OIL MIST LUBRICATION

CONTENTS

 HISTORY OF OIL MIST LUBRICATION.

 HOW MODERN OIL MIST IS GENERATED.
 WORKING PRINCIPLE.
 TYPES OF OIL MIST.
 ADVANTAGES OF OIL MIST LUBRICATION.
 BENEFITS OF OIL MIST LUBRICATION.
 APPLICATIONS.
 LIMITATIONS.
 CASE STUDY.
 CONCLUSION.

HISTORY OF OIL MIST LUBRICATION

The Oil Mist principle was developed by a bearing manufacturer in Europe during the 1930s.
The problem that nurtured this development was the inability to satisfactorily lubricate high-
speed spindle bearings on grinders and similar equipment. In 1948, oil mist was brought to
the United States in the steel industry. Since'the late 1950% oil mist has been servicing
rotating equipment 'in the refining industry. The first use of oil mist in the petrochemical
industry was in the Gulf Coast due to the high humidity and condensation resulting in
bearing failures. The speed of these bearing was too high for grease lubrication, and liquid oil
generated too much heat through fluid friction, necessitating an expensive recirculating

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system. Continuous thin-film lubrication with Oil Mist provided a solution. The purging and
slight cooling effects of the carrier air gave additional benefits. The Oil Mist generator
resulted later from this development and used a small amount of air to produce a dense
concentration of small oil particles. About 97% of these particles could be transmitted to the
bearings without condensing in the piping, regardless of the distance of the bearings from the
Oil Mist generator itself.

In 1958, air heaters were developed because it was discovered that, by heating the air used to
generate Oil Mist, oils of just about any viscosity could be atomized. Many applications,
subject to extremes in ambient temperature, use air heaters to ensure a constant oil/air ratio
regardless of the oil viscosity. Today Oil Mist is still used to lubricate high speed spindles in
grinders. Included in the increasing range of Oil Mist applications are systems applied to all
types of other machine tools, web and sheet processing equipment, belt and chain conveyors
rolling mills, vibrators, crushers, centrifuges, kilns, pulverizers, ball mills, dryers and liquid
processing pumps.

Oil Mist is an aerosol with an appearance of smoke or fog. Oil Mist systems are made up of
several simple but effective components, which can supply the proper lubrication for electric
motor bearings. The main components of an Oil Mist system are the generator head or
venturi, reclassifiers, vents and drains. Passing high velocity air over an orifice that pulls oil
into an air stream creates the oil mist.

Later the technology was extended in a limited fashion to the petrochemical industry. Initial
applications were for process pump lubrication. A great deal of caution was exercised with
the new technology and while progress was made, it was slow. Experience in recent years has
shown that many of the early concerns were not really applicable and that oil mist lubrication
is a very efficient and reliable method for attaining optimum bearing life.

HOW MODERN OIL MIST IS GENERATED

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Modern oil mist is generated by the introduction of liquid oil

and air into the sonic velocities at the neck of a vortex chamber (shown here). There the oil is
pulverized into a homogenous form creating oil particles or droplets of 1 to 3 microns within
the air flow

This oil suspension in dry instrument air is a mixture if 1 part oil to 200,000 parts air or 5
ppm oil to air. In this form the mist has the characteristics of a “dry mist” a lean stable
mixture which can be conveyed horizontally up to 600 feet. Incidentally, ambient
temperatures do not affect oil mist during the 7 minutes maximum it takes for the oil mist to
arrive at the bearings furthest from the generator.

It must be made clear that in order to achieve the maximum results the cleanliness of the air
and the oil must be assured before the generation of the oil mist in the Vortex chamber. For
this, when necessary, additional filters should be applied both for the air and the oil. For the
oil filters a minimum efficiency of β5 = 200 is recommended.

WHAT IS AN OIL MIST SYSTEM AND HOW DOES IT WORK?

Oil mist is formed of oil particles from 1.0-3.0 microns suspended in an air current,
consisting of 1 part oil to 200,000 parts air. This mixture is not a volatile organic compound
(VOC); therefore there is no risk of explosion or combustion. There are two main oil mist
applications, pure mist for lubrication and purge mist for preservation. The equipment and its
operating conditions determine the type of mist application that should be used. Due to its
advantages, whenever possible, pure mist is recommended to lubricate rotating equipment.

Oil Mist is a centralized system in which the energy of compressed gas, usually air taken
from the plant supply, is used to atomize oil. Oil is then conveyed by the air in a low pressure
distribution system to multiple points of lubricant application.

