LUBRICATION

FUNDAMENTALS
A Suncor Energy business

LUBRICATIONFUNDAMENTALS
FunctionsofaLubricant
LubricatingOilProperties
BaseOils
LubricatingOilFilms
OilAdditives

LUBRICATIONINDUSTRY
API

AmericanPetroleumInstitute

ASTM AmericanSocietyforTestingMaterials

SAE

SocietyofAutomotiveEngineers

NLGI

NationalLubricatingGreaseInstitute

STLE

SocietyofTribologists&Lubrication
Engineers

AGMA

AmericanGearManufacturers
Association

ISO

InternationalOrganizationfor
Standardization

TRIBOLOGY
Isthescienceandtechnologydealingwiththe
design,lubrication,friction,andwear of
interactingsurfacesinrelativemotion

FUNCTIONSOFALUBRICANT
ReduceFriction
MinimizeWear(KeepMovingSurfacesApart)
CoolParts(CarryAwayHeat)
PreventCorrosion
DisperseCombustionProducts(e.g.,Soot)
ActasaSealant
TransmitPower
5

WHYLUBRICATE?
Lubricationiskeywhensliding(area)contactispresent.
Lubricantsareusedtoreducefriction and wear bypreventing
metaltometalcontact.
Steel

Air

Steel

No Lubricant: High Friction

Steel

Oil
Film

Steel

Thin Film (Boundary)

Lubrication: Moderate Friction
6

Steel

Steel

Full Film (Hydrodynamic)

Lubrication: Low Friction

LUBRICATIONFUNDAMENTALS
FunctionsofaLubricant
LubricatingOilProperties
BaseOils
LubricatingOilFilms
OilAdditives
7

LUBRICATINGOILPROPERTIES
Viscosity
ViscosityIndex
Density/SpecificGravity
FlashPoint
FirePoint
PourPoint
CloudPoint
8

LUBRICATINGOILPROPERTIES
Whatisthemostimportant
characteristicofalubricatingoil?

LUBRICATINGOILPROPERTIES
Whatisthemostimportant
characteristicofalubricatingoil?

10

VISCOSITY
Measurementoftheoilsinternal
resistancetomotion

11

VISCOSITY
Measureofresistancetoflowata
giventemperature (Typically40 C&100 C)
o

Viscositychangesinversely with
temperature
* i.e.,Astemperatureincreases,oilbecomes
thinner

ChangeinViscosityisNOTlinear
12

VISCOSITYANDTEMPERATURE

ViscosityIndex(V.I.)
isaMeasureofthe
ViscosityTemperature
RelationshipforanOil
MultigradeOilsHaveHigher
V.I.sThanSingleGrades
ViscosityChangesLessWith
Temperature

13

Kinematic Viscosity, cSt

LubricantViscosityDecreases 1,000,000
DramaticallyWithIncreasing 100,000
10,000
Temperature
(LogLogRelationship)
1,000
100

10

Tar

Honey

Olive Oil

Cream

5
0

Water
-20 0 20 40 60 80 100 140

180

Temperature, C

220

260 300

VISCOSITY

VISCOSITY
Loadcarryingcapacity
increaseswithviscosity

LOADCARRYINGCAPACITY
14

VISCOSITYEXAMPLE
Usingtheviscositychartpaper
provided,determinetheviscosityof
thefollowingproductat70oC
32cSt@40oC
6.5cSt@100oC

15

This image cannot currently be display ed.

This image cannot currently be display ed.

Visc @ 40C

Visc @ 100C

VISCOSITYMEASUREMENT
Viscosity Systems (most common)
Kinematic (cSt) (metric)
American (SUS / SSU)

Absolute (cP)
* Low temperature

17

KINEMATICVISCOSITY
Measureoffluidsresistancetoflowdueto
gravity
Derivedfromthetimetakenforalubricant
totravelthroughacapillarytube
Measurement Stoke(St)
=1cm2 /second
Typicallyreportedascentistoke (cSt)
=1mm2 /second
18

ISOVISCOSITYSYSTEM

19

ISOViscosityGrade

Midpoint@40oc
(cSt)

Minimum
(cSt)

Maximum(cSt)

2.2

1.98

2.42

3.2

2.88

3.52

4.6

4.14

5.06

6.8

6.12

7.48

10

10

9.0

11.0

15

15

13.5

16.5

22

22

19.8

24.2

32

32

28.8

35.2

46

46

41.4

50.6

68

68

61.2

74.8

100

100

90

110

150

150

135

165

220

220

198

242

320

320

288

352

460

460

414

506

680

680

612

748

1000

1000

900

1100

1500

1500

1350

1650

ISO SYSTEM
+/- 10%

AGMA VISCOSITY SYSTEM

20

Equivalent ISO
Grade

Viscosity Range
(cSt @40oC)

