LUBRICANTS & LUBRICATION OF INDUSTRIAL EQUIPMENT

Introduction: Lubricant are materials (liquid, semi-solid, solid, gaseous) mainly used between moving
surface to reduce friction and wear.
 Any machine will operate most dependably when it is property lubricated
 It leads to minimum cost of maintenance; minimum breakdown
 Proper selection of lubricant is the most important task.
 Therefore, it is very important to get sufficient knowledge about properties of different lubricants.
Lubrication: Lubrication is the process of using some substances having lubricating property between two
rubbing surfaces of a running machine. The used substance produces a thin film and resists surface-to-surface
friction.
Lubricants perform the following key functions:
 Keep moving parts apart
 Reduce friction
 Reduce Noise
 Carry away contaminants & debris
 Transmit power
 Protect against wear
 Prevent corrosion
 Seal for gases
 Stop the risk of smoke and fire.
 To dissipate heat
Selection of Lubricants: The proper selection of the best-suited type of lubricant depends on:
1) Equipment design,
2) Operating conditions,
3) Method of application
4) Economic considerations
Classification of lubricants
1) Liquid lubricant: Mineral hydrocarbon oil, Synthetic hydrocarbon oil, Vegetable oil.
2) Semisolid lubricant : Grease
3) Solid lubricant: Dry graphite, PTFE, Molybdenum disulfide (Molycote), Tungsten disulfide, Boron nitride
4) Gaseous lubricant: Air, Nitrogen, Oxygen, Helium, etc.
Composition of Lubricating Oil: Lubricants are generally composed of a majority of base oil (90%)
plus a variety of additives (less than 10%) to impart desirable characteristics. Although generally lubricants are
based on one type of base oil, mixtures of the base oils also are used to meet performance requirements.
Base oil: Base oils may be mineral oil, vegetable oil, animal oil and synthetic oil
1) Mineral Oil: Hydrocarbon oils produced from crude petroleum of the refining process.
2) Vegetable oil: Olive oil palm oil
3) Synthetic oil: Polymerized hydrocarbons, poly glycols
4) Animal oil: Pork oil, fish oil
Base oil can be sub-divided depending on the prevailing compositions:
1) Paraffinic
2) Naphthenic
3) Aromatic
Selection of Base oil
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The selection of base oil depends very much on the purpose of which the lubricant is to be used. For compressors
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and diesel engines, for example, naphthalene-based oil will be preferred. Because it leaves a softer
"Carbon"deposit on the valves, which can be easily removed. To obtain the right properties, some lubricating oils
are made from more than one base oil. The base oils are mixed in carefully measured proportions with the
necessary additives.
Additives
The additives are chemicals, which are frequently mixed with base oil (Le. Petroleum or Synthetic oils) to improve
or to modify certain properties relating to performance. Their concentrations in finished lubricants may vary
widely, from only a few parts per million to appreciable percentage.
The following types of additives are generally mixed with lubricating oils to improve their properties
 Antioxidants
 Detergents
 Anti-wear
 Metal deactivators.
 Corrosion inhibitors, Rust inhibitors
 Friction modifiers
 Anti-foaming agents
 Viscosity index improvers
 Demulsifying/Emulsifying
 Stickiness improver,
 Pour point depressants
 Complexing agent (in case of greases)
Dosages of additives
The additives are laboratory chemical compounds used in dosages from under 1 to 33 % depending on the
application. The dosages of different lubricating oils are as follows
1) Industrial lubricants: 0.5 – 2 wt. %
2) Tractor, hydraulic and gear oil: 4 – 7 wt. %
3) Automotive engine oil: 3-16 wt. %
4) Zn free rail road oil: 7 – 20 wt. %
5) Marine cylinder oil: 10 – 30 wt%
Properties of Lubricating Oils
Lubricating oils must retain their properties within the range of operating conditions. Important properties of
lubricating oils are as below:
1) Lubricity
It is the term used to describe the lubricant's "oiliness", if two lubricants of same viscosity are used in the same
application and one cause a better reduction in friction than the other, it is said to have a better lubricity.
2) Color
The color of lubricating oil can range from practically clear to very dark green or black.[color change by oxidation,
deposits and contamination and increase oil temperature to color dark.]
3) Specific Gravity
Specific gravity is the ratio of the density of lube oil to the density of water at the same temperature The normal
𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑙𝑢𝑏𝑒 𝑜𝑖𝑙
lubricating oils have specific gravity values of 0.85 0.95. 𝑆𝐺 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟
4) Pour Point
As the temperature drops, the oil becomes thicker. The temperature at which oil has become thick that it can no
longer be poured out is called the "Pour point". With mineral oils this varies from 0°C to approx. - 35 0C depending
on the type. Naphthalene is used as a pour point improver. [at temp lute on stops its flow.]
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 5) Flash Point
The flash point of oil is the minimum temperature at which the vapor of oil will momentarily ignite (flash) in the
presence of a fire sourse.Once the source is removed, the flash will self-extinguish
Example. Flash point of industrial gear oil, Castrol Alpha ZN 220 is 210°C.
