Pumps & Compressors 1Lubricants Base OilThe general principles of lubricant base oilManufacturers use a series of steps to improve certain desirable lubricant properties. These include:Viscosity Index Oxidation Heat Resistance o! Temperature "luidity Pumps & Compressors 2Lubricants Base Oil#tarting from petroleum crude oil$ the typical process for ma%ing a lubricant base oil is the follo!ing:#eparation of lighter boiling materials such as gasoline$ &et fuel$ diesel$ etc. Removal of impurities including aromatics and polar compounds. 'istillation to give desired base oil viscosity grades. 'e!axing to improve lo! temperature (uidity. "inishing to improve oxidation and heat stability. Pumps & Compressors 3Lubricants Syntheticsube oils possessing a base oil that has been manufactured from chemical constituents or by the polymeri)ation of hydrocarbons. The three most common types of synthetic base oils are:*olyalphole+ns Organic ,sters *olyglycols . Pumps & Compressors 4Lubricants Synthetics#ynthetic lubricants have several advantages over conventional mineral oils:excellent lo! temperature (uidity lo! pour point high natural viscosity index excellent oxidation stability high (ash$ +re$ and auto-ignition points lo! volatility non-corrosive and non-toxic Pumps & Compressors 5Lubricating OilPumps & Compressors 6Lubricant Additives'etergentsThese chemicals are usually metallic based$ and are designed to control deposits and %eep engine components clean. They are able to clean existing deposits in the engine$ as !ell as disperse insoluble matter into the oil. 'etergents control contamination resulting from high temperature operation.'ispersantsThese are usually ashless organic chemicals$ !hich control contamination from lo! temperature operation. .oth detergents and dispersants attach themselves to contaminant particles$ and hold them in suspension. The suspended particles are so +nely divided that they pass harmlessly bet!een mating surfaces and through oil +lters. The contamination is removed from the engine !hen the oil is changed.Pumps & Compressors 7Lubricant AdditivesOxidation InhibitorsThese agents reduce oxygen attac% on the lubricating base oil./orrosion Inhibitors0cids are produced by the combustion process$ and !hen engine oil degrades !ith use. 1nless rendered harmless by the engine oil$ the acids can cause rapid deterioration of engine components. /orrosion inhibitors protect non-ferrous metals by coating them and forming a barrier bet!een parts and their environment.Rust InhibitorsRust inhibitors protect iron2steel from oxygen attac%$ by forming a protection screen over the surface of the metals.Pumps & Compressors 8Lubricant Additives0nti-3ear 0gentsThese agents prevent !ear due to sei)ure or rubbing surfaces. /ompounds such a )inc dial%yt-dithiophosphate brea%-do!n microscopic hot spots and form a chemical +lter !hich eliminates metal-to-metal contact."oam 'epressants'etergent and dispersant additives can facilitate aeration of an oil !hich results in foaming. This can reduce the lubricating ability of the oil$ and interfere !ith the pumping of the oil. 0 foam depressant controls this tendency.Pumps & Compressors 9Lubricant AdditivesViscosity Index 4VI5 ImproversVI improvers control the viscosity of multi-grade oils. They are polymers !hich act li%e 6popcorn6. 0t lo! temperatures$ they are 6tight-balls6 !hich do not signi+cantly increase the oils resistance to (o!. Ho!ever$ at high temperatures$ these 6tight balls6 explode into long chain polymers$ !hich inter!eave and increases the oil7s resistance to (o!4viscosity5. The tendency of an oil to 6thin6 at high temperatures is controlled and reduced.