Lubrication Fundamentals

& Applications
Dr Mostafa Abdelkhalek
Ain Shams University, Faculty
of Engineering


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Lubrication Principles
Friction

1- Sliding friction
2- Rolling friction

Lubrication Principles
Wear

Wear is defined as the progressive

damage resulting in material loss due
to relative contact between adjacent
working parts.

Lubrication Principles
Surface damage can be classified as
follows
1- Surface damage without exchange of
material
2- Surface damage with loss of material
3- Surface damage with gain of material

Lubrication Principles
Wear may also be classified
1- mild
2-severe

Lubrication Principles
Types of wear
1- Abrasive wear
2- Adhesive wear
3- Pitting wear.
4- Corrosive wear.


-1
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-3 .
-4
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-5


* :
-3
-1 -2


Viscosity
.1
Flash point
.2
Pour Point
.3
.4 ANTI - RUST
.5 ANTI - OXIDANCY
.6 ANTI - FOAM
.7 THERMAL STABILITY
.8 ALKALINITY
.9 ANTI - WEAR
.10 DISPERANCY
.11 DETERGENCY
.12


Anti - Oxid

: Anti - Rust

.


: Anti - Foam


( 70 / ) .


: Anti Wear
Grinard
Compounds :
- ( Zinc Dialkyl )ZDDP
. Dithophosphate
- ( Zinc Diaryi )ZRDP
. Dithophosphate


: Detertgent Properties



Detertgent

.


:
Disperancy Properites




.



:
-1 .
-2
.
-3 .
-4 .
-5 .


* -:
-1
-2
-3 Mineral oils
-4 synthetic oils

Paraffinic oils
Excellent stability (higher resistance to
oxidation).
Higher pour point.
Higher viscosity index.
Low volatility and, consequently, high flash
points.
Low specific gravities.

Naphthenic oils.

Good stability.
Lower pour point due to absence of wax.
Lower viscosity indexes.
Higher volatility (lower flash point).
Higher specific gravities.


-1

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%4.0

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%0.7
%4.7

 Saybolt Universal Viscosity (SUV) or

Saybolt Universal Seconds, (SUS)
the time in seconds required for 60 cubic
centimeters of a fluid to flow through the
orifice of the Standard Saybolt Universal
Viscometer at a given temperature under
specified conditions .

 D892-06 Standard Test Method for

Foaming Characteristics of Lubricating
Oils
D1401-02 Standard Test Method for
Water Separability of Petroleum Oils
and Synthetic Fluids


The viscosity of gas turbine oil is usually
between 2.5 - 30 cSt @ 40C .
Gas turbines operate on a family of
lubricating oils known as R&O oils
(Rust & Oxidation inhibited oil).


Gas turbine sump capacities can range in
size from 1,000 to 20,000 gallons, which
drives the economic incentive for a longlife lubricating oil.
Low turbine oil makeup rates
(approximately five percent per year) also
contribute to the need for high-quality,
long-life lubricants.


Without significant oil contamination
issues, turbine oil life is primarily dictated
by oxidation stability. Oxidation stability is
adversely affected by heat, water aeration
and particulate contamination.


Antioxidants, rust inhibitors and
demulsibility additives are blended with
premium quality base stock oil to extend
oil life.


Lube oil coolers, water removal systems
and filters are installed in turbine
lubrication systems for the same purpose .


Unlike most gasoline and diesel engine oil
applications, turbine oil is formulated to
shed water and allow solid particles to
settle where they can be removed through
sump drains or kidney loop filtration
systems during operation.


ASTM D2272 (Rotation Pressure Vessel
Oxidation Test) and TOST - ASTM D943
(Turbine Oil Oxidation Stability)
performance to meet these higher
operating temperatures .


To aid in contaminant separation, most
turbine oils are not additized with high
levels of detergents or dispersants that
clean and carry away contaminants.
Turbine oils are not exposed to fuel or soot
and therefore do not need to be drained
and replaced on a frequent basis .

Turbine Lube Oil System

Flushing

labyrinth seals

Modern Compressor Seal

Configurations

Modern Compressor Seal

Configurations

Modern Compressor Seal

Configurations

Compressor Lubricants
Premium-grade ISO VG 32 turbine oils are
used more often than the heavier viscosity
grades.
The typical viscosity index is 97, with a
pour point around -37C (-35F).
Oxidation stability (per ASTM D943)
should exceed 5,000 hours and the flash
point (per ASTM D92, COC) should be
206C, or 403F.

High-pressure Service, Forgedsteel, Double-acting Cylinder

Pair of Rotors from a Screw

Compressor

Compressor Lubricants
lubricants must provide the following:
1. Long life without need for change out
2. Prevention of acidity, sludge, deposit formation
3. Excellent protection against rust and corrosion,
even during shutdown
4. Good demulsibility to shed water that enters
the lubrication system
5. Easy filterability without additive depletion
6. Good foam control

Reciprocating Compressors
Proper lubrication includes
Selection of a high quality lubricant suited
for the particular service conditions
Cleanliness in storage.
Application of correct quantities in a
manner that permits effective
performance.

