7/21/2019 Right Use of Lubricants 20140525 http://slidepdf.com/reader/full/right-use-of-lubricants-20140525 1/91 Session Topic Best Practices in Maintenance Management for Process Industries Speaker : Designation : Organization : Right Use of Lubricants Hasmukh Gohel Consultant 27 May 2014 !eaker "ame 1
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• #hat is bloo$ to human bo$y% lubricant is to machine&• Lubrication is !robably not gi'en re(uire$ attention at !lant
le'el&• #e $e!loy best skills for maintenance% but !ut unskille$
!erson on
Lubrication )ob&• *t is not the costliest lubricant bur the right lubricant +ill
meet the re(uirement&• ,'ery ru!ee s!ent on lubricant im!ro'ement +ill return 10
times&• Lubrication im!ro'ement is e-!ress +ay to reliability&
• .,M/s recommen$ations are not al+ays correct&• .,M recommen$ation changes +ith $e'elo!ment in lube
el$&• est recommen$ation are a'ailable in bearing catalogues&• "o+ a $ays +e use mineralR. +ater% +hat about mc&• 3 $octor relies on !athological test of bloo$& o +e use oil
Lube .il are generally selecte$ base$ on.,M/s recommen$ations& #hen the .,M is
*n$ian% selection is easy% as theirrecommen$ations are *n$ian make lubes&#hen the .,M is foreign base$ +e ha'e torefer lube e(ui'alent charts& ome timeslube recommen$e$ by such .,M is not
a'ailable locally an$ +e ha'e to makecom!romises& #hen re!eate$ failure ofe(ui!ment is face$ the faile$ com!onentsare stu$ie$& 3n$ if the root cause of thefailure is attribute$ to lubricant& U!gra$ing
the lubricant is re(uire$& Generally this is$one in consultation +ith .,M& ue to$e'elo!ment in the el$ of lubricants "e+o!!ortunities are a'ailable& .ur basicre(uirement is to enhance the reliability% sobetter lubricants are use$&
C.riginal grease recommen$e$ by .,M% Molykot C 44&omegrease +as !rocure$ $uring !ro)ect stage& *n$ian make:olymol 44 +as selecte$ for im!ort substitution& =his grease+as turning into rubber like substance in the bearing% an$ noof failures +ere notice$% resulting into !lant s$& Later on *.C
make er'ogem H= grease +as use$ for this a!!lication& =hisgrease +as also not suitable& *t +as becoming charcoal likesubstance in the bearings&
Aaile$ bearings +ere stu$ie$ for failure !attern an$ it +asobser'e$ that the failure of the bearings +as $ue tolubrication failure&
"o+ by this time Ms o+ Corning ha$ set u! manufacturingfacility in *n$ia Molykot 44 grease +as !rocure$ an$ use$ inthe $rum $ryer bearings&=his is !robably +orst case oflubrication failure& *t ha$ coste$ com!any huge amount% at thesame time unsafe +orking of mech technicians& amage to
=his is a o!en gear $ri'e& aily in themorning% lube oil +as s!raye$ on the gears&Lube oil use$ Ser(os!stem *+," as !er
.,M recommen$ations&High +ear of the gears +as obser'e$& Gearsan$ !inions +ere $e'elo!e$ locally an$ +erere!lace$&
=his +as a case of intermittent lubrication%calling for using lubricant ha'ing stickiness!ro!erty& ince s!ee$ +as also lo+% *.Cmake Ser(oline -., lube oil +as !rocure$
an$ use$& ri'e become silent an$ +earre$uce$ consi$erably&
*n 33 !lant t+o nos +ashing mc areinstalle$ for remo'ing nitric aci$ from s!unto+& ;2 nos lo+er be'el gearbo-es areinstalle$ in each mc& !ee$ of the be'el
