Oil Mist Lubrication Training

Lubrication Systems Company
Don Ehlert is currently Manager for EPC Sales at Lubrication Systems Co., a Colfax Company, located in Houston, TX. His current responsibilities include providing technical training and sales presentations. He is also responsible for quotation packages for domestic and foreign engineering companies and end user projects.
Since joining LSC in 1984, Don has filled positions in equipment assembly, field maintenance, field installation, field management, sales and sales management. His vast experience allows him to provide technical support to oil mist users world wide. He has been instrumental with the development of oil mist related products and accessories for special applications. He has authored numerous articles related to lubrication systems and their applications. Prior to LSC Mr. Ehlert had spent time in the US Navy providing maintenance and operation support for aircraft on the hydraulic and flight control systems.
Pump Retrofit
Trico Oiler Plug on Top
Slinger Rings
Topics
Introduction & Evolution of Oil Mist What is Oil Mist Lubrication with Oil Mist
Applying Oil Mist To Equipment

Retrofitting Pure Oil Mist Purge Oil Mist Applications Justification of Oil Mist
Introduction & Evolution of Oil Mist Lubrication
Introduction to Oil Mist
Oil Mist can be applied to most rolling element bearings
Allows use of higher viscosity lubricants.

Pure Oil Mist eliminates oil sump issues. Oil Mist is the ultimate oil filter. Oil Mist is contamination control. Wear particles are not re-circulated. Cooling water in bearing jackets is eliminated. Oil Mist Generators are 99.9996% reliable.
Basic Oil Mist System

Air Controls Mist Generator Piping System Applications
Introduction to Oil Mist Large Scale System
3 to 30 SCFM Air Flow Range 2 Gal. Maximum Oil Consumption
Serves 15 to 80 Pumps and Drivers
Dry Mist Out
Instrumentation Air In
Vortex
Oil Mist Oil

Application & Lubrication
ABOVE WET MIST FOR LUBRICATION
OIL MIST PARTICLE SIZES

BELOW DRY MIST FOR CONVEYING
3 Microns
Generation & Distribution
Reclassifier Sizes
Bearing Inch
3 6 10 15 20 BI BI BI BI BI
SCFM
0.09 0.18 0.30 0.45 0.60
5 0 2

Standard reclassifier for single or double row bearings.
5 0 2
5 0 1
Double Row Thrust Bearing on 3 Diameter Shaft = 6 BI or .18 SCFM
Single Row Radial Bearing on 3 Diameter Shaft = 3 BI or .09 SCFM
Dry Mist to Wet Mist
Velocity and Turbulence Converts the Dry Mist to Wet Mist
Distribution Header
Reclassifier
502
Mist Manifold
Oil Mist Generator Spent Oil Collection Container
Typical Pump Application
Evolution of Oil Mist
Oil Mist was develop in Europe; 1930s. Introduced to the US Market ; 1948 STLE Mtg. First HPI system was in Amuay, Venezuela; 1960s.
First HPI paper on oil mist lubrication published by Mr. Charlie Miannay; 1974 Hydrocarbon Processing.
System reliability improved; early 1980s.
Pure oil mist became the standard; 1990s

Closed loop system developed; early 2000.
1960s System Installation
1960s Pure Mist
1960s Purge Mist
One Way System
Pure Mist Per API 610
2010 Purge Mist
Oil Level Is Visual
Closed Loop System

Return Header Distribution Header
OMG
Demisting Device
What is Oil Mist?
What is Oil Mist?
Oil mist systems are centralized lubrication systems that continuously and efficiently atomizes oil into small particles and then conveys and delivers the correct amount of the pressurized oil mist lubricant to bearings and metal surfaces resulting in improved lubrication, fewer failures/repairs, lower life cycle costs
and extended machinery life.
What is Oil Mist
Oil Mist is an Aerosol; Not a VOC Oil Mist 1 Part Oil & 200,000 Equal Parts Air Will Not Support Combustion Dry Mist is Generated for transportation 20 H2O Pressure Oil
What is Oil Mist?
Toxicity Considerations of Oil Mist

Per the American Conference of Governmental Hygienists
Long term threshold limit of 5 mg/m3 for 8 hours Short term exposure limit of 10 mg/m3 The 5 mg/m3 is not commonly exceeded around equipment in outdoor locations. Indoor applications use Closed-Loop Systems. California Rule 1173 Exempts Lubricating Fluids from being a Fugitive Emission or Volatile Organic Compound (VOC
Reference: Oil Mist Lubrication Handbook; Mr. Heinz Bloch
What is Oil Mist?

