Lubrication System

Our services to the perfect partner for your success!
TST CONSULTING CENTER

79 Nguyen The Truyen St., Tan Son Nhi Ward, Tan Phu Dist., HCMC
Tel: 84-8-54272780. Fax: 84-8-54272781
Email: info@tstvietnam.com. Website: http://tstvietnam.com
LUBRICATION COURSE
Basic Lubrication
Curriculum Structure: Lecture: 8 hours
Instructor: Nguyen Dinh Cuong
10/11/2022 1
Purchasing Engineering Storeroom
Maintain Identify
• Direct purchases • 4 phase project model • Sufficient quantity
Base Developing Failures Early
• Quality • Project reviews • Inventory management (Measure Deterioration)
• On time • Reliability predictions • Quality parts Conditions • Operating Teams Our services to the perfect partner for your success!
• Order status • Defect prevention • Parts reservation • Clean
• PM Resources
• Best cost • Technical Standards • Parts delivery • Lubricated • Outside specialists
• Tighten
Technical Database
• Design standards
• Plant loss data system
Subjective Objective Training
• Reference materials
• Project files • Inspection techniques
• Look • Vibration Analysis
• Study files Planning • Feel • Thermography • Wear characteristics
• Equipment files • • Ferrography • Standard deviations
• Listen
• Equipment ranking Prioritize
• Backlog Mgmt • Ultrasonic • Operating principles
• Smell
• Annual maintenance plan • Basic measurements
• MP design improvements
Scheduling
• Job Status
• Priority
Continuous Improvement
• Stabilize MTBF
• Lengthen equipment life
• Periodically restore deterioration
• Predict equipment life Do Unplanned
• Skills Maintenance
• Tools • Root cause analysis
• Parts staging - Why-why analysis
Analyze • Procedures - PM Analysis
• Component level - Failure Analysis
- X-Matrix
- Dice chart
- MTBF charts
- 7 TQ tools
Record
(Continuous Improvement Database) PLANNED
Effectiveness Measures • Standards for recording
• Equipment reliability & maintainability
• Maintenance efficiency
(PM card, Failure report, MTBF chart , etc.)
- Components repaired/replaced
MAINTENANCE
- Cause of failure
SYSTEM
• Maintenance cost
• Planning performance - Condition Discovered
- Action taken JLM
(11/22/96)
10/11/2022 08 - Lubrication System Page 2

Pillar DMS Build by Step
• Systems/Activities to improve maintenance techniques and skills

• Systems/Activities to expand equipment MTBFs
• Systems/Activities to shorten MTTRs
Efficiency
11. Maintenance Standards & Procedures System

9.- AM Support System
10. Countermeasures to Breakdown System
12. Predictive Maintenance System

(Effort & cost)
Maintenance Prevention Data System

1. Tools & Facilities System
Organizations, 2. Equipment Ranking System

Structures, 3. Planning & Scheduling System
Systems,
4. Shutdown Maintenance System-where appropriate Reduction
and
of
Activities 5. Lubrication Management System input
to promote
efficient 6. Maintenance Cost System
Maintenance 7. Maintenance Management Information System
8. Parts & Supplies Control System
Establish
Step 1 Step 4 Improving Output Planned
Zero failures and defects Maintenance
System
Step 2 Step 5
Effectiveness
(Equipment Availability/throughput)
Step 3

Lube Presentation Objectives
 Increase your awareness and interest level in lubrication
 Provide background on:

 Oil and Oil analysis
 Grease
 Regimes of Lubrication
 Bearings
 Lubrication systems.

Lube Functions
The primary function of lubricants:

 Reduce friction and wear
The secondary functions of lubricants:
 transfer heat
 prevent corrosion or rust
 scavenge debris
 transfer force/energy
 seal or block contamination
 cushion shock

CAUSES OF FRICTION
20
Load
 Friction is Caused by
Interactions at the 1
Surfaces of Adjoining Relative
Scale
Parts
Load Asperities
 At a Microscopic
Level, All Surfaces
Are “Rough”
 Surface Peaks
(Asperities) May
Bond to One Another
or Protrude Into
Contact
Adjoining Surface
Points
10/11/2022
G9800760, G9800761
08 - Lubrication System Page 6
CAUSES OF FRICTION
10/11/2022 7
Lubrication functions
1 ) FRICTION CONTROL
2 ) ABRASION CONTROL
3 ) TEMPERATURE CONTROL
4 ) CORROSION CONTROL
5 ) ELECTRIC INSULATION
6 ) PRESSURE TRANSMISSION (HYDRAULIC)
7 ) SHOCK ABSORPTION
8 ) CONTAMINATION REMOVAL
9 ) SEALANT
10/11/2022 8
Types of Lubricants
Basic classes of lubricant