gear !air is about 10 to 1B R:M& uite lo+&.,M ha$ suggeste$ to use *. 6G 1B0 lubeoil for this a!!lication& o$y of this G +aschange$ from C* to % $ue to se'erecorrosion $ue to nitric aci$ s!illage on theseG& *ngress of nitric aci$ +as seen in thelube oil through sight glasses& ame +asarreste$& ubse(uently lube oil +as change$to *.C make er'osystem ;20 the thickest
.riginally Ms umitomo ha$ recommen$e$*. 6G 220 for cyclo $ri'e accor$ingly *.Cmake er'osystem 220 or H:CL make ,nklo220 +as use$& ome failure of eccentric
bearings +ere face$&Ms umitomo in their latest literature ha'erecommen$e$ er'omesh : 1B0 for in$oora!!lications an$ er'omesh : 220 forout$oor a!!lications& ince this lube oil has,: a$$iti'e eccentric bearing !erformanceshoul$ im!ro'e&
*.C make er'osystem E@ lube +asbeing use$ for this a!!lication&"ormally for turbines% turbine oils are
use$& Aor making turbine oils base oilis im!orte$ an$ it is grou!9**& etter(uality base oil% less o-i$ation% lessslu$ge formation etc& =urbine oil hasthe a$$iti'e +hich gi'es it +atersha$ing !ro!erty& #ater accumulate$$ue to steam ingress can be $raine$
,-tru$er is a single line criticale(ui!ment& ,-tru$er gearbo- is $ri'enby H= motor ha'ing no +are houses!are& *.C make er'ogem; grease isuse$ for lubrication of this motor&ase$ on recommen$ation of one'en$or% elco grease +as trie$ for this
motor& *t resulte$ in tem!erature shootu! of the bearings& er'ogem ; grease+as re'erte$ an$ !roblem resol'e$&
oli$ +aste incinerator +ascommissione$ in 17& #ithin Emonths the +orm +heel of the +orm
re$uction gearbo- use$ for rotation ofthe kiln faile$& .il +hen checke$ +ithngers a!!eare$ to be light& am!le+as teste$ in laboratory an$ it +as *.6G 100& *t +as conrme$ by thetechnician that he has use$ lighthy$raulic oil& H: make :arathan ,: ;20
Are(uent failure of bearings of thise(ui!ment is chronic !roblem for !lant&:lant +as using er'ogem H= grease an$
s!herical roller bearing +ith metal cage forthis a!!lication& .,M literature +as not 'eryclear on this& .ne le from Ms "=" +as$o+nloa$e$ from internet an$ they ha'e
Ms "e+ 3llanbarry make s!iral gearbo- isinstalle$ for this agitator& .,M hasrecommen$e$ er'o Cyclo C4E0 lube oil for
this gear bo-& =his is thick lubricant& !ecialgra$e so not easily a'ailable from *.C& =hisoil gets thicker like tar in the gearbo-$icult to $rain $uring short s$& *n
consultation +ith .,M as +ell as base$ onrecommen$ations for similar gearbo- ma$eby other .,M like Ms Ra$icon < Ms ,lecon%the lube oil is change$ to er'omesh :
Aour nos s!herical roller bearingssuitable for 'ibrating screena!!lications are installe$& *nitially
1B0 lube oil +as use$ since this +asa rotating loa$ a!!lication% the lube oil+as not suitable& Castrol make =ribollube oil +as also trie$& Ultimately thebearings +ere change$ to greaselubrication& "o+ Mobil make MobilthHC 220 grease ha'ing synthetic oil is
=here are three !oly reactor agitatorsinstalle$ in ,, !lant& *.C makeer'osystem ;20 lube oil is being use$for this gear bo-es& #hen re'ie+e$& *t
+as obser'e$ that .,M ha$recommen$e$ hell make =urbo 220lube oil for this a!!lication& =urbostan$s for turbine oil& ince +e $on/tha'e turbine oil +ith *. 6G 220'iscosity& *t +as $eci$e$ to useer'osystem 220 or ,nklo 220 for this
Aor our ol$ balers *.C make er'osystem 4E%E@% 100 lube oil is use$ as !er the oila'ailable at that time&
"o+ .il com!anies ha'e im!ro'e$ the lubeoil for hy$raulic systems& *t has bettera$$iti'es for +ear an$ o-i$ation& *t is kno+nas er'osystem HL: 4E% E@ < 100& *ts anti
