperature
Heat exchange used Abrasive in oil
Higher viscosity
35. Viscosity Index
Viscosity index: measure of a fluid’s viscosity changes with temperature. The
higher viscosity index, the smaller the relative change in viscosity with
temperature.
Viscosity index is determined experimentally by taking its viscosity at 40 ◦C and 100 ◦C .
V i s c o s i t y
Viscosity/temperature chart
VI value Oil type
-20 to 0 Phosphate ester
0 to 60 Naphthenic mineral oil
60 to 100 Paraffinic mineral oil
100 to 200 Synthetic oil
36. Measurements of Viscosity
Absolute Viscosity (µ)
• Unit: Centipoise (cP)
• Formula: µ=ʋ* SG (mPa.s)
• Measurement device: Rotary
viscometer (Brookfield)
SG= Ꝭoil/ꝬH2O
SG: specific gravity
Ꝭ: Density
Kinematic Viscosity (ʋ)
• Unit: Centistoke (cSt)
• Formula: ʋ=µ/SG (mm2/s)
• Measurement device: Capillary
viscometer
V i s c o s i t y
39. Grease Application Method
• M a n u a l g r e a s i n g .
• S i n g l e p o i n t
l u b r i c a n t s .
• C e n t ra l i ze d m u l t i -
p o i n t l u b r i c a t i o n
s y s t e m .
40. Manual Grease Gun
Advantages:
• Lower cost.
• Simple to use.
• Low maintenance.
Disadvantages:
• High labor cost.
• Over or under greasing risk.
Manual Greasing Grease Application Methods
Tips to use:
• Purge a small amount of
grease to flush away
debris.
• Measure grease weight
per shot using scale.
• Wipe fitting before
dispensing.
• Use grease cap after re-
greasing.
How much volume per re-greasing?
SKF Formula: G= 0.005 DB
Where:
G: grease quantity in grams.
D: bearing outside dia (mm)
B: bearing width (mm)
41. Single Point Lubricants (SPL)
Application:
• Lubrication in remote or restricted access area.
• Enabling continuous or periodic lube supply.
• Increases machine reliability.
Types:
• Spring type grease cup.
• Gas type SPL.
• Pump type SPL.
Grease Application Methods
Spring type grease cup
Pump type SPL Gas type SPL
42. Centralized Multi-point Lubrication System
Components:
• Lubricant reservoir.
• Pumping station.
• Flow dividers.
• Metering/controlling valve.
• Lubricating nozzle.
Lubricating system:
• Parallel (non-progressive).
• Series (progressive).
Types:
Grease Application Methods
Single-line Parallel
System
Single-line Series
System
Dual-line Parallel
43. Oil Application Method
• L u b r i c a t i n g o i l
d e l i v e r y o p t i o n s .
• M a n u a l
l u b r i c a t i o n .
• D r o p a n d w i c k
fe e d c u p s .
• C o n s t a n t l e v e l o i l .
• O i l l i f t e r.
• S p l a s h l u b r i c a t e d
g e a r d r i v e .
• P r e s s u r e s p ray
l u b r i c a t i o n .
• O i l m i s t
l u b r i c a t i o n .
• C o n t i n u o u s f o r c e d
o i l c i rc u l a t i o n .
45. Manual Lubrication
Advantages:
• Lower cost.
• Easy to apply.
• Inspection can be performed.
Disadvantages:
• Require frequent re-lubrication.
• High contamination risk.
• High labor cost.
• Difficult to apply during running condition
Oil Application Methods
46. Drop and Wick Feed Cups
Advantages:
• Simple and low cost.
• Variable feed rate.
• Oil level can be inspected easily.
Disadvantages:
• Dirt and water can restrict flow in wick.
• Wick must be replaced frequently.
• Flow rate need to be adjusted frequently.
• High contamination risk during refilling.
Oil Application Methods
Drop feed oiler
Wick feed oiler
47. Constant Level Oiler
Advantages:
• Low maintenance.
• Oil level can be inspected easily.
• Sealed against contamination.
Disadvantages:
• Contamination risk during refilling.
• Gasket degradation.
• Adjusting to wrong oil level.
• Oil level can not be reduced.
Oil Application Methods
Mechanism
When reservoir level drops, air will
enter to the bottle and the oil will
flow to maintain the constant level..
48. Oil Lifter
Oil lifters utilizes rotating mechanisms to lift oil up to gears or bearings
during running.
Oil Application Methods
49. Splash-Lubricated Gear Drive
Splash lubrication: splash oil by gear teeth, or any projection dip into
the oil reservoir during running condition.
Notes:
• Channeling risk in cold-start conditions.
• Speed/viscosity limitations.
• Dry-start risk.
• Correct oil level is critical.
Oil Application Methods
50. Pressure Spray Lubrication
Pressure spray systems use compressed air to spray the lubricant
which delivered by pump on sliding parts.