(a) Oils. Ageneral term used to cover all liquid lubricants, whether they
are mineral oils, natural oils, synthetics, emulsions or even
process fluids.
(b) Greases. These are oils which contain a thickening agent to make
them semi-solid, but it is sometimes convenient to include the anti-
seize pastes and the semi-fluid greases under the same heading..
(c) Dry lubricants. These include any lubricants which are used in
solid form, and may be bulk solids, paint-like coatings or loose
powders.
(d) Gases. The gas usually used in gas bearings is air, but any gas
can be used which will not attack the bearings, or itself decompose
10/11/2022 9
OILS
10/11/2022 10
Characteristics of
Lubricating Oil
 Provide a film of protection.

 Carry away heat.
 Good medium for EP additives.
 Ease of application.
 Can be used at high Rpm's.
 Good storage stability.
 Higher oxidation resistance when compared to grease.
10/11/2022 11
Liquids lubrication
The way in which liquids lubricate can be simply explained by considering the
example of a plain journal bearing, as the shaft (journal) rotates in the
bearing, lubricating oil is dragged into the loaded zone and the pressure and
volume of the film, will depend on the shaft speed and the lubricant viscosity.
OIL FILM
THICKNESS
OIL CLEARANCE
STAND STILL BEGINNING MOVEMENT STABILIZED SHAFT
10/11/2022 12
Mineral Oils
Crude Oil
Color: Red, Brown, or Black
Viscosity: Water Like to Tar
Odor: None to Rotten Eggs
Crude Source
Each crude source has a different
composition of Hydrocarbons, Sulfur,
and Nitrogen Compounds.*
10/11/2022 13
COMPONENTS OF A LUBRICANT OIL

10/11/2022 14
Viscosity
 Viscosity is the most important property of a lubricating oil
 Liquids with a Low Viscosity, like water, flow easily
 Liquids with a High Viscosity, like honey, flow with difficulty
 Speed, load and operating temperature must be considered

to select the correct viscosity of oil for an application

10/11/2022 ISO 150 ISO 680 16

ISO 32
10/11/2022 ISO 150 ISO 680 17

ISO 32
ISO viscosity
10/11/2022 ISO 150 ISO 680 18

ISO 32
ISO viscosity
10/11/2022 19
1000 4600
2
v1
5 SUS
500 2300
Viscosity versus Speed 10
20
200 930
50
100 100
460
Approx.
200 Saybolt
50 230
Universal
Viscosity 500 RPM Seconds
(SUS)
(mm2/sec.) 20 1000 100
1500
2000
3000
4000
10 60
5000
10000
5 50000 40
100000
3 35
10 20 50 100 200 500 1000
Pitch Diameter (mm) dm mm
dm = (bearing bore + bearing O.D. ) ÷ 2
v1 = required lubricant viscosity for adequate lubrication at
the operating temperature
10/11/2022 20
1500 1500
250
1000 1000 8A
900
Lubricating Oil Viscosity

800
700
680 8
Grade Comparisons
600
500 140
460 7 Bright
400 Stock 150
300 320 6
200 220 5
50
175 90
N 900
850
150
150 4 40
125
85W
100 100 3
30
80
70
68 2
80W 320
60
N 300
50 20W
46 1
-20
40
32
30
150
10W 75W
20 22
100 N 100
15
15
5W
10
10
7 N 55
5
5
3
2
10/11/2022 21
Viscosity Index
V.I. 130
V.I. 90
VISCOSITY
Temperature increase
10/11/2022 22
Viscosity Index
V.I. 90
VISCOSITY
Temperature decrease
10/11/2022 23
Viscosity Index
Temperature Relationship for SAE 15W-40 Motor Oil

1,000,000
100,000
10,000
Kinematic Viscosity, cSt
SAE 40 Oil
1,000
140 V.I.
100 SAE 15W-40 Oil
10
SAE 15W-Oil
5
0
-20 0 20 40 60 80 100 140 180 220 260 300
Temperature, °F
Viscosity Index
10/11/2022 25

Make Up of Grease
IT IS GENERALLY USED OVER DEVICES

FUNCTIONING UNDER NORMAL CONDITIONS OF
VELOCITY AND TEMPERATURE.
GREASE
GREASE HAS SEVERAL BENEFITS OVER OIL:
IT’S EASIER TO APPLY AND PROVIDES

