3. INTRODUCTION
Wear is a major cause of material wastage, so any
reduction of wear can effect considerable saving.
Friction is a principle cause of energy dissipation
and considerable savings are possible by improved
friction control
Lubrication is the most effective mean of controlling
wear and reducing friction.
Lubrication as part of tribology, which is the science
and technology of friction lubrication and wear
4. LUBRICATION PRINCIPLE
Lubrication is introduced between two sliding solids by
adding a gaseous, liquid or solid lubricant at the sliding
interface.
Lubrication is the process, or technique employed to
reduce wear of one or both surface in close proximity
Make possible by interposing a substance called
lubricant between the surface
Function:
To reduce friction and wear
To carry away heat generated during the sliding process
To carry away debris generated during the sliding process
6. FLUID MANAGEMENT
Fluid management programs are being used to
extend lubricant life and reduce disposal costs.
Four essential components in a fluid management
program:
Selection and purchase of the lubricant
Lubricant monitoring during use
Lubrication maintenance using processing and
refortification techniques
Disposal of the spent lubricant
7. FOUR COMPONENTS IN FLUID MANAGEMENT
LUBRICATION SELECTION & PURCHASE
CRITERIA:
a) Correct lubricant for application
b) Premium lubricant is recommended
c) Lubrication meet equipment manufacturers’
recommendations and specifications.
d) Good quality, reliable and proven lubricant
e) Good services from lubricant supplier
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8. FOUR COMPONENTS IN FLUID MANAGEMENT
LUBRICATION MONITORING PROGRAM
a) The purpose is to evaluate the condition of the
lubricant and to detect early signs of equipment
failure.
b) Analysis of the used oil can be used to extend
lubricant life and establish oil change interval
c) This program mostly for large volume application
of industrial lubricant. Example:
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Turbine / circulating Compressors
Hydraulic Gear oils
9. FOUR COMPONENTS IN FLUID MANAGEMENT
LUBRICATION MONITORING PROGRAM
d) Small volume or once-through applications, need
no monitoring
e) Result of monitoring tests can be used in some
cases to correct conditions that are contributing to
degradation of the lubricant.
f) Results of monitoring program should be assess
dependent on the application and environment.
Table 2.1 shows properties and condemning limit
for most large volume application
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10. FOUR COMPONENTS IN FLUID MANAGEMENT
LUBRICATION MONITORING PROGRAM2
TABLE 2.1 – Condemning limits for used oil
11. FOUR COMPONENTS IN FLUID MANAGEMENT
LUBRICATION MAINTENANCE
a) Closely related with the monitoring program
b) Can be define as corrective action when used oil
analysis show results exceed condemning limit
(Table 2.1)
c) Some maintenance action is, filtration, additive
replenishment or lubricant cooling system.
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12. FOUR COMPONENTS IN FLUID MANAGEMENT
DISPOSAL
a) Last step taken when monitoring results show oils
is severely degraded and cannot be restore.
b) Option of disposal could be, recycling, burning,
land-filling and re-refining.
c) Method of disposal will depend on local authority
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14. LUBRICANT PROTECTION
1) Protection of lubricant to ensure its longevity and
satisfactory performance by proper handling and
storage of lubricants.
2) Protection practice to prevent:
a) Contamination of dirts
b) Contamination with excessive moisture or water
c) Exposure to extreme temperature
15. 5 WAYS OF LUBRICATION PROTECTION
LUBRICATION
PROTECTION
LOCATION &
PERSONNEL
FACILITIES
LIGHTING
BULK
STORAGE
FIRE
PROTECTION
16. LOCATION AND PERSONNEL
Provide clean and well-lighted room
Provision for heating if expose to cold weather /
environment
Assign trained personnel for inventory and
dispensing
Provide clear label for each type of lubricant
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17. FACILITIES FOR HANDLING
Facility to ensure easy handling and proper
storage arrangement
Facility design so that various type of lubricant
is mixed
Handling equipment must keep clean and well
maintained.
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19. LIGHTING
Proper lighting ensure healthy and comfortable
working environment
Proper records and monitoring can be done
Promote safety
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20. BULK STORAGE
Benefits:
Improved efficiency
Reduced handling costs
Reduced risk of contamination
Simplified inventory
Expensive investment:
Each products required its own dedicated system
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21. BULK STORAGE
Bulk shipments can be done with tank trucks, car or
tote bins.
Products should be inspected visually for clarity and
cleanliness and viscosity check prior to unload.
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22. FIRE PROTECTION
Enforce strict rules for safety:
No smoking area
Allow specific trained personnel to have access
Allow the used of sparking or arcing producing tool only
under the conditions of good ventilation
Only allow minimum quantity of waste or wiping rags and
stored in metal container
Oil dripped is prevented or cleaned up properly
Good safety features:
Suitable fire extinguishing equipment are available
Clean area
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28. CENTRALIZED AUTOMATIC
LUBRICATION SYSTEM
Centralized automatic lubrication system can be
readily justified for the following reasons:
SAFETY
MORE EFFICIENT LUBRICATION
INCREASED PRODUCTIVITY
REDUCED OPERATING COST
BETTER HOUSEKEEPING
29. SAFETY
• No climbing around machinery
• No excess spillage around machines to
cause slippery
• Difficult to access area due to location gas,
fumes or height
30. TYPES OF AUTOMATIC LUBRICATION
SYSTEMS
Automatic lubrication system generally fall into
below categories:
Oil mist
system
Orifice
control
system
Injector
system
Series-
progressive
system
Twin line
Duoline
system
Pump to
point
system
Zone control
system
Ejection
system
Injection
system
31. OIL MIST SYSTEM
Mostly used in high-speed precision service
Example:
Grinding machinery
Woodworking
Air craft compressor
Working principle:
Injecting oil drop by drop into a stream of low
pressure air to circulate just enough oil to wet the
operating surface
32. ORIFICE-CONTROL SYSTEM
Use only oil as a lubricant with viscosity usually
limited to 300 SUS or less
Orifice used to control the amount of lubrication
going into a bearing
Best for small, single purpose machinery in a stable
environment.
Generally cheap, and simple to design and install.
Additional point can be added without disrupting the
original system
Not suitable for area has vary temperature,
viscosity change as temperature change viscosity
Single broken line will disable complete system.
33.
34. INJECTOR SYSTEM
Can be used with oil and light greases,, usually
limited to NLGI 1.
Working principle: Quickly pressurized main system
line so that the lubricant on the discharge end of a
spool can be injected into a bearing.
Pump capacity usually sized four times higher than
the system’s requirement.
Easy system to design
Additional lubrication point can be added without
disrupting original design.
Broken line before any injector will disable complete
system
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36. SERIES PROGRESSIVE SYSTEM
Can operate with either oil or grease (suggested
minimum viscosity 100 SUS, maximum NLGI 2)
Provide positive displacement of lubricant by
supplying each bearing with predetermined amount
of lubricant before lubricating the next point.
Main characteristic, system will disable when a line
become plugged.
Tamper resistant
Complex design, expensive, require comprehensive
engineering study & required high skilled
maintenance personnel
Additional point require re-design system
