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LUBRICATION SYSTEM
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Lubrication and lubricants are the most important aspect for running a machine without
giving pre-matured failure. It is also used to minimize power loss, heat generation, wear and tear
of mechanical components as well as for smooth running of the machine. Production and
productivity are very much dependent on lubrication system.
This study material focuses on the subject “Lubrication”. Optimum and correct way of
using lubricants are the main issue now a days. This study material will help to know how
lubricants can be selected and where the use will be.
Study material includes the selection of lubricants, their specific place of application,
methods of using oil and grease lubrication, different lubrication equipments, etc. which are
needed for any lubrication personnel to know well. Our trainees and employees will be certainly
benefited by this study material.
_________________________ _________________________
Prepared by Approved by
Rohit Kumar & S.P.Sharma Mr. K N Choubey
Mechanical Group Head - Mechanical
1. What is Lubrication ? 3
2. Function of lubricants 3
3. Types of lubricants 3
4. Selection of lubricants 5
5. Principle of lubrication 10
What is Lubrication?
Lubrication is the science of reducing friction between two solid bodies in relative
motion by interposing a lubricant between their rubbing surfaces. It is the most vital
singular factor in plant maintenance. It keeps the plant young, contribute to better
profits by improving the life of the wear components, equipment availability and
reliability. Much work has been done in this direction my improving lubrication,
mechanization, modification of the existing lubricating system, elimination of
lubricant wastage and thus bringing down the consumption of lubricants and wear
parts.
Function of Lubricants :
The principal functions of lubricants are :
• Reduce friction.
• Control temperature rise.
• Control wear
• Control Corrosion
• Transmit Power in case of hydraulics
• Washout debris and contaminants
• Decrease power requirement
• Act as a seal (Seal out contaminants)
• Carry out heat (Sometime used for cooling)
• Dampen Shock
Secondary results include those leading to economic benefits :-
Types of Lubricants :
Liquid lubricants –
• Straight or unadulterated
• Compound with fixed oils or their derivatives
• Compound with special additives.
• Compounded with fixed oils or their derivatives, plus chemical additives,
such as polymers and metal soaps.
When the load is applied on the grease the soap will release from oil. The pressure
again redirects the oil to go back to soap. The phenomenon is known as
SWEATING. Under the load the grease is PLASTIC, and when the load is released
again it is solidified.
Solid Lubricants : Solid lubricants are rarely used directly, commonly it is added
with other lubricants to increase its some of the properties. Some Examples of Solid
lubricants are Graphite, Molybdenum disulfide, mica, talc or soap, lead carbonate,
wax, etc.
Additives : Additives are the substances which are added with the lubricants to
fortify some of their properties. Some of the Additives are : Metallic phosphates, few
additives, metallic oleates, metallic chlorides, Metallic sulfides, metallic stearates,
metallic oxides and metallic oxalates.
Selection of Lubricants
Grease Oil
• Stays longer • Has less internal friction.
• Drips less • Serves high speeds
• Serve certain extreme condition. • Serves close tolerance.
• Provide better sealing • Serves as a coolant
• Requires less frequent • Flushes away contaminants.
• Lower costs • Lower costs
Ranges Are The Penetration In Tenths Of A Millimter After 5 Seconds At 770F (250 F)
Cone Penetration : The cone penetration of grease is determined with the ASTM
(American Standard of Testing Material) Penetrometer. After sample is prepared, the
cone is released and allowed to sink into the grease under its own load for 5 sec. The
depth the cone has penetrated is the reads in tenths of a millimeter and reported as the
penetration of the grease. Since, the cone will sink further into softer greases. ASTM
penetrations are normally measured at 25 deg. C.
Dropping point : The dropping point of any grease is the temperature at which a drop
of material fall from the orifice of a test cup under prescribed test condition.
Oil Separation : The resistance of a grease to separate oil from thickener involves
certain compromises. When greases are used to lubricate rolling contact bearings a
certain amount of bleeding of oil is necessary in order to perform lubrication function.
On the other hand, if the oil separates too much readily from a grease in application
devices, a hard, concentrated soap residue may built up which will clog the devices
and prevent or retard the flow of grease to the bearing. Further leakage of separated
oil from bearings can damage materials in production or equipment components such
as electric motor windings.
In application devices, such as central lubrication system and spring loaded cup when
pressure is applied on the grease on more or less on continuous basis, oil can be
separated from greases by a form of pressure filtration. The pressure forces the oil
through the clearance spaces around plungers, piston or spool valves, but since the
soap cannot pass through the small clearance it is left behind. This may result in
blockage of the devices and lubricant application failure.
