Professional Documents
Culture Documents
James Faulk
June 18, 2015
Alemite Carbon Shield Oil Mist
INCREASE REDUCE
• Energy consumption due to friction
• Heat generation due to friction
• Wear due to friction
• Productivity • Noise due to friction
• Reliability • Downtime
• Availability and durability • Operating expenses
• Machine uptime • Product contamination
• Service intervals • Maintenance and repair costs
• Safety • Lubricant consumption
• Corrosion
The correct
lubricant…
…at the right
lubrication
point.
…supplied in the correct
amount …. …at the right time…
LUBRICATION
110 Gallon Bulk Oil Storage Tank Carbon Shield Oil Mist Generator
Intelligent diagnostics
Checks the health of components and
communicates warnings automatically.
Adaptive system
Built in intelligence capable of detecting
intentional and unintentional changes inside the
system.
Continuous control
PID closed loop continuous control ensuring
and maintaining the appropriate air/oil ratio,
replacing limited capability of old discrete
control systems.
Communications interface
Interface with existing DCS and enterprise
systems allowing easy access to system
information from a centralized location.
Historical data and trending
Simple data acquisition and trending.
Direct oil/air monitoring system
Accurate, reliable direct measuring of oil/air
mixture.
Compressed air is passed through a Venturi. Oil is siphoned from a reservoir by the air flow and is
atomized into a fine spray through the Venturi. Baffles downstream from the Venturi nozzle causing the
larger oil particles to coalesce and return to the reservoir. The remaining air-oil-mixture is atomized oil
particles (droplets) averaging 1-5 microns in diameter. The suspended oil particles in the air are dry enough
to be conveyed through distribution piping at velocities up to 6 meters per second.
on
cr
Mi
1-5
© SKF Group Slide 11 Thursday, December 15, 2022
How Does Oil Mist Work
You will recall that the oil mist droplets are 1-5 microns in size. Because of their small size, the dirt or wear
particles that can cause fatigue will not remain in suspension with the oil mist and will therefore drop out in the
oil mist generator. As some have accurately commented, oil mist is the ultimate oil filter.
During research done by Texas A&M University, it was discovered that pure oil mist deposits a wear
resistant layer of dry film on the wear surfaces of rolling element bearings. Their research did not find this layer
to be on bearings using conventional splash lubrication service or purge mist applications.
Most common question and concerns of those not familiar with oil mist lubrication is what will happen if
the oil mist fails to operate while their equipment is in operation. First thought is the bearings will fail
immediately. Not true, research and operation experience have shown that, because of this oil film, equipment
can safely operate up to 8 hours without oil mist lubrication.
Increased Reliability
By providing the right amount of lubricant in the right place, an oil mist lubrication system guarantees the smooth
running of mechanical rolling elements. Reduced vibrations and lower operating temperatures ensuring reliability
and extended life.
Environmentally Safe
Oil mist systems reduce oil consumption. With oil mist the amount of oil consumed is 40% less than traditional
sump lubrication. In addition to that more than 50% of the lubricant can be recovered. This reduces energy
consumption which in turn also reduces the emission of greenhouse gasses into the environment.
Reduction in seal and bearing failures.
Due to reduced friction, vibration and wear through effective lubrication, there is a reduction of up to 90% in
antifriction bearing failures and seal failures are reduced by on average 35%.
Reduced operating temperatures
Reduced operating temperatures in antifriction bearings of between 10ºC to 20ºC are obtained, when changing
from static oil bath to pure mist lubrication.
Cleaner lubrication with less contamination
When providing mist to a bearing housing a positive pressure is produced inside the chamber, which does not
allow the entrance of external contaminants, such as water and solid particles suspended in the atmosphere such as
dust and sand, therefore cutting down on the main causes of material wear.
Causes of Contamination
A contaminant is any substance that enters a system and adversely affects its function or reliability.
Contaminants such as solids, water and gases (primarily air and moisture) will react with lubricants also
decreasing the life of rotating equipment.