AGMA
R&O #

AGMA
EP #

AGMA
Synthetic #

32

28.8 35.2

0S

46

41.4 50.6

1S

68

61.2 74.8

2 EP

2S

100

90 110

3 EP

3S

150

135 165

4 EP

4S

220

198 242

5 EP

5S

320

288 352

6 EP

6S

460

414 506

7, 7 Comp

7 EP

7S

680

612 748

8, 8 Comp

8 EP

8S

1000

900 1100

8A, 8A Comp

8A EP

1500

1350 1650

9 EP

9S

2880 3520

10

10 EP

10 S

4140 5060

11

11 EP

11 S

6120 7480

12

12 EP

12 S

190 220 (100oC)

13

13 EP

13 S

SAEJ300 (1999)VISCOSITYCLASSIFICATION

21

Low Temperature
Pumping Viscosity,
Max (cP @ oC)

Kinematic
Viscosity @
100oC, Min
(cSt)

Kinematic
Viscosity @
100oC, Max
(cSt)

High Shear
Rate Absolute
Viscosity @
150oC, Max
(cP)

SAE
Viscosity
Grade

Low Temperature
Cranking Viscosity,
Max (cP @ oC)

0W

6200 at -35

60 000 at -40

3.8

5W

6600 at -30

60 000 at -35

3.8

10W

7000 at -25

60 000 at -30

4.1

15W

7000 at -20

60 000 at -25

5.6

20W

9500 at -15

60 000 at -20

5.6

25W

13000 at -10

60 000 at -15

9.3

20

5.6

<9.3

2.6

30

9.3

<12.5

2.9

401

12.5

<16.3

2.9

402

12.5

<16.3

3.7

50

16.3

<21.9

3.7

60

21.9

<26.1

3.7

0W-40, 5W-40 and 10W-40 grades

15W-40, 20W-40 and 25W-40 grades

LUBRICANTPROPERTIES:VISCOSITYINDEX(VI)
Viscosity isameasurementofresistancetoflowat
one temperature.
ViscosityIndex(VI)isameasurementoftherateof
changeofviscosityoverarange oftemperatures.
Insimpleterms:itmeasureshowfasttheoil
thickensupasitgetscolderorhowfastitthinsout
asitgetshotter.
WithMostlubricants,thehighertheVIthebetter

22

LUBRICANTPROPERTIES:VISCOSITYINDEX(VI)
TheViscosityIndexiscalculatedfrom
viscositiesat40Cand100C
HighVIisatermwhichmeansthattheoil
isusableoverawidertemperaturerange.
VHVI =VeryHighViscosityIndex

23

TYPICALVIOFDIFFERENTBASESTOCKS
BaseStocksaretherefinedoils(derivedfromcrudeoil)which
areblendedtogetherwithadditivestoproduceafinished
lubricant.Theyaredescribedinaseparatesection.
Traditionalsolventrefined paraffinicbasestockshaveVIsinthe
range85to 95.Processimprovementssuchashydrofinishing
canimprovetheVItoover100.
OurHydroTreated basestockshaveViscosityIndicesinthe
range90110.
OurHydrocracked isodewaxedbasestocksareover120VI.

24

VISCOSITYINDEX
ViscosityIndexisaninherentpropertyofthebaseoil usedto
blendalubricant.
VIcanbeimproved significantlybyblendingsolubleadditives
calledVIImproversintotheoil.
Theseadditivesarelongpolymermoleculeswhichuncoilat
hightemperaturestoincreaseviscosity,whileatlow
temperaturestheyformtightballswhichnolonger
contributemuchtoviscosity.
Onecaution:VIimproversdonotlastforever inablend.
Theycanbechoppeduporsheareddownbyconstant
mechanicalmotionintheoil.

25

HOWAVIIMPROVERWORKS
Large"stringlike"
Before
moleculesthatexpand
(unwind)athigher
temperatures,thereby
Effect of Temperature
preventingtheoilfrom
thinningouttoorapidly.
UnderShearStress(e.g.
goingthroughsmall
Effect of Shear Stress
orificesinhydraulicvalves,
orsqueezedbypiston
ringsoncylinderwalls)
theVIimprovercanbe
Effect of Rupture
rupturedandloseits
effectiveness.
26

After

VISCOSITY COMPARISON CHART

NOTE:
Readacrosshorizontally.
Assumes96Vlsinglegradeoils.
Equivalenceisintermsofviscosity
at40Conly.
Viscositylimitsareapproximate:
Forprecisedata,consultISO,
AGMAand
SAEspecifications.
Wgradesarerepresentedonlyin
termsofapproximate40C
viscosity.
Forlowtemperaturelimits,consult
SAEspecifications.

