Lubricants Base Oil
The general principles of lubricant base oil
Manufacturers use a series of steps to improve certain
desirable lubricant properties. These include:
Viscosity Index
Oxidation
Heat Resistance
Low Temperature Fluidity
Pumps & Compressors
Lubricants Base Oil
Starting from petroleum crude oil, the typical process
for making a lubricant base oil is the following:
Separation of lighter boiling materials such as
gasoline, jet fuel, diesel, etc.
Removal of impurities including aromatics and polar
compounds.
Distillation to give desired base oil viscosity grades.
Dewaxing to improve low temperature fluidity.
Finishing to improve oxidation and heat stability.
Pumps & Compressors
Lubricants Synthetics
Lube oils possessing a base oil that has been
manufactured from chemical constituents or by the
polymerization of hydrocarbons. The three most
common types of synthetic base oils are:
Polyalpholefins
Organic Esters
Polyglycols .
Pumps & Compressors
Lubricants Synthetics
Synthetic lubricants have several advantages over
conventional mineral oils:
excellent low temperature fluidity
low pour point
high natural viscosity index
excellent oxidation stability
high flash, fire, and auto-ignition points
low volatility
non-corrosive and non-toxic
Pumps & Compressors
Lubricating Oil
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Lubricant Additives
Detergents
These chemicals are usually metallic based, and are
designed to control deposits and keep engine
components clean. They are able to clean existing
deposits in the engine, as well as disperse insoluble
matter into the oil. Detergents control contamination
resulting from high temperature operation.
Dispersants
These are usually ashless organic chemicals, which
control contamination from low temperature
operation. Both detergents and dispersants attach
themselves to contaminant particles, and hold them
in suspension. The suspended particles are so finely
divided that they pass harmlessly between mating
surfaces and through oil filters. The contamination is
removed from the engine when the oil is changed.
Pumps & Compressors
Lubricant Additives
Oxidation Inhibitors
These agents reduce oxygen attack on the lubricating
base oil.
Corrosion Inhibitors
Acids are produced by the combustion process, and
when engine oil degrades with use. Unless rendered
harmless by the engine oil, the acids can cause rapid
deterioration of engine components. Corrosion
inhibitors protect non-ferrous metals by coating them
and forming a barrier between parts and their
environment.
Rust Inhibitors
Rust inhibitors protect iron/steel from oxygen attack,
by forming a protection screen over the surface of
the metals.
Pumps & Compressors
Lubricant Additives
Anti-Wear Agents
These agents prevent wear due to seizure or rubbing
surfaces. Compounds such a zinc dialkyt-dithiophosphate
break-down microscopic hot spots and form a chemical
filter which eliminates metal-to-metal contact.
Foam Depressants
Detergent and dispersant additives can facilitate
aeration of an oil which results in foaming. This can
reduce the lubricating ability of the oil, and interfere with
the pumping of the oil. A foam depressant controls this
tendency.
Pumps & Compressors
Lubricant Additives
Viscosity Index (VI) Improvers
VI improvers control the viscosity of multi-grade oils.
They are polymers which act like "popcorn". At low
temperatures, they are "tight-balls" which do not
significantly increase the oils resistance to flow.
However, at high temperatures, these "tight balls"
explode into long chain polymers, which interweave and
increases the oil's resistance to flow(viscosity). The
tendency of an oil to "thin" at high temperatures is
controlled and reduced.
Pour Point Depressants
<PBase oils contain hydrocarbons that tend to crystallize
into waxy material at low temperatures. Incorporation of
a chemical which reduces the size of wax crystal
formation can give an oil better low temperature fluidity.
Pumps & Compressors
Oil Applications
Concrete Form Oil
Lubricants which are formulated to provide a clean,
quick release of the plywood, metal, or plastic forms
from concrete after setting. Usually available in a light
viscosity to accommodate spraying of the lubricant on
the forms.