The compressed air is passed through a venturi. Oil, siphoned from a reservoir by the air
flow, is atomized into a fine spray. Baffles downstream from the venturi nozzle causing the
larger oil particles to coalesce and return to the reservoir. The remaining air-oil-mixture is Oil

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Mist. Oil Mist contains oil particles (droplets) averaging about 1-1/2 microns in diameter
(.00006 inches), which can be conveyed through distribution piping (mist manifold), at
velocities up to 24 feet per second, to application fittings (mist fittings which meter oil to
bearing housings). Air-borne oil particles are then "wetted out" by impinging upon bearing
surfaces rotating at sufficient speed to cause adherence and the formation of larger drop sizes.
Because there are no moving parts in the basis Oil Mist generator system, and because the
system pressure is very low (manifold pressures from 5 to 40 inches of water), it is a reliable
lubrication method. Also, the system can be interlocked with machine operation or an alarm
system to ensure proper functioning. Note that, even when malfunctions occur, most bearings
will operate for hours on an existing film of lubricant.

Fig: Principle Of Oil Mist Generation

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FEATURES OF OIL MIST GENERATOR

 Electrical Connections - All enclosed in a large oil-tight terminal box with cover, for
convenience and service.
 Mist-Generated Head - Available in three interchangeable CFM ratings for generating
microscopic "air borne" mist.
 Mist-Pressure Gauge - Indicates mist pressure in distribution system. Dual scale: 0 to
100" water column, 0 to 250 CM water column.
 Air Pressure Gauge - Indicates regulated air pressure to mist-generating nozzle. Dual
scale: 0 to 100 PSI, 0 to 7 KG / CM.
 Air Regulator - Provides accurate regulated control of discharged air pressure, from 0
to 80 PSI.
 Visual Oil-Level Gauge - Permits quick visual check of oil supply in reservoir.
Graduated in quarts.
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 Oil Thermometer - Indicates temperature of oil in reservoir. Dual scale: 20º to 240ºF,
minus 5º to 120ºC.
 Oil Heater - Maintain oil at proper temperature for atomization, through automatic
thermostat-down to 40ºF ambient.
 Solenoid Air Value - Automatically starts and stops the air supply. Synchronizes
lubrication with machine operation.
 Moisture Separator - Removes up to 98% of condensate from air. Automatic drain.
 Oil Reservoir - Provides useable oil storage capacity of 840 CU. IN. (3.6 GAL).
 Reservoir Safety Value - Protects oil reservoir from abnormal mist pressure. Opens at
10 PSI.
 Oil-Level Switch - Energizes a warning signal, either visual and / or audible, when
reservoir oil level is low.
 Mist Pressure Switch - A safety switch which responds to drop or rise in mist
pressure. May be used to energize a warning signal and / or stop machine.
 Locking Cover - Presents unauthorized adjustments of regulated air and oil flow, and
tampering with terminal strip (not shown).

OIL MIST DISTRIBUTION SYSTEM

Once generated, the mist is transported through a pipe, or distribution header. The header is
normally 2 inch NPT threaded galvanized steel pipe , schedule 40. The header must be
installed with a slope in the direction of the generating console, this allows greater efficiency
in oil consumption, since particles that get condensed in the pipe, by contact among them or
contact with the walls of the pipe, are returned to the reservoir of the console to be re-
circulated. The slope gradient will depend on the length of the header the viscosity of the oil
and the temperature. Figure contain some percentages of recommended inclination which
depend on the viscosity and temperature of the oil.

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Figure: Minimum slope towards the console of the mist distribution lines. A slope
of 2% indicates a descendant of 2" for every 100" of pipe.

In practice, usually the length of pipe is set on the header which will have the required slope.
Normally, in long headers (greater than 90 m), the first 15 meters will have a slope in the
direction of the generating console, since most of the condensation occurs in this area. If the
lines are smaller (30-45 m), the complete header can be inclined towards the console. To
reduce the quantity as well as the severity of impacts between particles, the speed of flow
within the header must be around 8m/s (26 ft/s) this assures a laminar flow and reduces the
amount of condensed mist.

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TYPES OF OIL MIST

Oil mist can be applied in two forms: pure mist (dry sump oil mist) or purge mist (wet
sump oil mist). With purge mist applications, the oil mist is injected into the vacant space
above the liquid oil bath, primarily in gear boxes with journal (plain) bearings. This is done
to exclude water and other contaminants. With pure mist applications, the mist replaces the
liquid oil bath in the rolling element bearing housing where there is no other lubricant being
supplied to the bearings.

 PURE OIL MIST:

Pure oil mist is often referred to as dry sump oil mist, which indicates that no oil or grease is
maintained in the bearing housing being serviced. The bearings are lubricated directly and
continuously by a supply of fresh, condensed clean oil. Coalesced oil is obtained by the
introduction of turbulence into the feed mist stream within an enclosed space. Additional
condensing action is provided by the rotation of the bearing elements. The mist application
fittings (reclassifiers) are individually sized to each bearing or the equipment chamber. This
is necessary to feed the appropriate amount of lubricant to the each of the various sizes and
types of bearings found within a drive/load string. While pure oil mist is the primary means
of lubrication for operating equipment it also acts to preserve and protect the rolling elements
within stand-by or stored equipment.