Reciprocating Compressors
Proper lubrication will lead to:
Reduced wear rates of sensitive and
critical parts
Avoidance of failure and malfunction
Reduced cost of system downtime, spare
parts, new oil, and labor for repair
Minimum power consumption

Reciprocating Compressors
A lubricant is expected to
Separate rubbing parts
Dissipate frictional heat through cooling and heat
transfer
Flush away entering dirt as well as debris
Minimize wear
Reduce friction loss and power required
Reduce gas leakage
Protect parts from corrosion
Minimize deposits

Reciprocating Compressors

Reciprocating Compressors
Full Pressure Circulation Lubrication .1

In this system, a positive displacement pump

draws oil from the reservoir and delivers it under
pressure to the main bearings and to the crankpin
bearings, and hence to the crosshead pin bearings
and crossheads.
On larger machines where large quantities of oil
are being circulated, oil coolers are provided.
Oil pressure safety devices are incorporated in the
system to shut the compressor down in the event
of oil pressure failure.

Reciprocating Compressors

Reciprocating Compressors

Reciprocating Compressors
FACTORS
AFFECTING
LUBRICATION
1- Viscosity
2- Film strength
3- Oxidation
4- Water

BEARING

Reciprocating Compressors
CYLINDER AND PACKING LUBRICATION
The lubrication system for compressor
cylinders and packing must be able to reliably
deliver relatively small amounts of oil at
higher pressures in order to lubricate the
wearing surfaces of cylinders and piston rods.
Excessive oil volumes can cause fouling of
valves, gumming of the packing, and
accumulation in the downstream piping
system.

Reciprocating Compressors
To effectively troubleshoot poorly performing
compressors , follow these steps:
1- Clearly define the problem based on observations and accumulated
information.
2- Review available historical system operation.
3- Identify and obtain any additional information and analysis that may
be required.
4- Identify and list potential root causes and consider each.
5- Deduce the root cause based on the accumulated information.
6- Execute corrective action.

Reciprocating Compressors
Excessive Carbon on Valves
1- Excessive lube oil
2- Improper lube oil (too light)
3- Oil carryover from inlet system or previous
stage.

Reciprocating Compressors
Low Oil Pressure
1. Low oil level
2. Dirty filter strainer
3. Defective pump or relief valve
4. Relief valve on header faulty
5. Worn bearings or excessive clearance
6. Low oil viscosity
7. High oil temperature

Reciprocating Compressors
High Oil Pressure
1.Relief valve in header faulty
2.Restriction in oil line
3.Improper grade of oil
4.Cold oil
5.Pressure regulating valve set too high

Reciprocating Compressors
Excessive Oil Consumption
1.Oil level too high in crankcase
2.Oil is too light
3.The oil pressure may be too high
4.Piston rings and cylinder are worn

Reciprocating Compressors

Force-Feed Lubricator
Incorrect Delivery of Lubricator
1. Feeds not vented of air
2. Low oil level
3. Plugged vent in lubricator reservoir
4. Oil check valve on cylinder faulty
5. Line leaking
6. Incorrect adjustment of pump stroke
7. Leak in line or fitting

Hydraulic Fluids

1.
2.
3.
4.

Purpose of Hydraulic Fluids

Power transmission
Lubrication.
Sealing
Cooling.

Hydraulic Fluids
Physical Characteristics
1. Viscosity.
2. Compressibility.
3. Stability
mechanical stress and cavitation, which can
break down the viscosity improvers and
cause reduced viscosity

Hydraulic Fluids

1.
2.
3.
4.

Oxidation stability
Temperature.
Pressure.
Contaminants.
Water and metal.

Hydraulic Fluids
Use of Additives

Hydraulic Fluids
Types of Hydraulic Fluids
1. Petroleum.
2. Fire resistant
a- Water-glycol.
b- Oil-in-water
c- Water-in-oil
d- Synthetic fire-resistant fluids

Determining Hydraulic Fluid

Viscosity Requirements

Determining Hydraulic Fluid

Viscosity Requirements

Determining Hydraulic Fluid

Viscosity Requirements

Functional properties of grease.

Functions as a sealant to minimize
leakage and to keep out contaminants.
Easier to contain than oil.
Holds solid lubricants in suspension.
Fluid level does not have to be
controlled and monitored

Disadvantages of grease
Poor cooling.
Resistance to motion.
More difficult to handle than oil for
dispensing, draining, and refilling.

Grease Characteristics
Apparent viscosity

Grease Characteristics
Bleeding, migration, syneresis
Bleeding is a condition when the liquid lubricant
separates from the thickener.
Migration is a form of bleeding that occurs when
oil in a grease migrates out of the thickener
network under certain circumstances.
Syneresis is a special form of bleeding caused
by shrinking or rearrangement of the structure
due to physical or chemical changes in the
thickener

Grease Characteristics
Consistency, penetration, and National
Lubricating Grease Institute (NLGI)
numbers
The measure of consistency is called
penetration.