*our *oint 'epressants8*.ase oils contain hydrocarbons that tend to crystalli)e into !axy material at lo! temperatures. Incorporation of a chemical !hich reduces the si)e of !ax crystal formation can give an oil better lo! temperature (uidity. Pumps & Compressors 10Oil Applications/oncrete "orm Oilubricants !hich are formulated to provide a clean$ 9uic% release of the ply!ood$ metal$ or plastic forms from concrete after setting. 1sually available in a light viscosity to accommodate spraying of the lubricant on the forms./utting OilsThe main functions of a cutting oil are to lubricate or reduce friction bet!een the tool and the !or%-piece$ and to act as a coolant by rapidly removing heat generated at the tool-!or%-piece interface.#oluble cutting oils are mixed !ith !ater in proportions of : to; resistance. /lassi+ed as 6tac%y6. *revent corrosion of the chain. Tip? The !inter grade may be used as an air +lter coating !here a tac%y product is re9uired for dust removal.Pumps & Compressors 12Oil ApplicationsHydraulic OilHydraulic systems provide a means to transfer po!er !here gears are impractical. 0 typical system includes a reservoir for the hydraulic (uid$ a pump$ transfer hoses$ and return hoses to the reservoir.The important characteristics of a hydraulic (uid are:Thermal stability /orrosion protection 0nti-!ear properties 0nti-foaming properties The oil is available in di>erent viscosity grades to accommodate a variety of ambient operating temperatures.Pumps & Compressors 13Oil Applications/ompressor and ,ngine OilOils !hich are formulated for use in reciprocating and rotary air compressors and gas engines. 0vailable in di>erent viscosity grades for use in di>erent ambient temperature ranges.Heat Transfer "luids0 lubricant used as a heat transfer medium in applications such as:*lastic extrusion machines. Textile dryers. 'ie casting. #ome high 9uality heat transfer (uids can provide clean$ odourless operation up to temperatures of :@AB/. Pumps & Compressors 14Oil ApplicationsIndustrial Cear ubricantsThese oils provide protection to di>erent types of industrial gears !hich are often operated under high contact pressures$ and intermittent shoc%-loading. Cear lubricants often contain an ,* 4,xtreme*ressure5 0dditive.0 !ide variety of I#O viscosity grades are available.Refrigeration ubricantThis lubricant is used in commercial refrigeration compressor systems.This oil is available in t!o formulations:"or use in /"/ 4chlorinated (uorocarbon5 systems. "or use in ammonia refrigeration systems. Pumps & Compressors 15GreasesCrease can be de+ned as a solid to semi-solid material produced by the dispersion of a thic%ening agent in a li9uid lubricant. Other ingredients may be included to impart special properties to the grease.Thickener Lubricating OilAdditives5 - 20% 75 - 95% 0-15%Pumps & Compressors 16Greases/omplex Crease0 complex grease is similar to a regular grease except that the thic%ener contains t!o dissimilar fatty acids$ one of !hich is the complex agent. This results in good high temperature characteristics to the +nal product.ubricating Oil.ecause of the high percentage of oil by !eight in grease$ the oil must be of high 9uality and the proper viscosity. ight viscosity oils are used for lo! temperature$ lo! load$ and high speed applications. /onversely$ a heavy viscosity oil is generally used for high temperature$ high load$ and slo! speed application.0dditivesThe most common additives found in grease are as follo!s:Oxidation Inhibitors ,*0 0gents 0nti-/orrosion 0gents 0nti-3ear 0gents Thickener Lubricating OilAdditives5 - 20% 75 - 95% 0-15%Pumps & Compressors 17Grease CharacteristicsThe most important factors a>ecting the properties and characteristics of a grease are:0mount and type of thic%ener Oil viscosity and physical characteristics 0dditives 0 grease is expected to:Reduce friction and !ear *rovide corrosion protection #eal bearings from !ater and contaminants Resist lea%age$ dripping$ and thro!