27

VISCOSITY RULES OF THUMB

28

LUBRICATIONFUNDAMENTALS

29

Functions of a Lubricant
Lubricating Oil Properties
Base Oils
Lubricating Oil Films
Oil Additives

LUBRICATINGOILS
Crude Oil

Synthetic Basestocks

Formulated Lubricant

Natural Gas
Mineral
Basestock

30

Additives

LUBEBASEOILS APICLASSIFICATION
BaseOilCharacteristics
APIGroup

Sulphurwt
%

Saturateswt
%

Viscosity
Index

Manufacturing
Method

>0.03

<90

80119

SolventRefined

II

<0.03

>90

80119

Hydroprocessed

III

<0.03

>90

120+

Severely
Hydroprocessed

IV

Polyalphaolefins(PAO)

Oligomerization

OtherBaseOils

Various

ViscosityIndexisforbaseoilonly notfinalblendedproduct.
31

HYDROTREATEDVS.SOLVENTREFINED
BENEFITS
Mayusepoorqualitycrude

Highercapitalcosts

Loweroperatingcosts

Requireshydrogensupply

TypicallyhavehigherVIs

Highpressureunits

Improvedoxidationresistance
Improvedhightemperature
stability

32

DISADVANTAGES

skilledtechnicians
Differentadditive
package

DEFINITIONS
MINERALBASED
Adistillate(physicalseparation)ofpetroleum
SYNTHETIC
Oilderivedfromchemicalmanipulation
resultinginsignificantmodificationfrom
originalsource
BIOBASED
Formulatedwithrenewableandbiodegradable
basestocks.Itsworthnotingthatsome
definitionsonlyconsiderbiodegradability.
33

ANALOGY
Crudeoilisextractedfrom
ground
GroupIoilismadefrom
solventdistillation
GroupIIandIIIoilsare
madeusinghighpressure
hydrogen
GroupIVoilsaremadeby
chemicallyselectinga
modifyingmoleculesizes

Cowismilked
Milkandcreamareseparated
bygravityonly
Milkisseparatedbycentrifuge
andthenpasteurizedwithhigh
temperatures
Butterismadebyforcingtiny
fatmoleculesintolarger
grouping
*Fluid Life Corp.

34

SYNTHETICOILS
Polyalphaolefin(PAO)
Diesters
Polyglycols
PhosphateEsters
PolyolEsters
Silicones
35

BASEOILSCOMPARATIVECHARACTERISTICS
Mineral
Oil

Polyalpha
olefin

Diester

Polyol
Ester

Poly
glycol

Phosphate
Ester

Silicone
Oil

Viscosity
Temperature

VG

LowTemperature

OxidationStability

VG

Compatiblewith
MineralOil

LowVolatility

AntiRust

AdditiveSolubility

VG

VG

SealSwell

P - Poor
36

F - Fair

G Good

VG - Very Good

E - Excellent

LUBRICATIONFUNDAMENTALS
FunctionsofaLubricant
LubricatingOilProperties
BaseOils
LubricatingOilFilms
OilAdditives

37

LUBRICATINGOILFILMS
Hydrodynamic
Elastohydrodynamic(EHD)
Boundary
Hydrostatic
Steel

Air

Steel

No Lubricant: High Friction

Steel

Oil
Film

Steel
38

Thin Film (Boundary)

Lubrication: Moderate Friction

Steel

Steel

Full Film (Hydrodynamic)

Lubrication: Low Friction

HYDRODYNAMICLUBRICATION
JournalBearings(CompactionSK09002)

Bearingatrest

Bearingat
slowspeed
Bearingat
highspeed

39

Oilwedgeproducespressure,
highviscosity,andfullfilm
hydrodynamiclubrication

LUBRICATIONFUNDAMENTALS
FunctionsofaLubricant
LubricatingOilProperties
BaseOils
LubricatingOilFilms
OilAdditives

40

ADDITIVES
Generalpurposes
Differentadditives
Specificpurpose
Howtheywork

41

WHYADDITIVES?
TOPROTECT THEMETALSURFACES
TOIMPROVE LUBRICANTPERFORMANCE
TOEXTEND LUBRICANTSERVICELIFE

42

ADDITIVES
SURFACEPROTECT
Rustinhibitor
Corrosioninhibitor
Antiwear
Extremepressure
Dispersant
Detergent
Tackifier
43