Grease Characteristics

Grease Characteristics

Contaminants.
Corrosion- and rust-resistance.
Dropping point.
Evaporation.

Grease Characteristics

Fretting wear
Oxidation stability
Pumpability and slumpability
Shear stability
High-temperature effects
Low-temperature effects.

Types of Greases

Calcium grease.
Sodium grease.
Aluminum grease
Lithium grease.

Compounded Gear Oils

These lubricants have been used extensively in worm gears with great
success in a wide variety of applications.
Compounded gear oil is a mineral basestock with normal rust and oxidation
inhibitors that is blended with four to six percent acidless tallow or synthetic
fatty acid (the compounding agent).
The surface-active compounding agent gives these products excellent lubricity
and prevents sliding wear in worm gears.
Many OEMs recommend compounded gear oils.
Compounded oils were initially used as steam cylinder lubricants because of
their ability to adhere to cylinder walls in the presence of steam.
The temperature limitation of compounded oils is approximately 180F (82C).
Because compounded lubricants are difficult to use out of this temperature
range, they are often replaced with EP gear oils for consolidation purposes.

Most applications normally use an AGMA Class 7

or 8 compounded oil (ISO VG 460 and 680). In
some cases, an 8A (1000 VG) is used.
The viscosity selection depends on the worms
type, size, speed and operating temperature.
Refer to the OEM for specific viscosity
recommendations.
Typical commercial oils: Mobil 600W Cylinder and
Super Cylinder Oil, Texaco Vanguard 460 and
680, Exxon Cylesstic 460 and 680, and Chevron
Cylinder Oils 460 and 680.

 Extreme Pressure (EP) Gear Oils

EP mineral gear oils are used more extensively in worm gears.
Under conditions of high pressure and temperature, the EP
(antiscuff) additive reacts with the metal surface to form a soft,
slippery chemical layer which prevents severe wear and welding.
Previously, there was a concern that sulfur-phosphorous EP
additives would react with the bronze gear. However, new EP
additive technology used by most of the major lubricant suppliers
has reduced the corrosive attack by utilizing nonactive sulfur.
EP lubricants work particularly well when shock loading occurs.
EP gear oils also protect steel gears better than compounded gear
oils.

Typical recommendations are for both

AGMA 7 and 8 viscosity grades. Like
compounded gear oils, EP gear oils limit
operating temperatures to under 180F
(82C).
Typical commercial oils: Shell Omala,
Texaco Meropa, Exxon Spartan EP,
Mobilgear 634 and 636, and Chevron EP
Gear Oil.

Synthetic Worm Gear Oils

Two major types of synthetic gear oils have been used successfully in
challenging conditions with worm gears: polyalphaolefins and polyalkelene
glycols.
Polyalphaolefins (PAOs) are the most common type of synthetic lubricant.
They have good high and low temperature properties and are compatible
with most mineral oils. Unlike some synthetics, PAOs dont attack paints or
seals.
Most formulations contain a small amount of organic ester or antiwear
mineral that improves boundary lubrication conditions.
Products that contain EP additives are also available. There are no major
disadvantages, other than cost, when using PAOs as worm gear lubricants.
Typical commercial oils: Chevron Tegra, Texaco Pinnacle, Exxon Teresstic
SHP, Mobil SHC, Shell Hyperia and Royal Purple Synergy.

 Polyalkylene glycols (PAGs) are excellent for worm gear

applications. They possess superior lubricity properties and have
good low and high temperature properties.
The Viscosity Index of PAGs is higher than most synthetics,
approaching 280.
Therefore, a lower initial viscosity grade can be used minimizing
internal friction resulting in improved worm gear efficiency.
Most PAGs contain antiwear properties but there are no
formulations with EP additives.
Besides cost, a major disadvantage of polyalkylene glycols is their
incompatibility with other fluids.
They also attack paints, seals and polycarbonate sight glasses.
Typical commercial oils: Shell Tivela and Mobil Glygoyle HE.

 Valvoline SynPower Gear Oil is a full synthetic, thermally stable,

extreme-pressure gear lubricant designed to operate and protect in
both high and low extreme-temperature conditions. SynPower Gear
Oil is specially recommended for limited-slip hypoid differentials .
Contains additives to assist in protecting gear teeth
Maintains excellent low temperature fluid protection down to -50F (46C )
Provides outstanding thermal stability for cleanliness and longer
service life
Contains special additives to reduce chattering in limited-slip
differentials
Recommended for (conventional and limited slip) manual
transmissions where an API GL-5 or MT-1 fluid is specified
Protects parts from rust and corrosion
Compatible with conventional gear lubricants

TYPES OF HYDRAULIC FILUIDS

1.
2.
3.
4.

Petroleum-Based Fluids
Synthetic Fire-Resistant Fluids
Phosphate Ester Fluid
Silicone Synthetic Fire-Resistant
Fluids
5. Water-Based Fire-Resistant Fluids