-o> .e compatible !ith seals Repel moisture Pumps & Compressors 18Grease DefinitionsConsistency-is the degree of hardness of a grease and may vary considerably !ith temperature. This has been classi+ed by the Eational ubricating Crease Institute (N.L.G.I.)into the follo!ing categories:!L!G!"! G#AD$ %$$T#AT"O & '()c*+,+-th ../000 445-47500 400- 300 355-3851 310-3402 265-2953 220-2504 175-2055 130-1606 85-115Pumps & Compressors 19Grease DefinitionsShear Stability F is the ability of a grease to resist a change in consistency during mechanical !or%ing. 1nder high rates of shear$ grease structures tend to change in consistency.Oil Separation F is the percentage of oil !hich separates from the grease under storage conditions. It cannot predict separation tendencies in use under dynamic conditionsHigh Temperature Stability F is the ability of a grease to retain its consistency$ structure$ and performance at temperatures in excess of ;@GBreeH/Pumps & Compressors 20Grease Selection%roperties Calciu. Lithiu. Sodiu.Alu.inu. Co.ple0Calciu. Co.ple0Bariu. Co.ple0Lithiu. Co.ple0%olyurea SyntheticBentone Clay Dropping Point C80-100 175-205 170-200 260+ 260+ 200+ 260+ 250+ None!" #empC65 125 125 150 150 150 160 150 150$ig% #emp &se'()oo* )oo* )oo* +", +", )oo* +", +", +",-o. #emp o/i0it12!ir )oo* Poor )oo* 2!ir Poor )oo* )oo* )oo*e,%( 3t!/i0it12!ir )oo* 2!ir +", )oo* 2!ir +", )oo* 2!ir4!ter 5esist!n,e+", )oo* Poor +", +", +", +", +", 2!ir6"i*!tion 3t!/i0it1Poor )oo* )oo* +", +", Poor )oo* +", )oo*#e"ture 3moot% 3moot% 3moot% 3moot% 3moot% 2i/rous 3moot% 3moot% 3moot%Pumps & Compressors 21Lubricant Shelf Life0s a general rule$ the simpler the oil formulation$ the longer the shelf life. The follo!ing is a guideline under protected conditions:%roduct Shelf Life7!se 6i0s8 Pro,ess 6i0s #%ree93: 1e!rs$1*r!u0i, 6i0s8 Compressor 6i0s8 )ener!0 Purpose -u/ri,!ting 6i0s#.o92: 1e!rs+ngine 6i0s !n* #r!nsmission 6i0s #%ree93: 1e!rs;n*ustri!0 !n* ing !n* Cutting 6i0s 6ne91: 1e!r)re!ses #.o92: 1e!rsPumps & Compressors 22Lubricant Shelf LifeThe follo!ing are signs of storage instability in a lubricant:#ettling out of the additives as a gel or stic%y li9uid "loc or ha)e *recipitates2solid material /olor change or ha)iness 3ater contamination in a lubricant can be detected by a 6mil%y6 appearance of the product.0 sign of grease deterioration is the separation of the li9uid oil from the solid grease.Greases)re!se ,!n /e *e?ine* !s ! so0i* to semi-so0i* m!teri!0 pro*u,e* /1 t%e *ispersion o? ! t%i,>ening !gent in ! 0i@ui* 0u/ri,!nt( 6t%er ingre*ients m!1 /e in,0u*e* to imp!rt spe,i!0 properties to t%e gre!se(Thickener Lubricating OilAdditives5 - 20% 75 - 95% 0-15%Pumps & Compressors 24GreasesComp0e" )re!se< ,omp0e" gre!se is simi0!r to ! regu0!r gre!se e",ept t%!t t%e t%i,>ener ,ont!ins t.o *issimi0!r ?!tt1 !,i*s8 one o? .%i,% is t%e ,omp0e" !gent( #%is resu0ts in goo* %ig% temper!ture ,%!r!,teristi,s to t%e ?in!0 pro*u,t(-u/ri,!ting 6i07e,!use o? t%e %ig% per,ent!ge o? oi0 /1 .eig%t in gre!se8 t%e oi0 must /e o? %ig% @u!0it1 !n* t%e proper =is,osit1( -ig%t =is,osit1 oi0s !re use* ?or 0o. temper!ture8 0o. 0o!*8 !n* %ig% spee* !pp0i,!tions( Con=erse018 ! %e!=1 =is,osit1 oi0 is gener!001 use* ?or %ig% temper!ture8 %ig% 0o!*8 !n* s0o. spee* !pp0i,!tion(!ge8 *ripping8 !n* t%ro.-o?? 7e ,omp!ti/0e .it% se!0s 5epe0 moisture Pumps & Compressors 26Grease DefinitionsConsistency-is t%e *egree o? %!r*ness o? ! gre!se !n* m!1 =!r1 ,onsi*er!/01 .it% temper!ture( #%is %!s /een ,0!ssi?ie* /1 t%e N!tion!0 -u/ri,!ting )re!se ;nstitute (N.L.G.I.)into t%e ?o00o.ing ,!tegoriesA!L!G!"