Components:
• Oil pump.
• Compressed air supply.
• Ejectors.
• Spar nozzles.
Oil Application Methods
51. Oil Mist Lubrication
Oil mist is the transport of an oil by air flow to machine surface to be
lubricated.
Advantages:
• Lower wear rate.
• Lower friction and energy consumption.
• Lower maintenance cost.
Disadvantages:
• Viscosity limitation.
• Risk of injectors clogging.
Oil Application Methods
Mechanism
Oil is lifted by vacuum generated by high air velocity
through Venturi, oil droplets then passes through
piping to target machine surface being lubricated.
52. Continuous Forced Oil Circulation Oil Application Methods
The lubricant is pumped to parts to be lubricated and returned to reservoir by
gravity passed through filters and coolers.
Components:
• Oi reservoir/tank.
• Oil pump.
• Filters.
• Coolers.
• Piping.
53. Handling, Storage and
Management of Lubricants
• L u b r i c a n t s u p p l y
o p t i o n s .
• L u b r i c a n t s t o r e
r o o m .
• L u b e r o o m s a fe t y
c o n s i d e ra t i o n .
• P r o d u c t s t o ra g e
l i fe .
• M a i n t a i n w e l l
l a b e l e d i nv e n t o r y.
54. Lubricant Supply Options
BULK STEEL DRUM PLASTIC DRUM
RACK-MOUNT
STATION
PORTABLE TRANSFER
EQUIPMENT
Handling, storage and
management of lubricants
55. Lubricant Store Room
Proper lubricant storage room, HOW IT IS LOOK?
Handling, storage and
management of lubricants
56. Lube Room Safety Consideration
Safety consideration:
• Fire extinguisher should be available and inspected regularly.
• All spills should be cleaned. Use solvent if still.
• Avoid oil contact with skin.
• Clean hand with warm water if comes in contact with oil.
• Read MSDS for each oil.
• “No Smoking” signs should be posted.
• Proper air ventilation.
• Proper lighting.
• Earthing/grounding to be used.
Handling, storage and
management of lubricants
57. Product Storage Life
• Don’t use products that have been stored for long time unless verified
with oil analysis.
• Cold temperature storing environment is risky for motor and gear oils
• Consult lubricant supplier regarding shelf life.
Handling, storage and
management of lubricants
Product Max. recommended
storage time (months)
Lithium Grease 12
Calcium Complex Grease 6
Lubricating Oils 12
Soluble Oils 6
Wax Emulsions 6
58. Maintain Well Labeled Inventory
Inventory label / tag should include: Color code tags:
• Reduce possibility of errors.
• Ease of knowing oil type.
• Reduce confusion associating with switching
suppliers.
Handling, storage and
management of lubricants
• Lubricant name:
• Lubricant viscosity grade:
• Date of purchase:
• Lubricant application:
• Inventory code:
• Expiry date:
59. Basics of oil analysis
• W h a t o i l a n a l y s i s
c a n t e l l ?
• W h a t t o c o n s i d e r
fo r r i g h t o i l
a n a l y s i s .
• Ty p e s o f o i l
a n a l y s i s .
• F T I R S p e c t ro s c o p y.
• R P VO t e s t .
60. What oil analysis can tell?
What oil analysis can tell?
• When something is occurring that can lead to failure?
• When in early stage fault exists.
• Nature of problem (background).
• How severe is the condition?
• Expected oil life-time.
• Corrective actions needed.
• What cause the machine to fail?
Basics of Oil Analysis
61. What to consider for right oil analysis
What to consider for right oil analysis?
• Right machine to sample.
• Correct sampling location.
• Correct sampling frequency.
• Right sampling procedure.
• Proper lab selection.
• Proper test to perform.
Basics of Oil Analysis
62. Types of oil analysis
Sensors
are
attached
to
machine
Unattended
Portable
instrument
are used at
machine
without
bottle
sampling
Portable
Bottles are
sent to lab
Laboratory
Basics of Oil Analysis
63. Fourier Transform Infrared Spectroscopy
• Fourier transform infrared (FTIR) spectroscopy is a
versatile tool used to detect common contaminants,
lube degradation byproducts and additives within
lubricating oils
• FTIIR is a rapid way to monitor multiple oil
parameters.
• This test method is relatively quick to perform and is
capable of simultaneously detecting multiple
parameters.
Basics of Oil Analysis
64. Rotating Pressure Vessel Oxidation Test
• The Rotating Pressure Vessel Oxidation Test
(RPVOT) is a test that determines the
oxidation stability of an oil.
• The test is very expensive to perform
routinely and is usually performed annually
on very large oil reservoirs such as a steam
turbine where volumes exceed 10,000 gallons
Applications
Mainly used for lubricants with antioxidant
additive packages to help monitor fluid health
and provide an estimate of remaining life.
Basics of Oil Analysis