LUBE ENHANCER
Anti-oxidant
Anti-foamant
Pour Point depressant
Vi improver
Friction modifier
Emulsifier
De-emulsifier

OXIDATIONINHIBITOR
WHATITDOES
Preventsvarnish,sludge&acidpre
cursorsfromforming
HOWITWORKS
ReactsmorereadilywithO2 thandoesoil

44

OXIDATIONINHIBITOR
Itwillbeusedup
Every10oCincreasein
temperatureresultsinoxidation
being2*faster

45

OXIDATIONINHIBITOR
Oxidationissignificantlyaccelerated by:
Catalysts suchasmetals,dust,water
Oxygen fromhighratesofairentrainment
Hightemperature
TemperatureoC

Hours

Days

80

10000

416

90

5000

208

100

2500

104

110

1250

52

120

625

26

130

313

13

Example Only Not real data

46

Every10oC risein
sumptemperature
over80oCdecreases
thelifeoftheoilby
onehalf

WATER+CATALYSTONOXIDATIONLIFE
150SSU@100oFTurbineOil
(32cSt@37.8oC)

47

Ref: Volume XXIII Proceedings of National Conference on Fluid Power, 1969, Weinschelbaum, M.

ANTIWEAR(AW)
WHATITDOES
Minimizeswearcausedbymetalto
metalcontact
HOWITWORKS
Formschemicalfilmonsurface
Filmrubsoff

48

ANTIWEAR(AW)
TypicallyZn/Pmaterial(ZDDP)
Sensitivetolongtermwater
contamination
Willresultinareddishdeposit
Willbeconsumed
Nottrackableinstandardoilanalysis
becausecannotdestroyZnorP
Needsbaremetalsurface
49

EXTREMEPRESSURE(EP)
WHATITDOES
Preventswelding&excessivewearunder
shockloading/highvibration
HOWITWORKS
Heatatpointofshockloadcauses
formationofnewcompound
Compoundwearsoff

50

EXTREMEPRESSURE
TypicallyS Pmaterial
Sulphurisreactivetoyellowmetals,
especiallyabove75oC
Willbeconsumed
Inthepresenceofwaterandheatcanform
S&Pacids
Needsbaremetalsurface

51

TIMKENEPTEST

TypicalResults
Reportedasthe
OKLoad

52

4BALLEPTEST

53

TypicalResults
WeldPoint
LWI Loadwearindex

VISCOSITYINDEX(VI)IMPROVER
WHATITDOES
Reducesrateofchangeofviscositywith
temperature
HOWITWORKS
Additiveactsasthickenerwith
increasingtemperature

54

VIIMPROVER

55

VIIMPROVER
Canbepermanentlysheareddownunder
certainhighload/highshearoperations
Mayormaynotbeanissue
Filtrationat1mmayimpactthisadditive
Before

After
Effect of Temperature

Effect of Shear Stress

Effect of Rupture

56

DISPERSANT
WHATITDOES
Keepsoxidationparticlesin
suspensioninoil
HOWITWORKS
Combineswithsmallparticlesto
preventformationoflargeparticles

57

DISPERSANT
Nonmetalliccocomponentwith
detergent
Willbeconsumed
Notgenerallyusedinindustrialoils

58

SootDispersed Low
ViscosityIncrease

SootAgglomerates High
ViscosityIncrease

DETERGENT
WHATITDOES
Preventsoxidationparticlesfromforming
sludge,varnishorgum
HOWITWORKS
Reactswithmetalsurfacestominimize
spaceforoxidationparticles

59

DETERGENT

60

Typicallymetallicadditive(Ca/B/Mg)
Willbeconsumed
Nottypicallyfoundinindustrialoils
Needsbaremetalsurface

RUST&CORROSIONINHIBITORS
Protectsironandsteelpartsfromattackbyacidic
contaminantsandwater
Formsaprotectivefilmonmetal
delicatebalance,caninterferewithothersurface
activeadditives

61

RUST&CORROSIONINHIBITORS
RustTest

CopperCorrosion

ASTMD665

Evaluatestheextentof
discolourationortarnishing
ofacopperstripimmersed
inthelubricant

60oC
24hours
Distilledor
Syntheticseawater
PassorFail

62

ASTMD130
2Hours@100oC
Alphanumeric(1a..4c)

ANTIFOAMAGENTS
WHATITDOES
Veryimportantpartoflubricantformulation
Helpsfoamtodissipatemorerapidly.
Largesiliconmoleculesdispersedintheoil.