Flammability of Oil Mist
The air-oil mixture is several orders of magnitude too lean to sustain combustion.
Experiments have shown the concentration of oil mist in the header ranges from 0.005 to as little as 0.001 of the concentration generally considered flammable.
The oil/air mixture is substantially below the sustainable burning point
Reference: Oil Mist Lubrication Handbook; Mr. Heinz Bloch
What is Oil Mist?

Oil Consumption with Oil Mist .65 in3 per Hour per SCFM 10 SCFM = 6.5 in3 per Hour Typical Pump = 0.27 SCFM 10 SCFM = 27 Pumps Max of 30 SCFM = 2 Gallons/Day
Lubrication with Oil Mist
Generate Dry Oil Mist for Conveying; Below 3 microns
Lubricate with Wet Oil Mist; Larger than 3 microns

Reclassifiers preferred location is on the mist manifold Locate the reclassifier within 2 meters of bearings
Bearing isolators are preferred to help contain the oil mist in the bearing housing
Reclassifiers

Vent/Drain of bearing housing is very
important
Oil mist flow is required to apply mist to bearings
Restricted flow exiting bearing housing

increases internal pressure reducing flow of oil mist Bearing housing vent/drain adequate to vent SCFM flow entering through reclassifiers
Single Row Bearings

Mist Flow for Bearing Lubrication Radial Brgs. & Motor Brgs.
Vertical Applications
Always
Flow through is always preferred.
Double Row Bearings

Mist Flow for Bearing Lubrication
Vertical Applications Recommended:
Brg. Isolators
150 Kw & Up 3000 RPM & Up Always
Flow through is always preferred.
Triple Row Bearings
Two Points
Two Points
Flow through is required.
Applying Oil Mist
Applying Oil Mist
Two methods of applying oil mist
Pure Oil Mist or Dry Sump No Oil Level
Purge Oil Mist or Wet Sump Oil Level is Maintained
Applying Oil Mist

Pure Oil Mist or Dry Sump
Common on all rolling element bearings Reduces bearing and mechanical seal failures Eliminates manual lubrication tasks Bearing temperature is reduced Eliminates recirculation of hot
contaminated oil
Allows removal of cooling water
Applying Oil Mist

Purge Oil Mist or Wet Sump Typical on sleeve bearings and gearing. Positive pressure prevents intrusion of air borne contaminates i.e. moisture & dust.
Oil level is maintained and must be controlled; Oil mist will increase the oil level. Heavily thrust loaded bearings may require the oil sump
Applying Oil Mist
Reclassifiers For Purge Mist

Sleeve, Babbitt or Plain Bearings are typically Purge Mist Applications Purge Mist = Light Service or Low Flow Rate
Oil Mist is not Primary Prevents Intrusion of Air Borne Contaminates
Applying Oil Mist
Sizing Reclassifiers For Pure Mist

Anti Friction Bearings are typically Dry Sump Applications
Formula Sf x D x N
Sf = Service Factor D = Shaft Diameter in Inches N = Number of Rows Sf = .009 for Light Loads i.e. Motors .022 for Moderate Service
.045 for Heavy Service
Oil Mist is Primary Lubrication with NO Oil Sump

Lubricates and Prevents Intrusion of Air Borne Contaminates
Retrofitting Oil Mist
Pump Retrofit
Trico Oiler Plug on Top
Slinger Rings
Pump Retrofit
Single Lube Point
Lip or Labyrinth Seals 3000 RPM and Less than 150 Kw
Remove Trico and convert to pure mist
Remove slingers, plug drain back ports when pump is out
Pump Retrofit
Single row bearing receives adequate lubrication
Single inlets and bearing isolators may require additional vent to allow flow through the multiple row bearing
Pump Retrofit
Two points required with 150 Kw and operating at 3000 RPM
Field retrofit two points with tap in bearing cap
Bearing isolators often

require a second lube point.
Remove slingers, plug drain back ports when pump is out
Pump Retrofit
API Specification calls for two lube points outboard of bearings

No Trico Oiler
No Slinger Rings No Oil Sump
Pump Retrofit
Older model between bearing pumps often require directional reclassifiers
Pump Retrofit
Bearing arrangement did not allow mist to flow through
Oil mist would not get to inboard brg.
Pump Retrofit
Oil mist is directed into the rolling elements and passes through to inboard bearing
Directional's are not required on current API edition between bearing pumps
1980 Pure Mist
Motor Retrofit
Not as easily retrofitted as pumps No defined or sealed bearing housing Grease must be removed completely.
Items of Concern Seal inlet port to junction box Oil Compatible lead wire insulation Oil compatible epoxy coating Case drain required on coupling end; plug fan end drain port Vent lines routed away from fan
Motor Retrofit
Oil mist must pass through the bearings from top to bottom
Sealed bearings are not compatible with oil mist lubrication