The most common source of entry is through breather caps, imperfect seals, or other unplanned openings
during normal operation of the equipment. This includes the addition of fluid during initial fills or top-offs.
As system or environmental temperatures change, the lubricant and air inside the Sump will expand and
contract; forcing air into or out of the housing know as breathing.
Stopping Contamination
The oil mist system provides a flushing action with fresh, clean lubricant and acts in a slight manner as a
bearing coolant. The carrier air used to distribute the oil provides additional benefits in that it maintains a
slight positive pressure in bearing housing. The "outward" air flow prevents the entrance of contaminants.
Where mist systems run continuously - and when equipment is inoperative (stand-by) – problems with
condensation reaching bearing surfaces are eliminated.
Remove &
Plug Vent Oil Mist Inlet
Positive Positive
Pressure Pressure
Once the oil mist has been generated it is then transported through a piping system, know as a distribution
header or supply header. The oil mist at this stage of distribution is know as “Dry Mist”.
The header is normally 2 inch NPT threaded galvanized steel pipe, schedule 40. or schedule 80. The header
can also be 2 inch welded stainless steel pipe. The header must be installed with a slope back in the
direction of the oil mist generating console. Since there are oil mist particles that get condensed in the pipe
this allows the oil to return to the reservoir of the oil mist generator console to be re-circulated, therefore
reducing oil consumption and increasing efficiency.
The distribution header must be installed in a way that it avoids abrupt changes of direction, sagging or
traps, with the purpose of maintaining a pressure of on average 20 inches of water column. By following
these recommendations, the oil mist can be transported in a horizontal radius of on average 600 ft (180
m) from the oil mist generator console.
Once the oil mist has been transported through the distribution header the oil mist is terminated at each
piece of equipment that is to receive lubrication. The oil mist is now transported through a mist manifold
and mist reclassifier (mist fitting).
Once the oil mist passes through the mist reclassifier it becomes more turbulent and is know as “Wet Mist”.
To Recap “Dry Mist” is for conveying the oil mist and “Wet Mist” is for lubricating the bearings and metal
surfaces.
TYPICAL INSTALLATION
Oil Mist Fitting Oil Mist particles become Turbulent causing them to
grow in size and become a wetter mist
(Reclassifier)
Pure Mist also known as (dry sump oil mist). In pure mist applications the oil level is
removed from the bearing housing of the equipment, eliminating the constant oil level and the
slinger ring.
The lubrication is provided by the reclassified oil mist that enters the housing and passes
through the bearings. The oil mist is condensed in the bearing housing and drained to a
collection container connected to the lower part of the equipment with tubing .
Purge Mist also known as (wet sump oil mist). With purge mist applications, the oil mist is
applied to the vapor space above the liquid oil in the bearing house, gear boxes, oil reservoirs,
and journal (plain) bearings. This is done to exclude water and other contaminants.
Often, users mistakenly believe that purge mist is better because it combines the benefits of
both lubrication methods. In fact, pure mist has substantial benefits over purge mist as we will
explain ahead.
Pure Mist
Purge Mist
Collection Container
Allows the collection of liquid oil from the
bearing housings due to the condensation of the
oil mist. Allows the excess oil to be drained to a
separate container.
ELECTRIC MOTOR
Today’s manufactures have made
provisions for Pure Oil Mist lubrication
(15kw and above)
MIST INLET
OIL LEVEL
SIGHT MIST VENT
ASSEMBLY
OIL LEVEL
DRAIN SIGHT
DRAIN TO BOTTLE
COLLECTION
CONTAINER
Mist Manifold
1. Mist manifold allows the transition of the
oil mist from Dry Mist to Wet Mist through
the mist fitting from the drop pipe to the
equipment.
2. Allows oil mist to be distributed to multiple
application points.
3. Oil Mist Manifold allows the visual
monitoring of the condensed oil that collects
in the drop pipe.