! G#AD$ %$$T#AT"O & '()c*+,+-th ../000 445-47500 400- 300 355-3851 310-3402 265-2953 220-2504 175-2055 130-1606 85-115Pumps & Compressors 27Grease DefinitionsShear Stability B is t%e !/i0it1 o? ! gre!se to resist ! ,%!nge in ,onsisten,1 *uring me,%!ni,!0 .or>ing( &n*er %ig% r!tes o? s%e!r8 gre!se stru,tures ten* to ,%!nge in ,onsisten,1(Oil Separation B is t%e per,ent!ge o? oi0 .%i,% sep!r!tes ?rom t%e gre!se un*er stor!ge ,on*itions( ;t ,!nnot pre*i,t sep!r!tion ten*en,ies in use un*er *1n!mi, ,on*itions1igh Te.perature Stability B is t%e !/i0it1 o? ! gre!se to ret!in its ,onsisten,18 stru,ture8 !n* per?orm!n,e !t temper!tures in e",ess o? 125reeCCPumps & Compressors 28Grease Selection%roperties Calciu. Lithiu. Sodiu.Alu.inu. Co.ple0Calciu. Co.ple0Bariu. Co.ple0Lithiu. Co.ple0%olyurea SyntheticBentone Clay Dropping Point C80-100 175-205 170-200 260+ 260+ 200+ 260+ 250+ None!" #empC65 125 125 150 150 150 160 150 150$ig% #emp &se'()oo* )oo* )oo* +", +", )oo* +", +", +",-o. #emp o/i0it12!ir )oo* Poor )oo* 2!ir Poor )oo* )oo* )oo*e,%( 3t!/i0it12!ir )oo* 2!ir +", )oo* 2!ir +", )oo* 2!ir4!ter 5esist!n,e+", )oo* Poor +", +", +", +", +", 2!ir6"i*!tion 3t!/i0it1Poor )oo* )oo* +", +", Poor )oo* +", )oo*#e"ture 3moot% 3moot% 3moot% 3moot% 3moot% 2i/rous 3moot% 3moot% 3moot%Pumps & Compressors 29Lubricant Shelf Life1 0i@ui* 20o, or %!De Pre,ipit!tesEso0i* m!teri!0 Co0or ,%!nge or %!Diness 4!ter ,ont!min!tion in ! 0u/ri,!nt ,!n /e *ete,te* /1 ! Fmi0>1F !ppe!r!n,e o? t%e pro*u,t(< sign o? gre!se *eterior!tion is t%e sep!r!tion o? t%e 0i@ui* oi0 ?rom t%e so0i* gre!se(Pumps & Compressors 312hy is greasing i.portant;t is estim!te* t%!t 95% o? !00 /e!ring ?!i0ures !re prem!ture(7e!ring ?!i0ure ,!n 0e!* to ,ost01 *o.n-time#%e oi0 gr!*u!001 o"i*iDes or is 0ost to e=!por!tion or 0e!>!ge#%e gre!se m!1 .!s% !.!1 or migr!te !.!1 ?rom t%e mo=ing p!rts)re!se must /e perio*i,!001 rep0enis%e* to !ssure proper /e!ring 0u/ri,!tionPumps & Compressors 32+st!/0is%ing !n +??e,ti=e )re!sing Progr!m1( +=!0u!te ,urrent pr!,ti,es2( +st!/0is% ,ommon pro,e*ure3( Pro=i*e tr!iningPumps & Compressors 331( +=!0u!te Current Pr!,ti,esI /urrent cost of motor2pump repairI 0vailable manpo!er and trainingI /urrent procedures and scheduling programI Crease gun practicesI *ersons assigned to regreasing activity I #afetyPumps & Compressors 345is>s o? ,%!nging ! ,urrent progr!m;? too mu,% gre!se is !**e* to motors t%!t %!=e not /een gre!se* ?or 1e!rs motor ?!i0ure r!te m!1 go up initi!001)re!se t%!t %!s %!r*ene* m!1 ?orm ! p0ug t%!t pre=ents t%e ne. gre!se ?rom purging5o00ing ,ont!,t e0ements m!1 s>i* !n* ,!use prem!ture ?!i0ure#emper!tures m!1 rise /e,!use t%e /e!ring is o=er?i00e*5ust ?rom t%e gre!se tu/e m!1 /e ?or,e* into t%e /e!ring#r!ining is re@uire* to institute ! ne. progr!m proper01Pumps & Compressors 352( +st!/0is% ! Common Pro,e*ure+=!0u!te 6+ re,ommen*!tions ?or t%e motors in t%e p0!ntConsi*er motor ,on?igur!tion !n* oper!ting ,on*itions+st!/0is% ?re@uen,1 gui*e0ines3t!n*!r*iDe on regre!sing !mountsPu/0is% ! st!n*!r* o? pr!,ti,ePro=i*e tr!iningPumps & Compressors 363otor O$3 #eco..endationsPumps & Compressors 374re5uency co..on guidelinesPumps & Compressors 385egre!sing ;nter=!0s 7!se* on +P5; NP-75027!se* on pro=en8 *o,umente* per?orm!n,ePumps & Compressors 39The right a.ountPumps & Compressors 40$ffect of grease a.ount on bearing te.peraturePumps & Compressors 41$ASA GuidelinesPumps & Compressors 42Grease A.ount7!se* on ,onso0i*!te* 6+ re,ommen*!tions ?or %oriDont!0 motorsPumps & Compressors 433uggeste* Pro,e*ure ?or ;niti!0 )re!sing o? otors"f .otor is disasse.bled1( $!n* p!,> t%e /e!ring( 2i00 en* /e00 !ppro"im!te01 30% ?u00( Pipe 0e!*ing to /e!ring s%ou0* /e ?u00 o? gre!se to pre=ent rust(