6) Viscosity
It is the most important property of lubricating oil. It is simply stated, the resistant to flow of an oil. This resistance
is determined by the amount of friction between the fluid particles. High viscosity, higher the resistant to flow.
Low viscosity, lower the resistant to flow. Viscosity changes with the temperature and therefore, its measurement
is always related to temperature. When the temperature increase then viscosity decreases. When the temperature
decrease then viscosity increase.
Industrial purpose, kinematic viscosity of liquid oil is generally measured by the time taken for the flow of a
certain volume of oil under gravity, at a fixed temperature through a calibrated glass capillary viscometer. It is
more usually expressed in mm³/Sec or Centistokes (cSt), 1 mm2/sec = 1cSt
7) Viscosity Index
Viscosity Index (VI) is an empirical system for expressing the ratio of change of viscosity of oil with change in
temperature. The higher the value of viscosity index, less the change of viscosity with temperature.So, all of high
viscosity index is always preferable. The VI generally les between 0 and 100.Example: VI of industrial gear oil,
Castrol Alpha ZN 220 is 95.
8) Aging
Mineral oils are inclined by nature to oxidize in the presence of air (Oxygen) and temperature. The oxygen in the
air will combine with the oil so that the oil degrades or "ages" and may even become unserviceable. Lubricating
oil does not oxidize much below 1000C.Metals such as copper, lead and iron speed up oxidation of oil
(Catalytically).
9) Foaming
Foaming is a mixture of oil and air and consists of air bubbles surrounded by a thin film of oil in practice
machinery breakdown owing to excessive foaming, because of air in the oil. All engine oils and many circulating
oils therefore contain an anti-foaming additive, which quickly breaks down any foam that may form.
10) Demulsification
The Demulsification of oil means the resistance of the oil to mixing with water, Some oils, such as turbine and
hydraulic oils must have good demulsifying properties because lubrication will otherwise be jeopardized.
11) Total Base Number(TBN):
TBN is an indication of the amount of base reserve additive available to neutralize strong acids that are produced
as a byproduct of combustion.Without this base reserve ,strong acids accumulating inside the engine can result in
corrosive wear.When TBN is high,oil has higher alkaline reserve and can neutralize more acedic components.
 Improved acid neutralization
 Extended oil life
 Enhanced engine protection
 Suitable for heavy duty application
12) Total Acid Number
TAN is a measure of concentration of acidie's constituents in an oil. In used oil, an increase in TAN can be an
indication of oxidation and an increase in the level of degradation of oil. Along with Oxidation comes an increase
in viscosity.
TBN indicate how much bore reserve remains in the oil, TAN can provide a more complete picture of the actual
operating. conditions within your engine.TBN value for a new engine oil can range anywhere from about 6.0-
13.0 mgKOH/g. (miligram of potasium hydrobride (KOH) per gram oil.
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 13) Dynamic Viscosity Vs kinematic Viscosity
Dynamic: is measure fluid internal resistance to flow, i.e. how much force required to more one layer of fluid
relative to another layer at a certain velocity. It is ratio of applied Shear stress to rate of shear.
kinematic: ratio of dynamic viscosity to fluid density. It characteristic relative ease with which a fluid flow under
the influence a of gravity.
14) Octane number
The octane number is a rating system for gasoline that indicates its ability to resist knocking (also known as
detonation) in a spark-ignition (SI) engine. Knocking is a phenomenon that occurs when the air-fuel mixture in
the engine combusts too rapidly and uncontrolled, creating a pinging or knocking sound. This can damage the
engine and reduce its performance. Higher octane numbers indicate a greater resistance to knocking. Modern
gasoline typically has an octane rating of 87 to 93. Engines with higher compression ratios generally require
gasoline with higher octane ratings to avoid knocking.
15) Cetane number
Cetane number indicates the ignition quality of diesel fuel. It refers to the time it takes for the fuel to ignite after
it is injected into the engine cylinder. A higher cetane number indicates a fuel that ignites more quickly and
smoothly, leading to more complete combustion and less engine noise. Typical cetane numbers for diesel fuel
are between 40 and 55.
16) Aniline point
The aniline point is a property of a petroleum product that indicates the minimum temperature at which equal
volumes of aniline and the oil sample will mix and form a clear, single liquid phase. Aniline is a colorless organic
liquid used in the production of dyes, pharmaceuticals, and rubber chemicals.
17) Calorific value
The calorific value, also known as heating value, is the amount of heat generated by the complete combustion of
a unit quantity of a fuel or other material. It is typically measured in units of energy per unit mass. because it
determines the amount of heat energy that can be obtained from a given amount of fuel.
Fuels with higher calorific values are generally more desirable because they can provide more heat output for a
given quantity of fuel.
18) Smoke point
The smoke point is the temperature at which a cooking oil or fat starts to break down and visibly decompose,
producing a bluish smoke. When oil reaches its smoke point, it starts to lose its flavor and nutritional value, and
it can form harmful chemicals. oils with higher smoke points are better suited for high-heat cooking methods such
as frying and stir-frying.