4. A Push button drain allows the operators to
drain the manifold when required
5. Stainless Steel Construction
When Oil mist is engineered, installed, operated, and maintained properly the systems are
cleaner than conventional lubrication. Lubricating oils are not VOC's; remember that oil
mist is not a vapor but a suspension. There are over 20,000 pumps in USA refineries on
pure oil mist in open loop systems. The number of open loop systems operating around
the world are 30 times greater than the number of closed loop systems installed.
Current environmental restrictions that apply to airborne oil mists are the OSHA values of
5.0 mg/m3. A number of evaluations have been conducted by corporate environmental
departments and have shown concentrations of mists well below the 5.0 mg level.
Maximum concentration have been observed was approximately 2.0 mg/m3 and this was
when measurements were made at six to twelve inches away from a disconnected 0.18
cfm reclassi.er
Blowing directly into the atmosphere. Other studies have measured concentrations around
the pump shaft and at purge mist vents.
Values were well below 0.5 mg/m3. Hence, given today’s limits, oil
Mist is easily in compliance with the standards.
Environmental laws, such as California’s Rule #1173, titled Fugitive Emissions of Volatile
Organic Compounds (VOC), specifically exempt oil mist as a Volatile Organic Compound
(VOC). This means that oil mist is not a smog producing mixture. Remember that oil mist
is not a vapor but a mixture of very fine oil droplets and air. In time, the oil droplets will
drop out of the air.
According to NIOSH publication 81-123-b-0472.pdf says that the “Permissible Exposure
Limit (PEL)… is
5 milligrams of mineral oil mist per cubic meter of air (mg/m 3) averaged over an eight-
hour work shift.” Incidentally, the Canadian Occupational Safety Administration sets oil
mist Occupational Exposure Limits at 5 mg/m 3 for an 8 hour Occupational Exposure
Limit (OEL) and 10 mg/m3 for a 15 minute OEL. Field measurements and testing never
found measurements to be anywhere near close to the imposed limits.
Since oil mist is so lean, 1 part oil to 200,000 parts air, explosions are impossible. For
the mixture to burn, the concentration would have to more than 1 to 250. Therefore, oil
mist is safe.
Features Benefits
Mist Fitting Sized per Bearing Reduces Oil Usage
Continuous One Through Mist Flow Bearings Run Cooler 15-25 Degrees C
Alemite LLC will provide the following Engineering Services as a Standard with each
Project. These services will be provided After Receipt of Order. Engineering
Requirements other than that list below will be quoted by Alemite at standard rates.
Documentation Review
The following documentation will be reviewed only if supplied by customer
Isometric Layout and routing of Oil Mist system.
Isometric Bill of Material
Piping Supports and Slope of Oil Mist Supply Header
Location of Oil Mist Generator
Location drain-legs
Review of Customer 3D model at 90% completion
Introduction
The term “Carbon Shield™” is nothing more than a registered trade mark for Alemite’s
oil mist products. The Alemite Carbon Shield™ oil mist products have been in service
for over 30 years, in a wide range of global locations including the Middle East
Countries such as Saudi, UAE and Bahrain. The mechanical function is still the same
highly reliable technology that Alemite is known for. In early 2008 Alemite improved the
monitoring parameters by replacing the old "Amot” brand controller which had limited
capabilities to a modern day Siemens PLC with a Siemens HMI color screen. The
Siemens PLC is able to monitor all the perimeters required in today's oil mist
specifications. The Siemens PLC does not require any outside wiring. All wiring and
programming is performed inside the Oil mist Generator, therefore it is a self serving
component for the Oil Mist generator and does not need the client’s DCS to operate.
There is how ever an option for Mod Bus if the client elects to monitor the Oil Mist
Generator from the DCS. Carbon Shield™ oil mist systems are a proven technology
that delivers both savings as well as environmental benefits to the refining and
petrochemical industry.
NEC,UL
Stainless steel cabinet construction, UL Listed designed for Class I, Div 2, Group B, C,
and D, T4 hazardous environment.
ATEX 94/9/EC
Stainless steel cabinet construction, ATEX Listed designed for, Class I Zone 2 Ex nC IIB
+H T4 hazardous environment.