Low point case drain is required on vertical motors
Pillow Block
Bearings operate 3C to 10C cooler with oil mist
No more over or under lubrication
No re-greasing
No oil changes
No dirty oil
Turbine Retrofit
Eliminates baking of grease
Mist flows through bearings top to bottom
Purge Oil Mist & Typical Applications
Purge Applications
Two Methods to Control the Oil Level

Oil Level Site Assy. Constant Level Oiler
Turbine Application
Little or no modifications required when retrofitting purge oil mist to existing equipment.
Prevents intrusion of steam condensate
Helps with lubrication when in slow roll mode
Gear Box Applications
Gear box applications are always purge mist applications. The oil mist prevents intrusion of
airborne contaminates, keeps internal components

coated with oil when equipment is sitting idle. Purge mist housing must have oil mist vent and level
control.
Gear Box Applications

Cooling Tower Fan Gear Box
Pure & Purge Applications
Purge Mist on Gearing
Pure Mist on Bearings
Oil Mist Justification

Operating Expense Items
Pump Bearings Mechanical Seals Fire Potential
Reliability Savings Cost & Risk Avoidance
Motors
Man Power Oil Savings Cooling Water
Lost Production
Non-Spared Equip.
Pump Maintenance Experience
Mechanical Seal Experience

Motor Brg. Experience

Manpower Efficiencies
Actual Experience
Maintenance staff no longer changes oil or regreases motors. 180 Oil Sumps Oil Changes: 2 per year Oil Fills/Checks: 4 per month Time Per Sump: 4.5 hours/year Cost: $67/hour Manpower Credit: $55,000/year .25 Hrs to re-grease mtrs. semi annual
With 600 Pumps and Motors oil mist redirects 3000 man hours per year to proactive failure avoidance and reliability improvement tasks.

Oil Savings

Potential Fire Damage
Get the Facts on Oil Mist Lubrication

Published in Hydrocarbon Processing August Issue 2008 Heinz Boch & Don Ehlert
Questions
Contact Info
Don Ehlert Lubrication Systems Co. Houston, TX USA Phone 1-713-464-6266 Email don.ehlert@colfaxcorp.com

Oil Mist Lubrication Training

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Oil Mist Lubrication Training

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Lubrication Systems Company

Lubrication Systems Company

Trico Oiler Plug on Top

Lubrication Systems Company

Applying Oil Mist To Equipment

Lubrication Systems Company

Introduction & Evolution of Oil Mist Lubrication

Introduction to Oil Mist

Lubrication Systems Company

Oil Mist can be applied to most rolling element bearings

Allows use of higher viscosity lubricants.

Introduction to Oil Mist

Lubrication Systems Company

Basic Oil Mist System

Introduction to Oil Mist Large Scale System

Lubrication Systems Company

3 to 30 SCFM Air Flow Range 2 Gal. Maximum Oil Consumption

Serves 15 to 80 Pumps and Drivers

Introduction to Oil Mist

Lubrication Systems Company

Dry Mist Out

Introduction to Oil Mist

Lubrication Systems Company

ABOVE WET MIST FOR LUBRICATION

OIL MIST PARTICLE SIZES

Generation & Distribution

Introduction to Oil Mist

Lubrication Systems Company

Introduction to Oil Mist

Lubrication Systems Company

Double Row Thrust Bearing on 3 Diameter Shaft = 6 BI or .18 SCFM

Single Row Radial Bearing on 3 Diameter Shaft = 3 BI or .09 SCFM

Introduction to Oil Mist

Lubrication Systems Company

Dry Mist to Wet Mist

Velocity and Turbulence Converts the Dry Mist to Wet Mist

Introduction to Oil Mist

Lubrication Systems Company

Oil Mist Generator Spent Oil Collection Container

Typical Pump Application

Evolution of Oil Mist

Lubrication Systems Company

Pure oil mist became the standard; 1990s

1960s System Installation

Lubrication Systems Company

1960s Pure Mist

Lubrication Systems Company

1960s Purge Mist

Lubrication Systems Company

One Way System

Lubrication Systems Company

Pure Mist Per API 610

Lubrication Systems Company

2010 Purge Mist

Lubrication Systems Company

Oil Level Is Visual

Closed Loop System

Lubrication Systems Company

Lubrication Systems Company

What is Oil Mist?

What is Oil Mist?

Lubrication Systems Company

and extended machinery life.