Cutting Oils
The main functions of a cutting oil are to lubricate or
reduce friction between the tool and the work-piece,
and to act as a coolant by rapidly removing heat
generated at the tool-work-piece interface.
Soluble cutting oils are mixed with water in proportions
of 3 to10%. They are used where rapid heat removal is
a major requirement. Usually formulated with
emulsifiers, rust inhibitors, and EP additives.
Insoluble cutting oils are used in operations involving
tough cutting such as tapping, threading, and
broaching. Lubricity and anti-weld characteristics are
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important characteristics
of this cutting oil.
10
Oil Applications
Chain Oil
These oils are formulated to lubricate saw chains, and
should provide the following benefits:
An unbroken film of lubricant between chain links and
bars.
Anti-wear characteristics to prevent chain and bar wear.
Chain oil should have throw-off resistance. Classified as
"tacky".
Prevent corrosion of the chain.
Tip! The winter grade may be used as an air filter coating
where a tacky product is required for dust removal.
Pumps & Compressors
11
Oil Applications
Hydraulic Oil
Hydraulic systems provide a means to transfer power
where gears are impractical. A typical system includes
a reservoir for the hydraulic fluid, a pump, transfer
hoses, and return hoses to the reservoir.
The important characteristics of a hydraulic fluid are:
Thermal stability
Corrosion protection
Anti-wear properties
Anti-foaming properties
The oil is available in different viscosity grades to
accommodate a variety of ambient operating
temperatures.
Pumps & Compressors
12
Oil Applications
Compressor and Engine Oil
Oils which are formulated for use in reciprocating and
rotary air compressors and gas engines. Available in
different viscosity grades for use in different ambient
temperature ranges.
Heat Transfer Fluids
A lubricant used as a heat transfer medium in
applications such as:
Plastic extrusion machines.
Textile dryers.
Die casting.
Some high quality heat transfer fluids can provide clean,
odourless operation up to temperatures of 326C.
Pumps & Compressors
13
Oil Applications
Industrial Gear Lubricants
These oils provide protection to different types of
industrial gears which are often operated under high
contact pressures, and intermittent shock-loading. Gear
lubricants often contain an EP (ExtremePressure)
Additive.
A wide variety of ISO viscosity grades are available.
Refrigeration Lubricant
This lubricant is used in commercial refrigeration
compressor systems.
This oil is available in two formulations:
For use in CFC (chlorinated fluorocarbon) systems.
For use in ammonia refrigeration systems.
Pumps & Compressors
14
Greases
Grease can be defined as a solid to semi-solid material
produced by the dispersion of a thickening agent in a
liquid lubricant. Other ingredients may be included to
impart special properties to the grease.
Thickener Lubricating Oil
5 - 20%
75 - 95%
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Additive
s
0-15%
15
Greases
Thickener Lubricating Oil
5 - 20%
A complex grease is similar to a regular grease except
that the thickener contains two dissimilar fatty acids,
one of which is the complex agent. This results in good
high temperature characteristics to the final product.
Lubricating Oil
0-15%
Complex Grease
75 - 95%
Additive
s
Because of the high percentage of oil by weight in
grease, the oil must be of high quality and the proper
viscosity. Light viscosity oils are used for low
temperature, low load, and high speed applications.
Conversely, a heavy viscosity oil is generally used for
high temperature, high load, and slow speed application.
Additives
The most common additives found in grease are as
follows:
Oxidation Inhibitors
EPA Agents
Anti-Corrosion Agents
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Anti-Wear Agents
16
Grease Characteristics
The most important factors affecting the properties
and characteristics of a grease are:
Amount and type of thickener
Oil viscosity and physical characteristics
Additives
A grease is expected to:
Reduce friction and wear
Provide corrosion protection
Seal bearings from water and contaminants
Resist leakage, dripping, and throw-off
Be compatible with seals
Repel moisture
Pumps & Compressors
17
Grease Definitions
Consistency-is the degree of hardness of a grease and
may vary considerably with temperature. This has been
classified by the National Lubricating Grease Institute
(N.L.G.I.)into the following categories:
N.L.G.I. GRADE
PENETRATION @ 25c(1/10th mm)
000
445-475
00
400- 30
355-385
310-340
265-295
220-250
175-205
130-160
Pumps & Compressors
85-115
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Grease Definitions
Shear Stability
is the ability of a grease to resist a change in
consistency during mechanical working. Under high
rates of shear, grease structures tend to change in
consistency.