E.P. and wear preventation test : As per ASTM (D2596) the standardized test
procedure to determine E.P properties of greases using the four ball extreme and the
Timken (ASTM D 2509) load tester.
PRINCIPLE OF LUBRICATION
The formation of a thick fluid film that will separate two surfaces and support a
load as the two surfaces moves with respect to each other, internal friction in the
fluid causes it to be drawn into the space between the surfaces. The force
drawing the fluid into space A is equal to the force tending it out, but since the
cross sectional area the outlet section is smaller than inlet, the flow of fluid is
restricted at the outlet. The moving surface tries to “compress” the fluid to force
it through the restricted section with result the pressure in the fluid rises. The
thickness of the film in this case is high enough to eliminate any contact
between the surfaces, thus the coefficient of friction micron is even in the order
of 0.005.
1. Firstly the machine is at rest with the oil shut off and the oil has leaked from
the clearance surface. Metal to metal contact exists between the journal and
the bearing.
2. Secondly, when the machine has been started and the oil supply turned on
filling the clearance space, the shaft begins to rotate counter clockwise and
friction is monetarily high so the shaft tends to climb the left side of bearing.
3. Finally , as it does this, it rolls onto a thicker oil film so that the friction is
reduced and the tendency to climb is balanced by the tendency to slip back.
As the journal gains speed, it draws more oil through the wedge shaped
space between it and the bearing. Pressure is developed in the fluid in the
lower left portion of the bearing that lifts the journal and pushes it to right.
Under steady condition the upward force developed in the oil film just equals
the total downward load and the journal is supported in the slightly eccentric
position.
One of the more common applications of the hydrostatic principle is an “oil lifts”
for starting heavy rotating machines, such as steam turbines, large motor steel
mills and rotary ball and rod mills. Because metal to metal contact exists
between the journal and the bearings when the journal is at rest, extremely high
In the case of rolling contact bearing as the ball or roller on their raceways, the
lubricant is carried into the convergent zone approaching the contact area and
as the pressure on oil increases. The viscosity increases. As the viscosity
increases, the pressure further increases. This hydrodynamic pressure
developed in the lubricant is sufficient to separate the surface at the leading
edge of the contact area and as the lubricant is drawn into the contact area and
as the lubricant is drawn into the contact area the pressure on it increases
further together with the viscosity. Due to this high viscosity and the short time
required for the lubricant to be carried through the contact area, the lubricant
cannot escape and separation of the surface can be achieved. Hydro-dynamic &
Hydrostatic films are for sliding contact surfaces whereas Elasto-hydrodynamic
film is for rolling contact surfaces.
Boundary Lubrication :
If none of the above these conditions exists the condition will be of boundary
lubrication. Boundary larger lubrication is obtained when the thickness of the
lubricating film is of the same order of magnitude as the individual oil molecules.
This condition may present when the quantity of oil is insufficient or the relative
movement between surfaces is too low. The coefficient of friction micron in this
cases is high-as high as 0.1, and on the incipient metallic contact, can rise to
0.5. When the coefficient rises, friction losses also increases. These are
converted into heat, which raises the temperature of the lubricant, thereby
reducing its viscosity so that the load carrying capacity of the film is even lower
in the most case so low that the surfaces seize together.
Once through oiling : Once through oiling is so named because the oil passes
through the bearing only once and is lost for further use. Method of this type
includes oil cane lubrication, drop feed oiling, gravity feed bottle, wick feed
lubrication.
a) Oil can Lubricator : This is the direct application of oil to a moving machine
part from a hand oil cane. It is used for small bearings, chains. This method
has limitations. The excess oil runs off bearing. The parts operate with
insufficient oil until next oiling.
c) Wick Feed Oiler : The wick feed oiler consists of an oil reservoir and a wool
wick. The wick draws oil from an oil cup by the capillary and siphoning action
of the wick and feed it into an opening in the bearing. The amount of oil
being delivered to the bearing can be regulated by changing the size of the
wick. The reservoir should be kept well filled, because the rate of oil feed
depends on level of the oil in the reservoir.