 PURGE OIL MIST:

Purge oil mist is often referred to as wet sump oil mist, which indicates that an oil level is
maintained in the equipment being serviced. The oil mist is applied on top of the oil sump
which creates a slight positive pressure that prevents thermal cycling of the cavity and
eliminates the intrusion of airborne contaminates. Purge oil mist is not the primary means of

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lubrication for operating equipment but it is extremely effective in preventing water build up
and corrosion in stand-by, idled and stored equipment.

The equipment outfitted for purge oil mist is typically gearboxes, turbines with sleeve
bearings, motors with sleeve bearings and oil reservoirs of lube oil systems.The continuous
film of oil that is applied to internal machined surfaces prevents corrosion from forming and
causing premature equipment failure.

The oil mist injection point must be above the oil sump with an unobstructed flow path to a
vent, also above the oil level. This can be accomplished by using two separate openings on
top of the housing, or by using a vent fill assembly in a single opening. The vent fill
assembly incorporates a mist injection tube, connection for venting and a removal cap for
adding oil to the sump. The pressure above and below the oil level must be balanced by using
an oil level sight assembly or a constant level oiler with balance line. An overflow tube
incorporated in the oil level sight assembly and constant level oiler is adjusted to allow
excessive oil buildup to overflow to the collection container and to vent the bearing housing.
The top of the overflow tube should be set ¼” above the desired oil level.

LUBRICANT CHOICE

Type of Oil:

For applications that EP oils are not required: Use mineral oils for turbine and for all
industrial applications. Use motor oils for applications in vehicles.

For applications that EP oils are required: It is better to use adequate oils for Oil Mist
applications. It is also adequate oils for industrial gears of vehicles.

In Oil mist installations oils with common additives can be used with the following
exceptions:

1. Oils with solid particles suspended like graphite, etc…should not be used without
manufacturer approval.
2. No-misted fluids ,specially silicone, in 5/million rates.
3. Additives for old motors and others similar components.

Oils made from lactic and soap basis:

It is possible to use additives detergent or materials that increase the oil viscosity which do
not have EP; in this way the excess of mist is reduced. They can also remove the residues of
the supports in the highest temperature applications. The rate oil/air is reduced depending on
these additives. Some of these additives can reduce excessively the expenditure of the oil, as

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well as sensible increases of condensation in the pipes, therefore these kind of applications
require special attention.

ADVANTAGES OF OIL MIST LUBRICATION

 Reduced friction losses in bearings.

 Cooler operating bearings.

 Longer bearing life.

 Exclusion of external contaminants.

 Reduced lubricant consumption.

 Elimination of lubricant misapplication.

 Increased Reliability.

 Energy efficiency.

 Reduced operating temperatures.

 Reduction in friction coefficients.

 Increase in the nominal life of bearings.

 Reduced Vibrations.

CONVERTING EXISTING MOTORS TO OIL MIST

Many motors can be converted to oil mist provided a few guidelines are followed. If an
operating unit has an oil mist system it will usually cost about $50 to $100 per motor to
extend oil mist to the motor. Normally, if the motor is oil lubricated with sleeve bearings,

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purge mist should be used. If it is oil or grease lubricated with rolling element bearings, pure
mist is recommended.

BENEFITS OF OIL MIST LUBRICATION

There are numerous direct benefits of oil mist, not the least of which is that it reduces bearing
failures by 90% with pure mist. A bearing manufacturer says that the bearing L10 life is
extended by a factor of 6 by oil mist.Oil mist reduces lubricant consumption by as much as
40% for once through, open total loss systems. If a closed loop system with the application of
the seals mentioned below is used, the oil consumption is reduced by considerably much
more. This reduction is achieved because the oil is precisely metered to each bearing: the
right amount in the right place at the right time. This reduction in oil consumption represents
a very strong argument for switching from mineral oils (about $3 per gallon) to synthetic oils
(about $18 per gallon) which results in an even longer service life both for the oil and for the
equipment, this provides an increase in energy efficiency through the additional reduction in
friction provided by these oils.

Because there is no liquid oil level and so no liquid friction, operating temperatures are about
10° F- 20° F cooler. One user reported 90° F cooler on a crude charge pump unit. According
to bearing manufacturers, there is an inverse relation between bearing life and temperatures:
the higher the temperature, the shorter the life. Another collateral benefit is up to a 3%
reduction in energy consumption. In virtually all hot oil pumps equipped with bearing
cooling jackets, the cooling water can be deleted. This is beneficial because cooling water
can actually decrease bearing life. Cooling water shrinks the outer race while the heat
conducted down the shaft expands the inner race, making the bearing run hotter due to the
increase in the friction caused by the deformations of the housing and consequently of the
track of the outer ring.