Oil Separation
is the percentage of oil which separates from the
grease under storage conditions. It cannot predict
separation tendencies in use under dynamic
conditions
High Temperature Stability
is the ability of a grease to retain its consistency,
structure, and performance at temperatures in
excess of 125ree;C
Pumps & Compressors
19
Grease Selection
Calcium
Comple
x
Barium
Comple
x
Lithium
Comple
x
Polyurea
Synthetic
Bentone
Clay
Properties
Calcium
Lithium
Sodium
Aluminum
Complex
Dropping
Point C
80-100
175-205
170-200
260+
260+
200+
260+
250+
None
Max
TempC
65
125
125
150
150
150
160
150
150
High Temp
Use
V.Good
Good
Good
Exc
Exc
Good
Exc
Exc
Exc
Low Temp
Mobility
Fair
Good
Poor
Good
Fair
Poor
Good
Good
Good
Mech.
Stability
Fair
Good
Fair
Exc
Good
Fair
Exc
Good
Fair
Water
Resistance
Exc
Good
Poor
Exc
Exc
Exc
Exc
Exc
Fair
Oxidation
Stability
Poor
Good
Good
Exc
Exc
Poor
Good
Exc
Good
Texture
Smooth
Smooth
Smooth
Smooth
Smooth
Fibrous
Smooth
Smooth
Smooth
Pumps & Compressors
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Lubricant Shelf Life
As a general rule, the simpler the oil formulation, the longer
the shelf life. The following is a guideline under protected
conditions:
Product
Shelf Life
Base Oils, Process Oils
Three(3) years
Hydraulic Oils, Compressor Oils,
General Purpose Lubricating Oils
Two(2) years
Engine Oils and Transmission Oils
Three(3) years
Industrial and Automotive Gear Oils
Two(2) years
Metal Working and Cutting Oils
One(1) year
Greases
Two(2) years
Pumps & Compressors
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Lubricant Shelf Life
The following are signs of storage instability in a
lubricant:
Settling out of the additives as a gel or sticky liquid
Floc or haze
Precipitates/solid material
Color change or haziness
Water contamination in a lubricant can be detected by a
"milky" appearance of the product.
A sign of grease deterioration is the separation of the
liquid oil from the solid grease.
Pumps & Compressors
22
Greases
Grease can be defined as a solid to semisolid material produced by the dispersion of
a thickening agent in a liquid lubricant. Other
ingredients may be included to impart
special properties to the grease.
Thickener Lubricating Oil
5 - 20%
75 - 95%
Additive
s
0-15%
Greases
Complex Grease
A complex grease is similar to a regular grease except that the
thickener contains two dissimilar fatty acids, one of which is the
complex agent. This results in good high temperature characteristics
to the final product.
Lubricating Oil
Because of the high percentage of oil by weight in grease, the oil
must be of high quality and the proper viscosity. Light viscosity oils
are used for low temperature, low load, and high speed applications.
Conversely, a heavy viscosity oil is generally used for high
temperature, high load, and slow speed application.