Reuse Methods : As referred to “all loss” lubrication, the lubricants supply to the
bearings gradually leaks away and is not reused. In short, the bearing passes
through the region of mix film lubrication and operate much of the time under
boundary conditions. A closer approach for maintaining a safe oils supply may be
accomplished with application devices such as wick feed oilers, drop feed cups
bottle oilers. Even with regular application of small amount of lubricant, their film
bearings require proper selection to control wear and provide satisfactory service
life. Reuse method of oil application include circulating supplying lubricant for one
or more machine and self contained system such as bath, splash, food and ring
oiling.
a) Chain Oiling : Chain oiling is similar to ring oiling except that a small linked
chain is substituted for ring. Chain will carry larger volume of oil than does
the ring.
b) Oil Collar : An oil Collar may be used to carry oil from reservoir to journal
which are rotating at high speed so that rings and chains would slip. The
collar fastened to the journal rotates carrying the oil to an over head scraper
which removes and distribute oil to bearing and gears.
c) Ring Oiling Method : In ring oiling method, a metallic ring larger in diameter
than journal rides on it and turns as it rotates. The ring dropping into oil,
carries oil to the top of the journal where it flows along and around the
journal providing lubrication before returning to the reservoir.
SHAFT
RING
d) Splash Oiling : In this method, some moving parts is in direct contact with
oil in the bottom of the casing. As the moving part turns, it splashes and
carries the oil in to the other parts within the casing keeping them well
supplied with lubricant. This is very reliable method of lubrication.
In gear boxes, one gear dips into the oil and carries to the moving parts and
to the meshing zones of the gears.
The gear teeth carry oil directly to some gears and splash it to others and to
collecting through which leads it to bearing not reached by splash.
e) Mist Oil Systems : In oil mist lubricators, oil is atomized by low pressure
(0.7 to 3.5 bar) compressed air forming a practically a dry mist or fog, that
can be practically a dry mist or fog, that can be transported relatively long
distance in small tubing. When the mist reaches the application point it is
condensed or collapsed into larger particles that wet the surface and provide
lubrication.
a) Reservoir
b) Pump
c) Cooler
d) Filter/Strainer
e) Different Gauges etc.
1. By hand
2. By hand operated mechanical devices like grease gun, which delivers the
grease to one point at a time.
3. By centralized grease systems which supply a number of points at a time
from a central reservoir.
Hand Application : As the name implies is the application of the grease directly to
the parts by hand. Ball and Roller bearings are greased by fingers into the space
between the balls and rollers. Grease application is also done to open Gears and
Guiders.
(a) Grease Cup : It consists of a small reservoir for holding the Grease and
pressure is exerted by screwing it down and forcing the grease into the Bearing.
GREASE CUP
(b) Grease Gun : The grease gun is a very popular device for grease lubrication at
the various lubricating points. The gun delivers the grease by operating the
lever, in turn grease is forced into the fittings to reach the bearing surface.
GREASE GUN
(a) Single line system : The three way valve, operated manually or automatically,
either directs pump pressure into the supply line or relieves the pressure in the
line to permit the spring return to reset the valves.
(b) Dual line (FARVAL) system: The four way valve operated manually or
automatically directs pump pressure to one line and then the other. When one
line is pressurized the other line is relieved.
(c) Multi line (DELIMON) system : The gear train moves the cam plate which in
turn moves each plunger up & down and creates suction & delivery. During
delivery the lubricant is forced out to the outlet pipe.
Note : This gun builds 2,500 lbs. of air pressure. Should this pressure not be
enough to free a bearing, the bearing should be removed and cleaned. Make
sure that the lubricant is packed solidly, so no air pockets can form.
f) Replace follower on the stem, and turn the crank to the right-clockwise-until
the fill lower is back in position.
g) Replace cap on cylinder.
h) Open the air relief valve. Turn the crank to the right until lubricant begins to
ozze out at the valve opening. Then close the valve.
i) Swing the pawl lever and handle up, into normal operating position.
j) Move the handle up and down until lubricant appears at the hoes coupler.
- Larger air pockets may be quickly removed by opening the air release valve and
turning the crank slightly to the right.
Correcting the faulty gun operation : If there is lubricants in the gun but it can not
be pumped out :
NOTE : Foreign particles in the lubricants may score the piston or casing,
and cut down the pump pressure and operating efficiency.
(b) Air Operated (Goliath) Grease Pump : It is an air operated grease gun. It has
heavy duty construction for longer life in difficult operating condition. Front
caster wheel and rear wheel tyres are made of rubber to suit in rough plant,
garage floor, etc. It is supplied with 7 feet hose with control valve. Helix arm and
worm gear construction assure positive mechanical priming to handle heavier
grease even in cold weather with no air pockets. The rugged air motor develops
greases pressure 33 times the air pressure applied.