PROTECTION AGAINST HUMIDITY AND OTHER
CONTAMINANTS.
10/11/2022 27
Make Up of Grease
Grease is a solid to semi-solid

material consisting of:
 BASE OIL - Does the lubricating
 THICKENER/SOAP – Carrier for the oil
 ADDITIVES - Improve oil
characteristics

Make Up of Grease
ADDITIVES
10%
OIL
80 - 90% BASE
10 -20%
10/11/2022 29
THICKENERS
GREASE COMPONENTS
10/11/2022 30
Make Up of Grease
10/11/2022 31
Oil Content of Greases
Starplex 2 Starplex HD 2 Starplex Moly 2 Same NLGI Grade
Penetration, ASTM 280 280 270 Same Consistency

at 77F Worked
Penetration, ASTM at 5 5 5
77F Worked, 10,000 Same Consistency
strokes % Change
Mineral Oil Viscosity 220 680 320 Different Oil

cSt at 40C Viscosities

NLGI Grade or Consistency
Consistency is measured in terms of penetration, the distance in

tenths of a millimetre to which a standard metal cone under standard
conditions will penetrate into the surface of the grease. The
penetrations almost all lie between 475 for a very soft grease and 85
for a very hard one. Consistency is also commonly described by the
NLGI classification developed by the American National Lubricating
Grease Institute. The relationship between NLGI number and
penetration for the full range of grease is shown in upper table
10/11/2022 33
The most important property of grease, which distinguishes it from

other types of lubricant, is its semi-solid mature. Greases can in fact
vary from very sort, o semi-liquid to hard and the relative hardness or
softness is called the consistency

GREASE GREASE
77 F. 77 F.
Cone Penetration Test

10/11/2022 35
Miscellaneous GREASE
FACTOIDS

Grease Gun Factoid:
Not all grease guns are the same
10,000 psi. 1 oz. at 25, 33, and 36 strokes

6,000 psi. 1 oz. at 21 strokes
3,000 psi. 1 oz. at 9 strokes
high volume: 1 oz. at 7 strokes.
double action: 1 oz. at 18 strokes and 1 oz.
at 33 strokes depending on pressure.

Dry or solid lubricants
10/11/2022 38
Depending on the nature of the two surfaces, a wide variety of solid

materials can can reduce friction and prevent seizure. For example,
dust, sand or gravel on the surface of the road can cause vehicles
to skid because they decrease friction between tyres and the road
surface. Technically speaking, they are acting as lubricants, but of
cause, no one would normally recommend dust, sand or gravel as
solid lubricants.
10/11/2022 39
 Teflon - Polytetrafluoroethylene
 Acid resistant plastic resin
 Graphite - A soft form of carbon.
 Occurs naturally or can be made from coal or
other carbon source. Color runs gray to black.
 Molybdenum Disulfide - Moly
 A powder that serves as a dry film lubricant. This
material polar bonds to metal to form a protective
film that is very resistant to heat and pressure.
10/11/2022 40
Lubrication supply systems
10/11/2022 41
Factors Affecting Proper Lubrication

The 5 Rs of Lubrication
 Right amount
 Right place
 Right time or frequency
 Right type
 right consistency
 right viscosity
 right additives
 compatibility checked
 Right quality (cleanliness)
10/11/2022 42
Right Type
DO NOT MIX GREASES WITH DIFFERENT THICKENERS!
A LITHIUM
GREASE... ...MIXED WITH A
SODIUM GREASE...
...ENDS UP IN A SOFTER GREASE

THAN EACH ONE ALONE...
LEAKAGE AND A LOWER TEMPERATURE

RESISTANCE WILL ENSUE.
10/11/2022 43
Right Type Right lubricants for bearing
The table for mixable lubricants
10/11/2022 44
Right Amount
This is especially important to rolling

elements because of the relationship to
heat generation and wear. Excess
lubrication actually builds internal
pressure against the rolling elements.
Overheating occurs as the rolling
elements attempt to turn at their
optimal speed. Underlubrication leads
to the rolling elements not having
enough “cushion” all around them.
Eventually rubbing can occur, causing
overheating and premature wear.
10/11/2022 45
Right Amount
Or by the formula:
G (ounce) = 0.11 x D (inch) x B (inch).
Or
G (g) = 0.005 x D (mm) x B (mm).
Where:
G = Quantity of grease.
D = Outside diameter of bearing .
B = Width of bearing .
1 Ounce = 28.35 g.
10/11/2022 46
Right Amount
Or by the formula:
G (ounce) = 0.11 x D (inch) x B (inch).
Or
G (g) = 0.005 x D (mm) x B (mm).
Where:
G = Quantity of grease.
D = Outside diameter of bearing .
B = Width of bearing .
1 Ounce = 28.35 g.
10/11/2022 47
Right Frequency
10/11/2022 48
Right Frequency How to Determine Relubrication Intervals for Bearings