Additives
The most common additives found in grease are as follows:
Oxidation Inhibitors
Additive
EPA Agents
Thickener
Lubricating
Oil
Anti-Corrosion Agents
s
Anti-Wear Agents
5 - 20%
Pumps & Compressors
75 - 95%
0-15%
24
Grease Characteristics
The most important factors affecting the properties and
characteristics of a grease are:
Amount and type of thickener
Oil viscosity and physical characteristics
Additives
A grease is expected to:
Reduce friction and wear
Provide corrosion protection
Seal bearings from water and contaminants
Resist leakage, dripping, and throw-off
Be compatible with seals
Repel moisture
Pumps & Compressors
25
Grease Definitions
Consistency-is the degree of hardness of a grease and may vary
considerably with temperature. This has been classified by the
National Lubricating Grease Institute (N.L.G.I.)into the following
categories:
N.L.G.I. GRADE
PENETRATION @ 25c(1/10th mm)
000
445-475
00
400- 30
355-385
310-340
265-295
220-250
175-205
130-160
85-115
Pumps & Compressors
26
Grease Definitions
Shear Stability
is the ability of a grease to resist a change in consistency
during mechanical working. Under high rates of shear,
grease structures tend to change in consistency.
Oil Separation
is the percentage of oil which separates from the grease
under storage conditions. It cannot predict separation
tendencies in use under dynamic conditions
High Temperature Stability
is the ability of a grease to retain its consistency, structure,
and performance at temperatures in excess of 125ree;C
Pumps & Compressors
27
Grease Selection
Calcium
Comple
x
Barium
Comple
x
Lithium
Comple
x
Polyurea
Synthetic
Bentone
Clay
Properties
Calcium
Lithium
Sodium
Aluminum
Complex
Dropping
Point C
80-100
175-205
170-200
260+
260+
200+
260+
250+
None
Max
TempC
65
125
125
150
150
150
160
150
150
High Temp
Use
V.Good
Good
Good
Exc
Exc
Good
Exc
Exc
Exc
Low Temp
Mobility
Fair
Good
Poor
Good
Fair
Poor
Good
Good
Good
Mech.
Stability
Fair
Good
Fair
Exc
Good
Fair
Exc
Good
Fair
Water
Resistance
Exc
Good
Poor
Exc
Exc
Exc
Exc
Exc
Fair
Oxidation
Stability
Poor
Good
Good
Exc
Exc
Poor
Good
Exc
Good
Texture
Smooth
Smooth
Smooth
Smooth
Smooth
Fibrous
Smooth
Smooth
Smooth
Pumps & Compressors
28
Lubricant Shelf Life
As a general rule, the simpler the oil formulation, the longer the shelf
life. The following is a guideline under protected conditions:
Product
Shelf Life
Base Oils, Process Oils
Three(3) years
Hydraulic Oils, Compressor Oils,
General Purpose Lubricating Oils
Two(2) years
Engine Oils and Transmission Oils
Three(3) years
Industrial and Automotive Gear Oils
Two(2) years
Metal Working and Cutting Oils
One(1) year
Greases
Two(2) years
Pumps & Compressors
29
Lubricant Shelf Life
The following are signs of storage instability in a lubricant:
Settling out of the additives as a gel or sticky liquid
Floc or haze
Precipitates/solid material
Color change or haziness
Water contamination in a lubricant can be detected by a "milky"
appearance of the product.
A sign of grease deterioration is the separation of the liquid oil
from the solid grease.
Pumps & Compressors
30
Why is greasing important
It is estimated that 95% of all bearing failures are
premature.
Bearing failure can lead to costly down-time
The oil gradually oxidizes or is lost to
evaporation or leakage
The grease may wash away or migrate away
from the moving parts
Grease must be periodically replenished to
assure proper bearing lubrication
Pumps & Compressors
31
Establishing an Effective Greasing
Program
1.