HOWITWORKS
Promotescombinationofsmallbubblesintolargebubbles
whichbreakupmoreeasily.
Changessurfacetensionofoil
Verylowconcentrationsarerequired

ASTMD892
Threetests,SequenceI,II,III
Reportthevolumeoffoam(ml)after5minuteblowingperiod
and10minuterestperiodateachtestsequence.(i.e.10/0)

63

SequenceI
24oC
SequenceII 93.5oC
SequenceIII1 24oC
1. On same oil after Sequence II test.

POUR/CLOUDPOINTDEPRESSANTS
Inhibittheformationoflargewaxcrystals
Enhancestheloweroperability
temperatureoftheoil
Highmolecularweightpolymers

64

POUR/CLOUDPOINTDEPRESSANTS
Temperatureatwhichnomovementisobserved
for5seconds
Waxcomesoutofsolutioninsmallcrystalsas
theoilnearspourpoint.Smallcrystalsforma
gelthatkeepstheoilfrommoving.

FRICTIONMODIFIERS

Increaseoilfilmstrength
Longchainmolecules
Polarendadsorbstometalsurface
Effectiveatlowtemperaturesandmildsliding
conditions
Fattyacidorfattyoilderivatives
AshcontainingcompoundssuchasMolybdenum
Disulphide(MoS2),graphite,Teflon(PTFE),are
alsocalledFrictionModifiers
Sometimescalledantiseizeorsolidlubricants
66

Commonly found in Engine Oils to

improve fuel economy.

DEMULSIFIERADDITIVES
Addedtooilsinimprovetheabilityofwaterto
shedfromtheoil.
Desirablefor:

papermachines
hydraulics
turbines
gears

Additivesthatareaddedtotheoilforother
reasonsoftenattractwater(i.e.detergents).
67

DEMULSIBILITYTESTS
Determinestheabilityoftheoiltoshedwater.
ASTMD1401,D2711(shouldbeusedforoils
containingEPadditives)
Reportedas:
Oil/Water/Emulsion(minutes)
38438(20)

SULPHATEDASH
Determinesthenoncombustibleresidueina
lubricatingoil(ASTMD874)
Sometimesusedasanindicationoftheamountof
detergentinanewoil
Metallicadditivecomponents Calcium,
Magnesium,Zinc
Newspecsarelimitingtheashcontent
Primaryfunctionofthesulfatedashistominimize
valvewear(recession)inNGEO

69

USEOFADDITIVES
ADDITIVE
Detergents
Dispersants
Anti-Oxidants
Rust Inhibitors
Anti-Wear
E.P. Agents
VI Improvers
Pour Point
Depressants
Anti-Foam
Dyes
Friction
Modifiers
70

Engine
Oils

ATF

General
R&O Oil

AW
Hydraulic

Industrial Automotive
Grease
Gear Oil
Gear Oil

HVI

Some

Some

ADDITIVESATWORK
AntiFoam

Dispersant

Pour/CloudPointDepressant
OxidationInhibitor
VIImprover

Someadditivesworkintheoil,someworkonthemetalsurface
71

VERYDELICATEBALANCE

CLEANLINESSAND
CONTAMINATIONCONTROL

OILCLEANLINESSand
CONTAMINATION
CONTROL

AGENDA
INTRODUCTION
CONTAMINATION SOURCES
Internal
Corrosion
Wear Debris

Ingress
Airborne Contaminants
Moisture
Dirty Oil

Wrong Lubricant
ISO PARTICLE COUNT SYSTEM
PREVENTION
Storage
Lube Rooms, Dispensing

Handling and Distribution

CLEANLINESSANDCONTAMINATIONCONTROL
Contaminationisthegreatestsinglecauseof
lubricantdegradationandmalfunctionleadingto
abnormalwearandfailureofequipment
components.
Because

Contaminationsourcesareeverywhere
Itcauseswearandsurfacedegradation
Itcausesthelubricanttomalfunction
Itcostsyoumoney!

WHATISCONTAMINATION?

Anythinginafluidthatdoesnotbelongisa
CONTAMINANT.

SOURCESOFCONTAMINATION
Builtincontamination
Generatedcontaminants
Externalingression
Maintenanceintroduced
contaminants

SOURCES(CONTD)
Builtincontaminantsfromcomponents:
Cylinders,fluids,hoses,hydraulicmotors,
linesandpipes,pumps,reservoirs,valves,
etc.