The columns a, b, and c represent the Bearing Class
classification of the bearing from

Step 1. The curved lines on the chart
represent shaft size. The numbers at
the bottom and outside of the chart
represent rpm of the shaft, and from
100 to 1000, each number represents
rpm in hundreds, and from 1000 to
10,000 each number represents rpm operating hours
in thousands.
Find rpm at the bottom of the chart

and then move straight up until rpm
intersects with the line that
corresponds to shaft size. Once the
point of intersection is established,
preliminary tf hours can be
determined to the left side of the
chart from the proper bearing class
column. Rpm
10/11/2022 49
Lubrication Control System
Lube Map
Lube Standards
Color Coding System
10/11/2022 50
Lubrication Control System
• Saves Time
– Less time to inventory and store
– Less time spent searching for right lubricant
• Saves Money
– Less money tied up in lube inventory
– Less chance of wrong lube in component
– Stronger relationship with vendor
• Saves Space
– Less space needed for storage
• Increases Availability of Lubricant
10/11/2022 51
Lube Maps
Lubrication Map
Initial Tentative X Final Our services to the perfect partner for your success!
Department: Process North Date Issued: 10/19/99

Equipment: C/T Units Date Revised: 1/18/2000
Lubrication Point Map:
19 6 23
17
7
13
9 9
14
9
15
9
10 11
9
18
12
9
21
42
5
4 1
2
16
20
Point Freq.
Lubrication Surface Lube Type Amount Tools
No. (Days)
1 Transfer Roll Bearing - Inner ALG-08 8 shots Pistol Grip Grease Gun 35
2 Transfer Roll Bearing - Outer ALG-08 8 shots Pistol Grip Grease Gun 35
3 Cutter Roll Bearing - Inner ALG-08 8 shots Pistol Grip Grease Gun R
4 Cutter Roll Bearing - Outer ALG-08 8 shots Pistol Grip Grease Gun R
5 Cutter Roll Worm Gear - Inner ALG-08 4 shots Pistol Grip Grease Gun R
6 Cutter Roll Worm Gear - Outer ALG-08 4 shots Pistol Grip Grease Gun R
7 Pivot Arm - Inner ALG-08 2 shots Pistol Grip Grease Gun R
8 Pivot Arm - Outer ALG-08 2 shots Pistol Grip Grease Gun R
9 Cutter Roll Drive Gear ALG-12 2 shots Pistol Grip Grease Gun 14
10 Transfer Roll Drive Gear ALG-12 Cover Surface Pistol Grip Grease Gun 14
11 Intermediate Drive Gear ALG-12 Cover Surface Pistol Grip Grease Gun 14
12 Main Drive Gear ALG-12 Cover Surface Pistol Grip Grease Gun 14
13 Web Pull Roll Drive Gear ALG-12 Cover Surface Pistol Grip Grease Gun 14
14 Upper Intermediate Web Pull Roll Drive Gear ALG-12 Cover Surface Pistol Grip Grease Gun 14
15 Lower Intermediate Web Pull Roll Drive Gear ALG-12 Cover Surface Pistol Grip Grease Gun 14
16 Cutter Roll Eccentric Housing - Outer ALG-08 2 shots Pistol Grip Grease Gun R
17 Cutter Roll Eccentric Housing - Inner ALG-08 2 shots Pistol Grip Grease Gun R
18 Drive Shaft Pillow Block Bearing ALG-08 2 shots Pistol Grip Grease Gun R
19 Web Pull Roll Bearing - Inner ALG-08 1 shot Pistol Grip Grease Gun R
20 Intermediate Drive Gear Insert Bearing ALG-08 2 shots Pistol Grip Grease Gun R
21 Drive Shaft 3 Bolt Flange Bearing ALG-08 1 shot Pistol Grip Grease Gun R
22 Web Pull Roll Outer Drive Bearing X
23 Web Pull Roll Inner Drive Bearing X
x = sealed component Activities <= 30 are on CIL

Lubrication Standards
(clean is good start)

Lubrication Standards
(Neat is sweet)

Standard Lube Label
ALG ##
USDA RATED: H-1
BLU ## LU ##
USDA RATED: H-2 USDA RATED: None

Display Colors

Tank Identification

Lube System Labels

CASUMINA
VISUAL CONTROL STANDARD
COMPONENT:
Drive– Transmissions : Truyền phát động
Gear box : Hộp số
METHOD:
Use green and red label, one side adhesive.
Dùng nhãn màu xanh và đỏ có chất bám dính
CONTROL POINTS:
Oil Level in the gear box
Mức dầu trong hộp số
STANDARD CONSIDERATIONS:
1. These standards apply to big gearbox in order to visualise Abnormal Operating Range
the oil level for easy to see
Tiêu chuẩn áp dụng visual giúp dễ dàng kiểm tra mức dầu bôi
trơn trong hộp số lớn Normal Operating Range
2. The oil level can be built on the guard in ways.