Evaluate current practices
2. Establish common procedure
3. Provide training
Pumps & Compressors
32
1. Evaluate Current Practices
Current cost of motor/pump repair
Available manpower and training
Current procedures and scheduling program
Grease gun practices
Persons assigned to regreasing activity
Safety
Pumps & Compressors
33
Risks of changing a current program
If too much grease is added to motors that have not
been greased for years motor failure rate may go up
initially
Grease that has hardened may form a plug that prevents the
new grease from purging
Rolling contact elements may skid and cause premature
failure
Temperatures may rise because the bearing is overfilled
Rust from the grease tube may be forced into the bearing
Training is required to institute a new program
properly
Pumps & Compressors
34
2. Establish a Common Procedure
Evaluate
OEM recommendations for the motors in
the plant
Consider motor configuration and operating
conditions
Establish frequency guidelines
Standardize on regreasing amounts
Publish a standard of practice
Provide training
Pumps & Compressors
35
Motor OEM Recommendations
Pumps & Compressors
36
Frequency common guidelines
Pumps & Compressors
37
Regreasing Intervals Based on EPRI
NP-7502
Based on proven, documented performance
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38
The right amount
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39
Effect of grease amount on
bearing temperature
Pumps & Compressors
40
EASA Guidelines
Pumps & Compressors
41
Grease Amount
Based
on
consolidated OEM
recommendations for
horizontal motors
Pumps & Compressors
42
Suggested Procedure for Initial
Greasing of Motors
If motor is disassembled
1. Hand pack the bearing. Fill end bell approximately 30% full. Pipe
leading to bearing should be full of grease to prevent rust. Assemble
the motor. At start-up, operate motor for at least 15 minutes with
drain plug open to expel excess grease.
If motor is assembled
1. Wipe the grease nipple clean and inspect. Replace if needed.
2. Remove the drain plug and install grease relief valve if not
already equipped
3. With a hand-operated grease gun, pump grease into the cavity
until new grease comes out the drain or relief fitting.
4. Operate the motor for 15 minutes to expel excess grease.
5. Replace plug.
Pumps & Compressors
43
Motor Greasing Procedure
Install grease cartridge in designated grease gun
Remove grease plug, if accessible; Check that relief
fitting moves freely
If motor is stopped, remove any hardened grease from
the plug area.
Wipe around grease fitting with clean rag.
Pump out and discard one stroke of grease
Place nozzle of gun onto the fitting and SLOWLY inject
the proper number of full strokes
Pumps & Compressors
44
Motor Greasing Procedure Continued
STOP if high resistance is detected.
STOP if clean grease is observed coming out of seal, drain, fitting or
relief plug.
With motor running, allow grease to purge out of the open plug for at
least 15 minutes.
Check for water or rust in "old" lubricant.
Replace plug.
Wipe fitting and plug area clean. Cover fitting with a clean plastic
cover
Report unusual noise, odor, temperature, vibration, visible
contamination, caked grease or other unusual conditions
Pumps & Compressors
45
3. Provide Training
Training is essential to the
success of a new greasing
program
Training explains why it is
important to put the right amount
of the right grease in the right
place at the right time
Training should also emphasize
how to minimize contamination
and improve equipment reliability
Pumps & Compressors
46
Grease Relief Valves
Grease relief valves may
minimize risk of gross overlubrication
Small spring-loaded relief opens
with positive grease pressure
Excess grease vents out relief
Many bearings have
removable plugs near the
bottom of the housing
Best greasing procedure is to
remove the plug, then add
grease and allow to run for 30
minutes, then replace the plug
Pumps & Compressors
47
Industry Best Practice
Prefill filler pipes and lines with
grease to prevent emptying
lubricator and protect against
rust
Industry best practice is to write
the expiration date on the
lubricator
Check periodically that grease
level is going down as
expected
Color coded grease cartridges
and covers Minimizes chance
of mixing incompatible greases
Pumps & Compressors
48
Feedback Tools for RightQuantity Greasing
Temp
Vibe
G2224
Ref: CSI/COG/KBrown
Pumps & Compressors
49
Sonic/Ultrasonic
Lubrication Monitoring
Pumps & Compressors
50
Lubrication and Bearing
Problems Wrap Up
Types
and applications of lubricants
Pad Bearings
Plain Bearings
Rolling Element Bearings
Pumps & Compressors
51