Generatedcontaminants:
Assemblyofsystem
Breakinofsystem
Operationofsystem
Fluidbreakdown

SOURCES(CONTD)
Externalingression
Reservoirbreathing
Cylinderrodseals
Bearingseals

Contaminantsintroducedduringmaintenance
Disassembly/assembly
Makeupoil

OILCONTAMINATION
PARETOPRINCIPLE

80/20RULE
80%ofconsequencescomefrom20%ofcauses.

WATER+CATALYSTONOXIDATIONLIFE
150SSU@100oFTurbineOil
(32cSt@37.8oC)

Ref: Volume XXIII Proceedings of National Conference on Fluid Power, 1969, Weinschelbaum, M.

BEARINGLIFEVS.PARTICLESIZE
Improving cleanliness
in this range
produces HUGE life
extensions

14

Fatigue Life - Million Revolutions

13
12
11
10
9
8
7
6
5
4
3
2
1
0
1

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

Absolute Filter Size in Microns

Ref: SKF Ball Bearing Journal #242

SMALLEST PARTICLE SIZE

SEEN WITH THE NAKED EYE.

WATERONBEARINGLIFE

Relative Life

1.0

0.5

0.0
0

100

200

300

400

500

600

Water Concentration (ppm)

*Cantley, R., The Effect of Water in Lubricating Oil on Bearing Fatigue Life

700

800

900

1000

HOWCLEANISCLEAN?
TypicalOperatingDynamicFilmThickness
COMPONENT
RollerBearings

THICKNESS()
0.4 1

BallBearings

0.1 0.7

JournalBearings

0.5 100

VanePump

0.5 13

PistonPump

0.5 40

DieselEngine

5 45

Gears

0.1 1

BEARINGFILMTHICKNESS
5m

10m

5m

Machine
Clearance

Load,
No Motion

Theoperatingordynamicclearanceisnotequaltothemachine
clearance,butdependsupontheload,speedandlubricant
viscosity.Alubricantfilmseparatesmovingsurfacestoprevent
metaltometalcontact.

BEARINGFILMTHICKNESS
Journal
Bearing

9m

Rolling Element
Bearing

Dynamic
Clearance

1m
Load & Motion
& Lubricant

Cage

Lubricant
Film

VALVEWEAR/STICTION

Valve Dynamic Clearances

Servo valve
Proportional valve
Directional control valve

1 - 4 m
1 - 6 m
2 - 8 m

Clearance Size Particles Cause:

Slow response, instability
Spool jamming/stiction
Surface erosion
Solenoid burnout

EFFECTSOFCONTAMINATION

CylinderDrift
JerkySteering
SlowerPerformance
ErraticOperation
ShorterServiceIntervals
HigherOperatingCosts
LostProductivity

LOSSOFEQUIPMENTLIFE
Loss of Usefulness

Obsolescence
(15%)

Surface Degradation
(70%)

Corrosion
(20%)

Abrasion

Accidents
(15%)

Mechanical Wear
(50%)

Fatigue

Ref: Dr. E. Rabinowicz, 1981

Adhesion

CONTAMINATIONSOURCES
Generated
Corrosion
WearDebris
Ingress
Airborne
Moisture
DirtyOil
WrongLubricant

CORROSIVEWEAR
Corrosionisachemicalattackonthe
material

Causespitting
Producesacorrosionproduct

CORROSIVEWEAR
Acidsformedduringoiloxidation
Internalcombustionengineswill
generateacidsintheoil

CORROSIVEWEAR
CONDITIONSPROMOTINGWEAR
Corrosiveenvironment
Corrodiblemetals
Rustpromotingconditions
Hightemperatures
CONTROL
Eliminatecorrosivematerial
Usemorecorrosionresistantmetal
Reduceoperatingtemperature
LUBRICANT
Removecorrosivematerialsuchastoochemicallyactive
additiveandcontaminates
Corrosioninhibitor
Usefreshoil

GENERATED:WEARDEBRIS

TYPESOFWEAR
1. AdhesiveWear
Metaltometalcontact(lossoffluid)

2. AbrasiveWear
Particlesbetweenadjacentmovingsurfaces

3. FatigueWear
Particledamagedsurfacessubjectedto
repeatedstress

ADHESIVEWEAR
Metaltometalcontact

Heatisgenerated
Somediscoloration
Weldingormicrowelding
Metalbreakageortransfer

ADHESIVEWEAR

CONTROLOFADHESIVEWEAR
Steel

Steel
control

Steel

Metal-to-metal contact

Steel

Control: lubrication

PreventingAdhesivewearisprimarily
controlledbyselectingtherightviscosity
andtherightadditivepackage.