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WHERE DOES IT APPLY?

Oil Mist is applied to the centrifugal pumps, electric motors, gear boxes, fans and blowers of
continuous process plants; such as petroleum refineries, gas and power generating plants and
textile, steel and paper mills etc.

Centrifugal pumps:
The pumping of fluids is the most important task within the processes of a refinery,
petrochemical plant and in general, any process plant where production depends on the
operation of centrifugal pumps. Due to this, a high degree of equipment reliability is
required, which is only obtained by the use of the best available lubrication and maintenance
techniques.
Lubrication by pure oil mist is the best-proven method of lubrication for centrifugal pumps
and electric motors; this is the reason why its application to the total equipment population in
a plant is necessary to achieve a greater degree of reliability and energy efficiency.

Electric Motors:
Modern pure mist lubrication is a proven, environmentally friendly, energy efficient and
economically viable method of lubrication for electric motors in process plants.

* The application of mist to explosion proof motors is still a subject that requires agreement,
though in several refineries it has been noted that applying mist to these motors does not
involve risk, nevertheless, some manufacturers specifications and some maintenance
departments do not guarantee the equipment if modifications are carried out to install oil
mist.

Gear Boxes:

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Applying purge mist avoids the entrance of humidity and polluting agents to the interior of
the gear box due to the slight positive pressure created with the injection of oil mist.

LIMITATION OF OIL MIST LUBRICATION

While mist systems have dramatically reduced maintenance and operating problems,
establishing flow rates in a system has proved troublesome and the following details
commonly need attention:

The air stream in feed lines must be kept laminar, below approximately 24 feet/second,
because turbulence causes oil particles to impact the pipe wall and be removed from the air
stream before reaching delivery points. At abnormally low velocities, on the other hand, oil
droplets may also settle out prematurely.

Performance is sensitive to temperature. Even when not required by viscosity considerations,

heaters are often employed to stabilize the oil/air ratio under widely varying ambient
temperatures. When used, air heaters are usually accompanied by oil reservoir heaters.

Spray mist involves environmental hazards. Vent lines are needed at lubrication points for
collecting stray mist which has not been classified. OSHA requirements state that in an eight-
hour period, a person can be exposed to no more than five milligrams of oil per cubic meter
of air.

CASE STUDIES

1. An aluminum refinery in the Gulf Coast has a bank of 34 large fans equipped with pillow
block bearings. The failure rate was such that bearings lasted only six months. The bearings
were switched to pure oil mist in 1998. To date, there have been no reports of bearing
failures.
2. One of the largest oil companies in the world says that they have two similar olefin plants;
both have about 200 pumps. They are both operated under the same operating philosophy.
One plant has oil mist and the other doesn’t. The one without oil mist has an average of 50
pump failures per year.

3. A Gulf Coast refinery operating unit spent on average $35,000 per year on pump repairs.
They installed oil mist in 1989. Since that time, their pump repairs have averaged < $5,000
per year.

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4. There are many more success stories but I will end with a comparison of two similar
refineries in Thailand. Both are owned by the same company and, like Case Study # 2, they
have the same operating philosophy and the same reliability improvement programs. The
difference between the two is that one does not have oil mist and the other one does. There
were noticeable differences between their performance parameters in 2001:
a. Annual oil consumption in liters/bearing/year – 14 versus 5
b. Bearing failures as a % of installed bearings – 4.4 versus 0.3
c. Seal life (MTBF) in years – 4 versus 9.

CONCLUSION

Oil mist is a proven technology that demonstrates every day around the world that it
significantly reduces bearing failures, reduces maintenance costs, improves machinery
availability, reduces energy consumption, reduces the need for warehoused repair parts,
reduces life cycle costs, and reduces the stress of operating a plant. It not only improves
machinery reliability but frees up operators and maintenance personnel to perform their
primary functions, to put on spec product out the door and to help make the company a
profitable business. Oil mist is discretionary but there is probably not another thing that a
plant may do that can achieve these level reliability improvements than as can oil mist
lubrication. It is also an effective method for lubricating electric motor bearings. Studies have
shown significant increases in bearing life compared to grease lubrication.

REFERENCES

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[1] C. A. Towne, "Practical experience with oil mist lubrication," ASLE Paper 82-AM-4CI,
April 1982.

[2] Heinz P. Bloch & Abdus Shamin, “Oil Mist Lubrication: Practical Applications,” (1998).

[3] Branham, D., “Improving Machinery Reliability with Oil Mist Technology”, Lubricating
System Company, presented at IMC-2003 the 18th International Maintenance Conference.

[4] Internet “Sources related with oil mist lubrication on Google”.

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