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    11 views5 pages

    Lubrication Article PDF

    Uploaded by

    Sureshbabu Lakshminarayanan

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    Maintenance and Reliability ro T. SAHOO, Indian Oil Corp. Ltd, Paradip, India Enhance reliability of process pumps with lubrication management for antifriction bearings Rolling bearings must be adequately lubricated to operate reliably and to prevent direct metal-to-metal contact between rolling elements, raceways, cages and other components. Lubri- cantalso inhibits wear and protects bearing surfaces against cor- rosion. The choice ofa suitable lubricant and lubrication meth od, and controlling contaminants, are important fr improving the reliability of the machinery where these bearings are used. The lubricant in a bearing gradually loses its lubricating properties as a result of mechanical working, aging and the buildup of contaminants. Poor lubrication may be due to an incorrect type of lubricant, improper lubrication method, correct quantity of lubricant, contaminated lubricant or lubri- cant degradation For proper management of lubricant condition, contami nants control and machine wear should be monitored proper! Lubricant condition can be monitored with tests that quantify the physical properties of the oil to ensure that itis service- able. The entry of contaminants—such as air, ust, moisture, chemicals and process liquid—can be controlled and reduced, or even eliminated, by efficient sealing or filtration of ae sup plies. Metal and debris associated with component wear ate measured to monitor equipment health. Introduction. Today, petroleum and petrochemical plants have focused on extending the mean time between failures (MTBF) for thei rotating equipment; inchading pumps. Maxi- mizing lubrication effectiveness in process pumps will contsb- tte significantly to meeting this goal. Proper lubrication for pump bearings is essential for reliable service. Various studies have been carried out on the causes of premature roling ele- rent bearing failure; the No. 1 cause can be attributed to poor lubrication. Some industry findings show that improper libri- ‘ation can account for more than 308 of bearing failures. ‘Causes of poor lubrication may include: + Incorrect type of lubricant + Improper lubrication method + Incozeect quantity of lubricant + Contaminated lubricant + Lubricant degradation. Lubricant selection. Effective lubricants provide a sepa rating film between a bearing’ rolling elements, raceways and cages to prevent metal-to-metal contact and undesired friction, Friction generates excessive heat that could cause wear, metal fatigue and potential fasing of bearing contact surfaces. Ad- equate lubrication for bearings also help inhibit wear and cor- rosion, and helps guacd agsinst contamination damage. ‘When choosing a lubricant fora particular piece of equip- rent, the equipment manufacturers operation and mainte nance manual should be consulted. The operation and mainte- nance manual will usually outline the required characteristics of the lubricants, as well as a recommended schedule fr replace- ‘mentor filtering. Two type of lubricants ae primarily used for lubrication of antifiction bearings—grease and ol Grease, Greases are composed ofa soap thickening agent in petroleum oil. Soap is formed by combining a metallic alkali, such as the hydroxide of sodium or lithium, with a fatty mate- sil. The type and quality of soap determines the grease consis- tency; texture, melting point and solubility in water Additives are used to impart properties, such a increased load carrying ‘capacity rust prevention and oxidation stability. Oil selection. For the lubrication of rolling bearings, min ral ols and synthetic oils are essentially suitable. Oils with a ‘mineral oil base are used most frequently. Special ols, often synthetic ols, are used under extreme operating conditions, or where special requirements relating to ol conditions oF oil resistance exist. Mineral lubricating oils are obtained from the distillation of crude petroleum, while synthetic ols are manu factured. The selection of ol fora specific application depends ‘on four factors viscosity, speed, temperature range and operat ing environment ‘Ol vs. grease. Greases are now used for lubricating most rolling bearings. The extensive use of grease has been dicta cd by the possibilities of simpler housing designs, less main- tenance less difficulty with leakage and better sealing against dirt.On the other hand, limitations exist that donot permit the tase of grease ‘Where a lubricant must dissipate heat rapidly, grease should not be used, As solid when not under shear, grease forms an ef- fective collar at bearing edges to help seal against dirt and water. During startup periods the bearing isinstantly lubricated; where as with pressure or splash ol systems, there can bea time interval during which the bearing may operate before oil ow reaches the bearing, However extreme load at low speed or moderate loads at high speed may create sufficient heat in the bearing to make yctocorben Processing | MARCH 2017 49 Haag) Maintenance and Reliability ‘grease lubrication unsatisfactory. In grease lubrication, the cor: rect amount of ubricant is not as easily controlled as with oil, ‘Type of lubrication method. The choice of which lubrica- tion strategy to apply for pump bearings has implications for both the short-term characteristics exhibited by the bearings and thei long-term reliability. When lubricating rolling element bearings, four basic strategies have historically been used: + Grease. Simple to apply, grease can be retained within a bearing’s housing and offers extra sealing protection. Depending on the rotational speeds and operating temperatures, relubrication may be required to combat short grease life. Asan attractive alternative when ‘operating conditions allow, sealed "greased-for life” bearings have been developed to eliminate the need for relubrication and related maintenance tasks. + Oil bath. This option establishes an oil level at the center of the bearing’ bottom rolling element and represents the comparative baseline of bearing friction among the lubrication methods. Bes results overtime can be achieved using a constant-level oiler. ubrication via slingers disc or oil ring. In this ‘method, an oil rings suspended from the horizontal shaft into an ol bath positioned below the bearings. ‘The rotation ofthe shaft and ring flings ol from the bath {nto the bearings. The reduced oil volume in the bearing reduces the viscous friction in the bearing system to allow higher shaft speeds and improved cooling, + Oil mist and air-ol. In this case, oils atomized and carried by an air stream to the bearing. Among ll pump bearing lubrication approaches, this process generates the least amount of friction (allowing rotational speed to be based on the bearing design rather than on lubrication limitations) and creates a postive pressure within the bearing housing (preventing invasive contaminants). Oil bath method. The simplest method of ol lubrication is, the ol bath (F161). The oil, which is picked up by the rotating components of the bearing, is distributed within the bearing and then flows back to a sump in the housing, Typically, the oil level should almost reach the center of the lowest rolling clement when the bearing is stationary. The bearing rolling ¢: cements pass or “plough” through a portion of ths oil sump as the shaft revolves. Ball ameter an FIG. 1 Gi bath lubrication showing a typical ol level 50. marci 2007 | HyerocarborPrcesingcom For smaller bearing arrangements and slower speeds, oil bath lubrication arrangements are commonly utilized. As hheat reduces oil film strength and greatly accelerates the rate at which oil oxidizes, the oil bath lube method is avoided on process pumps whenever DN, the inches of shaft diameter (D) ‘multiplied by shaft revolutions per minute (N), exceeds 6,000. illubrication via slinger disc or oil ring. For larger bear- ings that rotate at 3,000 rpm and higher, many manufacturers utilize cil lifting lubrication via oil ring or oilslingers. The goal ‘of these arrangements is to maintain a normal oil level below the rolling element bearing (which accounts forthe lifting re- quired), to minimize heat generation due to oil churning. Oil ring design considerations. Oil rings are loose pieces that rest on the shaft under gravity and the bottom point that

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