Mắt dầu vá lỗ thông hơi được vẽ theo cách như hình bên.
59
CASUMINA
VISUAL CONTROL STANDARD
COMPONENT:
Pneumatic
Khí nén
METHOD:
Use green and red label, one side adhesive.
Dùng nhãn màu xanh và đỏ có chất bám dính
CONTROL POINTS:
Oil Level in the air filter
Mức dầu trong bộ lọc khí nén
STANDARD CONSIDERATIONS:
1. These standards apply to air filter in order to visualise the Abnormal Operating Range
oil level for easy to see
Normal Operating Range
Tiêu chuẩn áp dụng visual giúp dễ dàng kiểm tra mức dầu bôi
trơn trong bộ lọc khí nén
60
System Products
Effective lubrication of equipment

 no on-the-run bearing/equipment failures
 extend equipment life
 on-run lubrication (balanced work load)
 reduce maintenance work
System to provide supplies and disposal

SAVE MONEY

Where to Learn More
PM Pillar Web Site

Lubricant Vendors
Equipment Manuals
Bearing Vendors
Site Lube Team (do you have one?)
Lube CBA

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Our services to the perfect partner for your success!

TST CONSULTING CENTER

Curriculum Structure: Lecture: 8 hours

Instructor: Nguyen Dinh Cuong

10/11/2022 08 - Lubrication System Page 2

• Systems/Activities to improve maintenance techniques and skills

11. Maintenance Standards & Procedures System

10. Countermeasures to Breakdown System

12. Predictive Maintenance System

Maintenance Prevention Data System

Organizations, 2. Equipment Ranking System

10/11/2022 08 - Lubrication System Page 3

 Increase your awareness and interest level in lubrication

 Provide background on:

10/11/2022 08 - Lubrication System Page 4

The primary function of lubricants:

10/11/2022 08 - Lubrication System Page 5

6 ) PRESSURE TRANSMISSION (HYDRAULIC)

Basic classes of lubricant

 Provide a film of protection.

STAND STILL BEGINNING MOVEMENT STABILIZED SHAFT

Color: Red, Brown, or Black

Viscosity: Water Like to Tar

Odor: None to Rotten Eggs

COMPONENTS OF A LUBRICANT OIL

 Viscosity is the most important property of a lubricating oil

 Liquids with a Low Viscosity, like water, flow easily

 Liquids with a High Viscosity, like honey, flow with difficulty

 Speed, load and operating temperature must be considered

10/11/2022 08 - Lubrication System Page 15

10/11/2022 ISO 150 ISO 680 16

10/11/2022 ISO 150 ISO 680 17

10/11/2022 ISO 150 ISO 680 18

Our services to the perfect partner for your success!

Lubricating Oil Viscosity

Temperature Relationship for SAE 15W-40 Motor Oil

10/11/2022 08 - Lubrication System Page 26

IT IS GENERALLY USED OVER DEVICES

IT’S EASIER TO APPLY AND PROVIDES

Grease is a solid to semi-solid

10/11/2022 08 - Lubrication System Page 28

Starplex 2 Starplex HD 2 Starplex Moly 2 Same NLGI Grade

Penetration, ASTM 280 280 270 Same Consistency

Mineral Oil Viscosity 220 680 320 Different Oil

10/11/2022 08 - Lubrication System Page 32

Consistency is measured in terms of penetration, the distance in

The most important property of grease, which distinguishes it from

10/11/2022 08 - Lubrication System Page 34

Cone Penetration Test

10/11/2022 08 - Lubrication System Page 36

10,000 psi. 1 oz. at 25, 33, and 36 strokes

10/11/2022 08 - Lubrication System Page 37

Dry or solid lubricants

Depending on the nature of the two surfaces, a wide variety of solid

Lubrication supply systems

Factors Affecting Proper Lubrication

DO NOT MIX GREASES WITH DIFFERENT THICKENERS!

...ENDS UP IN A SOFTER GREASE

LEAKAGE AND A LOWER TEMPERATURE

Right Type Right lubricants for bearing

The table for mixable lubricants

This is especially important to rolling

G (ounce) = 0.11 x D (inch) x B (inch).