ABRASIVEWEAR

ABRASIVEWEAR

ABRASIVEWEAR
Piston Pump

ABRASIVEWEAR
Control of Abrasive Wear
Filtration/Clean Handling/Good
Housekeeping

FATIGUEWEAR
NORMALFATIGUE
Whendesignedfatiguelifeismet.
Whendesignedserviceconditionsarefollowed.
Ex:load100lbs,lifewillbe5years

PREMATUREFATIGUE
Whendesignedlifeisnotmet
Couldbeafunctionofloadormaterial
ex.Designedload=100lbs
actualload=300lbs

InitialSurfaceDamage

FATIGUEWEAR
After"N"cycles,fatiguewearoccurs
characterizedbyspallingofsurface
Load

FATIGUEWEAR

Cracks from surface propagating downwards

FATIGUEWEAR
FactorsaffectingFatigueLife:
Loadandhighstresspoints
Material
Temperature
Timeorcycle

CONTAMINATIONSOURCES
Generated
Corrosion
WearDebris
Ingress
Airborne
Moisture
DirtyOil
WrongLubricant

TWOTYPESOFCONTAMINATION
DirtYouCanSee

40Microns&Larger
WeldSplatter
ShotBlast
PaintChips
MachineChips

DirtYouCantSee

Under40Microns
WearMetals
Silica
Coal
Dirt
Soot

AIRBORNECONTAMINANTS
Exampleofaircontaminants
thatonlybecamevisiblewith
thecameraflash

Theenvironmentmaybereality butwhatpreventsrealityfromgettingintothesystem?

Sometimesthenormaljobfunctionopensthecomponenttotheenvironment!
Isthereanotheroption?Whataboutasightglass?

OEMbreathersmaynotbeadequateforprotectingyourequipmentfromtheworkingenvironment.

INGRESSEDMOISTURE

Itsnotjustthewateritselfthatisanissue.ManyEPadditivescontainsulphurwhich
mayreactwiththemoisturetocreateotherunwantedacids.

DIRTYOIL

Didtheragdoitsjoband
keepthecontainerclean?

Pickacontainer anycontainerwilldo?NO!!!!!

CONTAMINATIONSOURCES
Generated
Corrosion
WearDebris
Ingress
Airborne
Moisture
DirtyOil
WrongLubricant

FITFORUSE?

Thiscontaineris
guaranteedtohave
lubeoilinit.
WhichOne????

AGENDA
INTRODUCTION
CONTAMINATION SOURCES
Internal
Corrosion
Wear Debris

Ingress
Airborne Contaminants
Moisture
Dirty Oil

Wrong Lubricant
ISO PARTICLE COUNT SYSTEM
PREVENTION
Storage
Lube Rooms, Dispensing

Handling and Distribution

BUTFIRST WHATISAMICRON?
1MillionthofaMeter
1ThousandthofaMillimeter

MEASURINGCONTAMINANTS
TheMicrometer(m)
Smallestdotyoucanseewiththenakedeye=40m
25m=1/1000ofaninch
1m=0.00004inch

Humanhair(80m),particles(10m)at100x(14m/division)

ISOCLEANLINESSCODE
IdentifiesquantityofcontaminantinonemLofFluid

4m / 6m / 14m

11,000

4,000

500

TYPICALCLEANLINESSLEVELS
NewOilFrom
Barrel
23/20/18

SystemWith
Typical
Hydraulic
Filtration
20/18/16

NewSystem
w/Builtin
Contaminants
23/22/20

Systemwith
B3 >200
Clearance
Protection
Filtration
16/13/11

TYPICALHYDRAULICCLEANLINESSTARGETS
1,500
2,500psi

>2,500psi

16/14/12

15/13/11

14/12/10

17/15/12

16/14/12

15/13/11

17/16/13

17/15/12

16/14/12

18/16/14

17/16/13

17/15/12

18/16/14

17/16/13

17/15/12

19/17/14

18/16/14

17/16/13

19/17/14

18/16/14

17/16/13

19/17/14

18/16/14

18/16/14

19/17/14

18/16/14

18/16/14

Operating
<1,500psi
Pressure
ServoValve
ProportionalValve
VariableVolumePump
CartridgeValve
FixedPistonPump
VanePump
Pressure/FlowControlValve
SolenoidValve
GearPump

Adjusttocleanerlevelsfordutycycleseverity,
machinecriticality,fluidtype(forexample,water
base)andsafetyconcerns.