Other Features :
a. Capacity - 40 lbs.
b. Maximum pressure – 5,000 psi.
c. Minimum air pressure required – 40 psi.
d. Discharge – 14 ozs / minute average
e. Height – 31.5”
f. Width - 17.75”
g. Length – 39”
h.
Outlet has double check valve with 3/8” & ¼” bush to connect ¼” hose.
It is a hand operated dual line pump. 2 to 200 bearing points can be lubricated
at a time up to ¼ mile distance. It’s selector is 4/2 way hydraulic change over
valve to supply lubricant in both lines alternately when pressurized by handle of
the pump. It has 2 suction port with strainer, two check valves for double acting,
inlet line to tank for excess lubricant for easy handling of selector. It requires
less maintenance. It is used for centralized lubrication, remote and difficult
approach & normal industrial
machines etc.
Other Features :
Work Design : All lubrication lines are plumbed directly from the pump to the
lubrication points. The lubricant is metered by the pump, the quantity being
adjustable. The pump may be operated manually or by an electric motor.
Mode of operation : The worm which is fitted to the drive shaft engaged the worm
wheel, which is attached to the vertical distributor sleeve. This sleeve rotates the
scraper with wedge plate, which pushes the greases out of the container through
the strainer into the Gear Box. The rotating movement of distributor sleeve is
transmitted to the distribution cylinder through the two Bevel gears which has
transmission ratio of 1:1.
The cam plate which is fixed on top of the distribution cylinders turns with the latter
and moves each cylinder up & down once or three times per revolution depending
on the rise of the cam plate (single/three). During the suction stoke a quantity of
lubricant is drawn through the suction port of the distribution cylinder. During the
feeding stroke the lubricant is forced out of space through the pressure port into the
outlet ports.
The principle of separating and purifying liquids by centrifugal force in the disc type
centrifuge is equally easy to understand, for the discs divide the liquid into thin layers
so that centrifugal force can act on the thin liquid strata most.
In the bowl of a centrifugal oil purifier, a mixture of oil water and dirt will be separated
by centrifugal force into three layers. Each whirling particle or droplet will lend to “fly
out” like the ball on the string. The dirt will go to the periphery of the bowl. The water
will form the next layer and the oil. Lightest of the three, will collect at, and be
discharged from, the point nearest the centre.
Techniques of Separation:
Definitions :
Throughput : This means the quantity of liquid supplied per unit time. The throughput
is given in cu.m/h or I/h (lmp.galls/h).
Reception ability : This means the largest liquid quantity that the bowl can treat per
unit time, expressed in cum/h or 1/h (Imp. Galls/h)
Size and shape of Particles : The larger the particle, the quicker is the
sedimentation. The particles to be separated off must not be so small that the mixture
is getting near colloidal state. The smooth and round particle is easier separated off
than the irregular and elongated one. Rough treatment such as in pump can split the
particles, with reduced size and separating speed as a result.
Viscosity : The more fluid a liquid is, the quicker is the separating process and the
better the separation. In other words, low viscosity improves the separation result. The
viscosity can in many cases be reduced by heating.
Time in centrifugal field : If the separation is not satisfactory, the throughput must be
reduced. Lower throughput gives a better separating result.
Handling : Drums can be unloaded without damage from trucks by sliding them down
with the help of wood or metal skids (05 mm * 2.5 mm). Before unloading the brakes
of the truck should be set firmly and wheel should be blocked. The skid should be
securely attached to the truck.
A drum standing on end with bungs up can collect rain water or condensed
atmospheric moisture inside the too annular. This water can gradually be drawn in
around the bungs by the breathing of the drums as the ambient temperature rises and
falls. This can occur even with the bungs drawn tight and the temper proof seals in
place.
PROTECTIVE DEVICES
DEVICES TYPES
a) Dipstick
30. More greasing should be avoided. It normally damages lubricating seals and
packings.
31. Some oils are injurious for our eyes and skin. Avoid touching of oil.
32. Lubrication oil should not be used for cleaning components. Proper solvents
should be used only.
33. Lubricants are too costly, avoid misuse of lubricants.
34. Lubricating oil should not be used in hydraulic system. Hydraulic oil has some
specific properties, which a lubrication oil does not have normally.
35. While using coupler, points of grease buttons should be cleaned properly.