Lubrication Moves The World - mi-wea.org · The Practical Handbook of Machinery Lubrication: ... tings.com/Oil_Analysis_Basi c_Industrial_p/pol- ... Scheduling Grease & Oil Maintenance
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Lubrication Moves The WorldMaintenance & Lubrication For Water & Wastewater Personnel
Oil•Greasy, usually liquid, substances from plant, animal, or mineral sources that do not dissolve in water and are used as lubricants.
• Webster’s Dictionary
Oil
•Viscosity – Volatility - Toxicity
Oil•Viscosity
•Flow
•Temperature
•SAE•Multi-Grade
Cannon FenskeViscometer
Oil•Volatility
Oil•Toxicity
Oil•Mineral Based•Dinosaurs
•Synthetic•Laboratories
The Practical Handbook of Machinery Lubrication:http://store.noria.com/products/the-practical-handbook-of-machinery-lubrication-4th-edition
Oil•Mineral Based•Refined Crude•Additives
Fundamentals of oil refining:
http://www.machinerylubrication.com/Read/28960/mineral-oil-refining
Oil•Myth: All lubricating oils are the same.
• From hydraulic fluids to gear lubricants to motor oils, each lubricant, be it synthetic or mineral-based, is uniquely formulated for its application with a specific viscosity; additive package; physical, chemical, and performance properties; and regulatory requirements. Various products may or may not be compatible with each other
• Chris Kniestedt, Motion Industries
Oil•Myth: Tacky and stringy greases and oils offer better protection than non-tacky products.
• It’s important to understand that lubricants are only 20-microns thick (or less) at the point of contact.
• Film thickness is a function of the rated oil viscosity at operating temperature and speed,
• load has only a small effect.
• Tacky lubricants with higher percentages of thickener can actually cause problems at high operating speeds.
Oil•Mineral Based•Additives
Common Additives by Type of Machinery
Oil
•Synthetic•Polyalphaolefins (PAOs)•Polyalkaline glycols (PAGs or PGs)•Dibasic Acid Ester (Diester) •Polyol Ester
OilSynthetic Vs Conventional
•Viscosity•Lifespan•Cost
Oil•Changing
•Mixing
•Testing
Non-Engine, oil analysis kit, $22.53:
http://www.stainlesssteelfittings.com/Oil_Analysis_Basic_Industrial_p/pol-bia.htm?gclid=CKDUoZnQn8oCFQMMaQodJxsKrg
Example:Oil Analysis Report
Example:Oil Analysis Report
Filtering
•Change filters OFTEN
•Filter oil before use
Filtering•Filter oil before use
Filtering•Filter oil before use
•http://www.machinerylubrication.com/Read/28847/when-oil-filtered
Grease
Grease
•Mineral Based•Dinosaurs
•Synthetic•Laboratories
GreasePhysical Properties:
•Grease is expected to:
•Reduce friction and therefore wear.
•Provide corrosion protection.
•Seal bearings from water and contaminants.
•Resist leakage, dripping and throw-off.
GreasePhysical Properties:
•Grease is expected to:
•Resist change in structure or consistency during service.
•Maintain mobility under conditions of application.
•Be compatible with seals.
•Tolerate or repel moisture.• www.boucherandjones.com/grease.h
tm (Page saved as pdf in info pack)
GreaseWhat is extreme pressure grease?
•EP LITHIUM GREASE is multi-purpose extreme pressure grease made from lithium soap stock which imparts good high and low temperature characteristics and chemical stability.
GreaseWhat is extreme pressure grease?
“EP” refers to load capability, not pressure like in a canister or tank.
•The load carrying additives contain no environmentally undesirable lead or metals.
•www.lsc-online.com/extreme-pressure-lithium-grease/
Grease
•Mineral Based•Oil + Thickener•“Soap”
Grease
•Myth: If a little is good, more is better.
• Over-greasing of bearings is a major cause of failure. Seal failures and overheating are commonly caused by too much grease.
• Always check the O&M manual and err on the side of caution.