Semisolid lubricant
Grease is called semisolid lubricant. It consists of-
1) Mineral oil or synthetic oil ( 75- 95% )
2) Thickening agent (4 - 20 %)
3) Additives (0 -5%)
Classification of grease
On the basis of soap skeleton, grease may be classified as-1) Calcium base grease. 2) Sodium base grease.
3)Lithium base grease. 4)Aluminum base grease.
Properties of grease
The chief properties of grease which predict the quality of grease are-1).Dropping point, 2).Consistency,
1. Dropping point : Dropping point of grease is the temperature at which first drop of oil falls from the
grease
2. Consistency: When the quantity of soap in the grease and the viscosity of the oil are changed the hardness
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or consistency of the grease also changes accordingly.

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Solid lubricant
Solid material employed to reduce friction and wear between two moving surfaces is called solid lubricant. It is
generally used for operating conditions of very high and very low temperature in a wide range, e.g. -200° C to
850° C. The solid lubricant may be used on their own or in Combination with oils and greases. Examples of solid
lubricants are Graphite, Molybdenum disulfide (Molykote), Boron nitride, Cadmium iodide, Borax etc.
Gaseous lubricant
Gaseous lubricants belong to the simplest and lowest viscosity lubricants known. They include air, nitrogen,
oxygen and helium and are applied in aerodynamic and aerostatic bearings. Gaseous lubricants can be applied at
very high and very low temperatures. Their chemical stability eliminates any risk of contamination of the bearings
by the lubricant. This is of importance for the machinery used in many branches of industry, primarily in the food,
pharmaceutical and electronic industries
ISO classification of industrial lubricating oil
The majority of industrial oils, for which viscosity is a significant criterion, are classified into 18 viscosity grades
according to ISO 3448. The grades are given below:
ISO Viscosity grade nos. Viscosity grade ranges, Cst at 40°C
Min. Viscosity Max. viscosity
2 1.98 2.42
3 2.88 3.52
5 4.14 5.06
7 6.12 7.48
10 9 11
15 13.5 16.5
22 19.8 24.2
32 28.8 35.2
46 41.4 50.6
68 61.2 74.8
100 90 110
150 135 165
220 196 242
320 288 352
460 414 506
680 612 748
1000 900 1100
1500 1350 1650
Lubrication systems
Lubrication systems for industrial applications provide the appropriate lubrication quantity at the correct intervals,
minimizing friction and wear and optimizing bearing and machinery service life.Lubrication systems are designed
to lubricate individual machines or complete plants Lubrication systems perform the task of supplying lubricants
in individual lube points or group of points with varying amounts of exactly metered lubricant from one central
location. Lubrication systems enhance the operating readiness and ide of your machines.
Lubrication systems have a range of benefits in the process
 Significant savings in repair and spare costs.
 Increased machine reliability.
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 Up to 50% savings in lubricant costs due to accurate timing and dosing of lubricants.
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 Fewer shutdowns and production losses.

  Reduced environmental impact.
 Greater workers' safety.
In a lubrication system:
 A lubricant is fed by a feed pump.
 A lubricant is distributed into the needed amount by distributors, dozers or feeders.
 The lubrication system is monitored and controlled by manitoring units, pressure and lubricant switches,
control units, etc.
 Fittings and accessories are completing the components of a lubrication system.
Lubrication system components
1. Pumps and pumping units
 Piston pumps
 Gear pumps
 Gerotor pumps.
 Vane pumps,
 Oil circulating pumps units.
2. MQL units
3. Oil+Air lubrication units
4. Lubricant distributors
5. Monitoring devices and switches
6. Control unit
Lubrication management tools
To evaluate the performance of lubricants or to design and plan lubrication activities there are some lubrication
management tools devices.
 Grease test kit: Portable grease analysis kit for field use.
 Oil check monitor: Detects changes in oil condition
 Oil storage station : Modernize your oil storage and handling practices.
 DialSet: Quick tool for re-lubrication calculation.
 Lubrication Planner: A Use friendly tool to administer your lubrication plan
 VisioLub: Productive maintenance software for chain lubrication systems.
Manual lubrication tools
A basic element of lubrication plans
The main pitfall of manual lubrication is ensuring accuracy and top cleanliness. The manual lubrication tools are designed
to help with the storage, handling, dosing and supplying of lubricants for machinery in a clean and easy way.
 Grease packer : To lubricate open bearings
 Grease guns :Easy grease filling.
 One hand Operated grease gun: Easy grease filing with one hand.
 Battery driven grease gun : Quick and easy grease filling and user friendly.
Grease filler pumps
 High quantity grease packer.
 Suitable for filling grease guns.
 Easy to install.
Grease pumps
 Meeting all lubricating grease needs.
 Manual and air-operated grease pumps are designed to empty lubricating grease drums
 Can be connected directly on the greasing points
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 Suitable for centralized lubricating grease systems.

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Easy to install.