o-i$ation !ro!erty is also better& "e+ baler!rocure$ for :R1 has er'osystem HL: 4Elube oil&
!herical roller bearings +ith a lubricationgroo'e an$ three lubrication holes in theouter ring shoul$ be oriente$ correctly +henmounting insi$e the machine& =his is toensure that there is a$e(uate amount oflubricant in the outer ring race+ay of thebearing& Make sure the lubrication hole isnot locate$ at the si- oIclock !osition
other+ise the lubricant +ill $rain out fromthe bearing an$ re$uce the le'el of lubricantinsi$e the bearing& =his ti! is 'ery im!ortantfor bearing lubrication +ith grease% oil s!ray
.ne of the more im!ortant an$ fre(uently botche$ com!onents of
the greasing strategy is relubrication 'olume& #hen aske$ ho+in$i'i$uals $etermine the amount of grease to a!!ly to a !articularcom!onent% a common res!onse is Jho+e'er much it takes&K =his
is ob'iously not a !recise metho$& =here are many acce!tablemetho$s for estimating the a!!ro!riate relubrication 'olume& 3
common metho$ is recommen$e$ by A% +here grease
re!lenishment 'olume is $ene$ by the follo+ing e(uation>'p ; ,",,+ < D < B
grease from the !lug& #i!e aroun$ greaseni!!le& :um! out an$ $iscar$ one stroke ofgrease& :ut the no88le on the grease ttingan$ slo+ly in)ect !ro!er amount of grease
strokes& to! if clean grease comes out& #ithe(ui!ment running allo+ grease to !urgeout of o!en !lug for 1B minutes& Re!lace!lug& #i!e out !lug an$ grease tting&Re!ort any abnormal noise&
necessitate an oil change> $egra$ation ofthe base oil% $e!letion of a$$iti'es an$contamination& ome of these con$itions canbe reme$iate$% yet others cannot&
=he most common ty!e of base oil failure islikely o-i$ation& #hen oil o-i$i8es% the!rimary by9!ro$ucts are aci$ an$ insolublematerials% +hich can lea$ to serious surface
$e!osits an$ corrosi'e +ear& =o a$$ress this!roblem% most lubricants are formulate$+ith antio-i$ants% but they $onIt last fore'er&
Like many lubricant a$$iti'es% o-i$ationinhibitors are use$ u! as they !erform theirinten$e$ function& .nce these a$$iti'es are
consume$% the base oil begins to o-i$i8eContaminants also cause signicant changesto the rate of o-i$ation% acting as catalystsfor the reaction or% in the case of air%!ro'i$ing one of the reagents&
3$$iti'e e!letion> 3lthough many a$$iti'essuch as antio-i$ants enhance the !ro!ertiesof the base oil% other a$$iti'es !erformfunctions the base oil cannot& 3nti9+ear%e-treme !ressure% $etergents an$$is!ersants are e-am!les of such a$$iti'es&,'en if a lubricantIs base oil is in goo$con$ition% the lubricant can no longer!erform all of its $uties +hen certain
Contamination> Many ty!es of contaminantscontribute to the $egra$ation of lubricating oils% butthatIs not the +orst of it& .f course% +e all kno+
that contaminants such as !articles are res!onsiblefor the ma)ority of mechanical +ear in manymachine com!onents& ecause of this% +e oftenchange oil before it fails% sim!ly to remo'e thecontamination&
Aor systems +ith no means of contaminationremo'al% such as mechanical lters% this is the only+ay to control contaminants an$ ensure !ro!erlubricating con$itions& Ho+e'er% changing oil toremo'e contamination +ill be only !artially
e?ecti'e% at best& #hen the oil is change$ in mostmachines% a signicant !ortion of the ol$contaminate$ oil is left behin$&