Examples of Over-greasing
Examples of Over-greasing
Grease
•Synthetic•Water
•Heat
•Pressure•Corrosion
Grease
•Synthetic grease advantages:•http://www.ehow.com/list_7434581_advantages-synthetic-grease.html
Mixing•Brands•Grades •Types
Myth:•Food Grade lubricants are never as good as Non-Food Grade lubricants.• Advances in base-oil technology and
additive chemistry have made Food Grade H1 products stronger than ever, particularly with synthetics. There are many applications where a correct, strong Food Grade H1 product will work as well as a non-Food Grade H2 mineral-oil-based equivalent.
Myth:• All products are compatible.
• Grease is formulated with various thickeners (lithium, lithium complex, aluminum complex, calcium, polyurea, bentone, and silica gel), which may or may not be compatible with each other.
• When changing grease, laboratory compatibility testing MUST be done.
• If incompatibility exists between old and new products, purge bearings before changing to the new one.
Scheduling Grease & Oil Maintenance
•O&M Manuals
Scheduling Grease & Oil Maintenance•Manufacturers Recommendations (Warranty)
Scheduling Grease & Oil Maintenance
•Lubrication Survey
Scheduling Grease & Oil Maintenance•Lubrication Survey
• Every piece of Equipment that gets lubrication
• Frequency of Lubrication for each asset
• Every type & quantity of lubrication used
• And more…
Scheduling Grease & Oil Maintenance•Observation & Experience
•Location•Temperature•Moisture•Calendar VS Hour Meter
The Missing Link in Reliability Lubrication Maintenance
http://www.machinerylubrication.com/Read/1126/reliability-lubrication-
maintenance
Observation & Experience
•Water
•Dust & Rust
•Paint
•Chemicals
•Other Stuff
CMMS•Computerized Maintenance Management System
• Documentation of work performed• Documents repairs & preventive maintenance• Excellent Planning Tool
•Database system tied to all equipment• Perfect tool for PM Work Orders• Perfect Tool for Lubrication Survey
Bearings
•Plain Bearings
•Rolling Element Bearings
Bearings•Plain
Bearings•Plain Bearings
Plain Bearings: Split Journal
Plain Bearings: Babbitted Bore
Bearings•Babbitt
• Like a lot of stuff, named after the guy who invented it…
Bearings•Rolling Element Bearings
Bearings•Conventional Ball Bearings
Bearings•Conventional Spherical Roller Bearings
•Thrust
Bearings
•ThrustBearings
Thrust
Bearings•Fluid Bearings• Hydrostatic• Hydrodynamic
•Fluid Bearings•Hydrostatic
•Fluid Bearings•Hydrodynamic
Bearings•Magnetic Bearings•Passive•Active
Earnshaw’s Theorem:
• Earnshaw's theorem states that a collection of point charges cannot be maintained in a stable stationary equilibrium configuration solely by the electrostatic interaction of the charges.
• Point charges – Magic electro-physics
• The hole in Earnshaw’s Theorem is the word “Stationary”
Active Magnetic Bearings
Bearings•Bearing failure causes and distribution
• Graphic Courtesy of LUBCON, GmBH
BearingGrease
•Adding•Mixing
BearingGrease
Adding:
•StoppedVs
•Moving
Automatic Grease Systems
Bearing
Grease
What are advantages of Automatic Lubrication?Reduces Repairs by increasing bearing life.
Prevents Waste of Lubricant by dispensing precise amounts.
Reduces Man-Hours by eliminating manual lubrication.
Eliminates Machine Downtime thereby increasing production.
Eliminates Product Spillage by controlling amount of lubricant to the bearing.
Reduces Energy requirements by increasing machine efficiency (lowers bearing friction).
Increases Machine Output by allowing faster speed in operation at machine.
Safety No climbing on or over the machinery. Also safe lubrication of bearings inaccessible due to
gas, fumes, or height.
Machine Tolerances are maintained longer by consistent automatic lubrication.
Better Housekeeping - A closed, sealed system eliminates spillage. Machines remain cleaner. No
spillage promotes safer environments for workers.