TYPICALCELANLINESSTARGET
MACHINEELEMENT

ISOTARGET

RollerBearing

16/14/12

JournalBearing

17/15/12

IndustrialGearbox

17/15/12

MobileGearbox

17/16/13

SteamTurbine

18/15/12

Guidelinesonly confirmwithOEM

CONTAMINATIONCONTROLEXAMPLE

Amount of Dirt in Oil

Amount of Dirt Flowing

Through Pump in One Year

ISO 21/18

630 lb/yr

ISO 18/15

79 lb/yr

ISO 16/13

20 lb/yr

AGENDA
INTRODUCTION
CONTAMINATION SOURCES
Internal
Corrosion
Wear Debris

Ingress
Airborne Contaminants
Moisture
Dirty Oil

Wrong Lubricant
ISO PARTICLE COUNT SYSTEM

PREVENTION
Storage
Lube Rooms, Dispensing

Handling and Distribution

MANAGECONTAMINATION

Thesinglegreatestopportunity
forincreasingcomponentlife
andloweringoperatingcostsis
toeffectivelymanagefluid
cleanliness.

HOUSEKEEPINGFAILURES
Sweepfloorsdaily
Cleanupspillsimmediately
Keepworkbenchesuncluttered
andfreeofdebris
Limituseoffloorstorage

NOWTHATSBETTER!!

NOWTHATSBETTER!!

STORAGE
Takemeasurestoexcludecontaminantsfrom
becomingpartofthelubricantorfluid
Thismusthappeninthemainwarehouseandat
theindividualstoragestationsthroughoutyour
plant.

STORAGE
OilRoomDesign
Contributingfactorsforoilroomdesign:
Location,location,location
Firesafety
Workerssafety
Ergonomics
Lubricantmixingcontrol
Lubricantcontaminationingresscontrol
Proceduresforbringingnewoilintoservice
Abilitytodocumentactions(recordkeeping)
CourtesyProactiveLubeManagerInc.

STORAGE

STORAGE

STORAGE

HANDLING
Preservingtheintegrityofthefluidwhile
gettingitfromstoragetousage
Bearinmindthatoftenthebestwaysare
alsotheeasiestandmostefficientways

HANDLING
Topup/smalloilchangeout,containers

HANDLING
Containersthatreducethepotentialandriskofadding
unwantedcontamination.

Courtesy Proactive Lube Manager Inc.

HANDLING
Dontbeafraidtogoonestepbetter.
Considerretrofittingcontainerswithairbreathers,and
handpumpswithquickcouplers.

Courtesy Proactive Lube Manager Inc.

HANDLING

CourtesyProactiveLubeManagerInc.

HANDLING
Greaseismoresusceptibletoparticulate
contamination

Singleandmultipointautogreasershave
gainedacceptanceforreducingparticulate
ingressrisk,andoverandundergreasingof
components.

HANDLING
Greasegunsarehandledimproperly

Transparentgreasingtoolseliminatetheageold
problemofpickingupthewronggreasegunand
mixingproducts.

HANDLING

CourtesyProactiveLubeManagerInc.

DISTRIBUTION

EXCLUSION
Thecostofcleaningdirtyoilis10X
higherthankeepingitcleaninthefirst
place!

BREATHERS
Therearebreathersthat
willexcludeparticlesas
smallasmicron
Thesesamebreathersare
ratedat20CFMofairoran
equivalentof150gpm
changeintankfluidlevel
Lookfordesiccant
breatherstoexclude
moisture
Courtesy Des-Case.

BREATHERS

PARTSHANDLINGANDSTORAGE
Keepcomponentspackageduntilreadyto
install
Returnpartstostorageinpackaging
Protectinprocesscomponents
Washcomponentsbeforeassembly

LIFEEXTENSION CLEANLINESS

LIFEEXTENSION MOSITURE

BENEFITSUMMARY
COMPONENT

IMPROVEMENT

Pump/Motor

4 10xincreaseinpumpsand
motorlife

RollerBearing

50xextensionofrollerbearing
fatiguelife

JournalBearing
HydrostaticTransmission
Valves
ValveSpool
Fluid

10xextensionofjournalbearinglife
4 10xincreaseinlife
5 300xincreaseinvalvelife
Eliminationofvalvestiction
Extensionoffluidlifethrough
reducedoxidation

METHODSTOACHIEVETHESEBENEFITS
StartwithCleanTanks
Filtration
Priortobulktank
Postbulktank
Dispensingpoint(dropreels)

HighEfficiencyBreathers
Properlabeling
Useoilsafecontainers
CLEANCLEANCLEAN
UsetheRIGHToilintheRIGHTcomponent