Reduces Rejects by maintaining closer bearing tolerances, which allow for closer product
tolerances.
Eliminates Bearing Contamination by supplying lubricant from a closed circuit. Most oilers do not
clean grease fittings before manually lubricating them.
Purges Bearings in intense dirty work environments. Automatic lubrication systems will purge or
flush bearings thus reducing bearing failures due to contamination.
Bottom Line Automatic Lubrication reduces manufacturing costs thereby allowing companies to
increase profits and remain competitive in the marketplace.
Promotes More Efficient Lubrication A). Lubricates while machine is running. B). Delivers the right
lubricant, in the right amount, at the right time.
To Bearing
To Bearing
To Bearing
PARALLEL
SYSTEM
Injector System
Orifice System
Filter
Check Valve
Fixed Orifice
Dual Line
System
To Bearing
To Bearing
To Bearing
SERIES
SYSTEM
Automatic Grease Systems
Manual Grease Systems
Bearing
Grease
Bearing
Grease
Manual Grease Systems
Zerk Fittings•What to look for:
Zerk Fittings•What to look for:
Zerk FittingsOscar U. Zerk applied for and was granted a patent in January 1929. As an employee of the AlemiteManufacturing Corporation, the patent was assigned to them. If you have ever heard them called “AlemiteFittings”, now you know why. Alemite already sold a form of ball check valves which would screw in as replacements for O.E.M. grease cups and marketed as upgrades.
Zerk's fitting was a big improvement, more forgiving of misaligned attachment and less vulnerable to dirt.
Many companies make these grease fittings in both Metric and English sizes.
Quantity isImportant
Bearing
Grease
The Formula:
•G = 0.114 x D x B
•Where G = the amount of grease in ounces
•D = the outer race diameter in inches
•B = the bearing width in inches
•Next, calibrate all grease guns and train the technicians on the proper procedures.
Get your grease gun(s) and a scale. Determine the weight in ounces per full stroke (shot).
Calculate the number of shots it takes to equal 1 ounce of grease. Permanently mark the grease gun(s).
Re-calibrate annually.
Calibration
Multiply the number of strokes per ounce times the number of ounces
required
Calculate
Discontinue greasing if you feel abnormal back pressure.
Always make sure exhaust ports are cleaned out from any debris or old, hard crust that could be blocking the passageway.
Tips to Control Overgreasing
Tips to Control Over-greasing:
Consider installing grease guns with pressure gauges, shut-off grease fittings or relief-type vent plugs.
Slowly pump grease into bearings every few seconds. Using a quick-lever action could cause seal damage and not allow the grease to distribute throughout the bearing correctly.
Check the O&M Manual to
confirm the bearings are re-greasable & due
for service.
Whenever possible, stop the
motor and lock out the
machine.
Find the Grease Zerkdesigned to accept the grease & clean it.
Find the vent point to allow the old grease
easy escape and remove
the plug.
Attach the grease gun and slowly
add the calculated volume.
Plug the vent, clean up, & return the machine to
service.
Procedure
Myth: Add Grease to a Noisy Bearing
Adding grease to a bearing that’s making
noise only provides temporary relief.
Noisy bearings should be closely monitored
and replaced as quickly as possible.
When a bearing is making noise, internal
damage has already occurred.
If the bearing continues to run
without being replaced, more internal
damage will occur and the potential
for failure is greatly increased.
Possible causes of noise are
spalling, false brinelling, frosting and
excessive thrust load.
Myth: Add Grease to a Noisy Bearing
Oil Bath Bearings
•Oil is generally used to lubricate rolling bearings when:• high speeds or operating temperatures
preclude the use of grease.• excessive heat has to be removed from
the bearing position.• adjacent components (gears etc.) are
lubricated with oil.
Oil Bath Bearing System
•Bearings are not flooded• Normal level is halfway up
the diameter of the lower rolling elements.
• Spherical, Cylindrical, Tapered Cylinder, etc.
Spalling•Spalling is when pieces break off of the bearing metal. The noise from spalling is a random, high-pitched sound. (Not Enough Lubricant)
False Brinelling
•False brinelling -elliptical wear marks in an axial direction at each ball position with a bright finish and sharp demarcation, often surrounded by a ring. (Vibration)
True Brinelling
•Dents in the race(s)
Frosting•Electrical discharges at 60Hz (millions per hour) arc between the internal surfaces and the bearing race becomes marked with pits known as frosting. (Bad Ground, VFD)
What to look for:
•O&M Manual•Sealed Bearings?•Grease Type?•Quantity
•Supply fitting
•Vent fitting
Power Transmission Devices
•Gearboxes
•Sprocket & Chain
•Sheaves & Belts
Gears & Gearboxes:
Spur Gears
Bevel Gears
Helical Gears
Hypoid Gears
Worm Gears
Gearboxes:
•Oil Level•Sight Glass•Reversing
Gearboxes:
•Oil Level• Ports top, middle, & bottom
• Fill through the top port until level reaches middle port
Gearboxes:
•Reversing• Input shaft can usually rotate
in either direction• Output shaft cannot be used
to drive worm shaft.Input
Gearboxes:
•Sight Glass•Many Designs•Potential Problems
Gearboxes:
•Sight Glass•Many Designs•Expensive Solutions
Gearboxes:
•Sight Glass•Many Designs•Potential Problems
Gearboxes:
•Sight Glass•Low Cost Solution
Gearboxes:•Myth: If a little is good,
more is better.• Overfilling gearboxes will also lead to
problems, including failed shaft seals or increased operating temperatures.
• A gearbox that has too much oil will have to work harder to move through the lubricant, subsequently generating more heat or churning the oil into foam.
Gearboxes:•Change Direction
• Right Angle Drives• Forward & Reverse• Input & Output Shafts
•Change Speed• Slower Output – Greater Torque• Faster Output – Reduced Torque• Gear Ratios
Gear Ratios•Big / Little = Fast / Slow
Chain & Sprockets
•Roller Chain
•Sprockets
•Lubrication
•Tension Adjustment
Chain & Sprockets
•1. Outer plate
•2. Inner plate
•3. Pin
•4. Bushing
•5. Roller
Chain & Sprockets
•Sprocket Wear
Chain & Sprockets
•Lubrication
Chain
•Proper Tension
Belts & Sheaves•Alignment
•Tension Adjustment
•Sheave Bearings
Motors & Couplings
•VFD Motors & Components
•Couplings
Motors & Couplings
•VFD Motors & Components
Motors & Couplings
•Couplings
Alignment•Wear•Vibration•Alignment Tools & Procedures
Alignment•Wear
Remember, all these types ofmisalignment are 3 dimensional,each illustration can be consideredeither a plan view or an elevation.
This represents misalignment in 3 dimensions. Both of these illustrations could be from the same situation
Elevation
Plan View
The shafts of the components will run along the “X” axis, parallel misalignment means shaft centerlines are parallel, but in different planes.
Parallel Centerlines, Different Planes
Angular misalignment means shaft centerlines are not parallel, and therefore coupling faces are not parallel.
Alignment•Wear
Alignment•Vibration
Soft Foot•When the foundation is out of plane OR the plane of all four motor feet do not match.
•Effects alignment process because vertical positions change each time bolts are tightened after corrections.
•Motor frame distorts each time bolts are tightened.
•Result is bearing misalignment – Vibration & Heat.
Soft Foot
Soft Foot•Check for & correct “Gross” Soft Foot
•Start with all the bolts loose
•If there are no shims under any feet, try to slip a 0.005” shim under each foot.
•If there are shims under the feet, check to see if any are loose.
Alignment
•Alignment Tools
Alignment•Alignment Tools
Review• Mineral Vs Synthetic, Mixing is bad
• Testing before changing is good, Contaminants bad
• PM Scheduling & CMMS
• Bearings & Drive Components
• Adding grease & Oil to rotating Equipment
• Alignment
Questions?Thank you for your participation!!!
www.mi-wea.org
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