lubricants fundamentals ioci
DESCRIPTION
Lubricants for plantTRANSCRIPT
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INDIAN OIL CORPORATION LTD
Fundamentals of
Lubrication
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ASPERITIES
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Types of lubrication
BOUNDARY LUBRICATION
ELASTO HYDRODYNAMIC LUBRICATION
HYDRODYNAMIC LUBRICATION
MIXED FILM LUBRICATION
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Boundary Lubrication
HIGH ADHESIVENESS HIGH FILM STRENGTH
HIGH LUBRICITY OR OILINESS
PROPER VISCOSITY OR CONSISTENCY
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Excellent chemical stability Ability to separate from water , dust and other
contaminants Reasonable degree of lubricity, adhesiveness and film
strength
Fluid Film Lubrication
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Mixed Film Lubrication
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Elasto - Hydrodynamic Lubrication
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LUBRICANT
• Lubricant can be defined as any material, when interposed between
two surfaces in rubbing contact, is capable of reducing friction.
LUBRICANT = BASE OIL + ADDITIVE
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Lubricant Additive can be defined as any specialitychemical which when blended into a base oil, imparts or modifies its properties.
- Careful balance of both base oils and the performance enhancing additives goes in designing a lubricant which is a complex and complicated task.
ADDITIVES
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FORMULATOR IS A WIZARD OF CHEMISTRY
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Correct lubrication is
RIGHT LUBRICANT
RIGHT PLACE
RIGHT TIME
&
IN RIGHT MANNER
What are the other functions of lubricants ???
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FUNCTIONS OF LUBRICANTS
• Friction & wear control
• Contaminant control
• Corrosion control
• Heat transfer
• Conserves Energy
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LUBE OIL
BASE OIL
Antifoam
Anticorrosion
Antioxidant
Anti-wear
Demulsibility
PPDs
VI Improvers
Detergents & Dispersants
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CLASSIFICATION OF LUBRICATING OILSCRANKCASE OILS1. SAE ENGINE OIL CLASSIFICATIONS
2. API ENGINE SERVICE CLASSIFICATIONS
3. ILSAC ENGINE OIL CLASSIFICATION
4. CCMC CLASSIFICATION
5. ACEA CLASSIFICATION
6. US MILITARY SPECIFICATIONS
7. IS SPECIFICSATIONS
GEAR OILS1. SAE GEAR OIL CLASSIFICATION
2. API SERVICE DESIGNATION
3. U.S MILITARY DESIGNATION
4. UK DEFENCE SPECIFICATIONS
5. IS SPECIFICATIONS
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SAE VISCOSITY LOW TEMP (deg. C) BORDERLINE
GRADE VISCOSITY (cP) PUMPING TEMP
MAX (deg C) MIN MAX
0W 3250 at ( - ) 30 ( - ) 35 3.8 -5W 3500 at ( - ) 25 ( - ) 30 3.8 -10W 3500 at ( - ) 20 ( - ) 25 4.1 -15W 3500 at ( - ) 15 ( - ) 20 5.6 -20W 4500 at ( - ) 10 ( - ) 15 5.6 -25W 6000 at ( - ) 5 ( - ) 10 9.3 -20 - - 5.6 < 9.330 - - 9.3 < 12.540 - - 12.5 < 16.350 - - 16.3 < 21.960 - - 21.9 < 26.1
KIN. VISCOSITY
at 100 deg C
ENGINE OILSSAE VISCOSITY GRADES CLASSIFICATION
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SAE VISCOSITY MIN TEMP (deg C)GRADE FOR VISCOSITY OF
150 cP MIN MAX
70W ( - ) 55 4.1 -75W ( - ) 40 4.1 -80W ( - ) 26 7.0 -85W ( - ) 12 11.0 -90 - 13.5 24
140 - 24.0 41250 - 41.0 -
VISCOSITY at 100 deg C(cSts)
GEAR OILSSAE CLASSIFICATIONS
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CLASSIFICATION TYPE APPLICATION SERVO' GRADES
GL-1 STRAIGHT MINERAL OIL AUTOMOTIVE MANUAL
TRANSMISSION SERVO GEAR SM
(TRACTORS & TRUCKS)
GL-2 CONTAINS FATTY WORM GEAR DRIVES -
MATERIALS INDUSTRIAL GEAR OIL
GL-3 CONTAINS MILD SPIRAL BEVEL GEARS -
EP ADDITIVES 9NOT WIDELY USED)
GL- 4 MIL - L- 2105 SPEC SPIRAL BEVELS & HYPOID GEARS SERVO GEAR HP
50 % OF GL5 ADDITIVE LEVEL UNDER MODERATE CONDS SERIES
GL - 5 MIL - L- 2105D SPEC
RECOMMENDATION FOR MODERATE AND SEVERE SERVO GEAR
MOST PASSENGER CARS CONDITIONS SUPER SERIES
AND TRUCK BUILDERS
GL-6 TECHNICALLY OBSOLETE FOR SERVICE CONDITIONS REQUIRING
MORE ANTI-SCORING PROTECTION -
THAN PROVIDED BY GL-5
GEAR OILAPI SERVICE CLASSIFICATION
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INDUSTRIAL OILS
International Organisation for Standards
Viscosity grade
ISOVG CLASSIFICATIONS
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ISO VISCOSITY (cSts) ISO VISCOSITY (cSts)
GRADE RANGE AT 40 deg C GRADE RANGE AT 40 deg C
2 1.98 -2.42 68 61.2 - 74.83 2.88 - 3.52 100 90 - 1105 4.14 - 5.06 150 135 - 1657 6.12 - 7.48 220 198 - 24210 9.00 - 11.0 320 288 - 35215 13.5 - 16.5 460 414 - 50622 19.8 - 24.2 680 612 - 74832 28.8 - 35.2 1000 900 - 110046 41.4 - 50.6 1500 1350 - 1650
INDUSTRIAL OILSISOVG CLASSIFICATIONS
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CLASSIFICATION OF GREASES
BASED ON CONSISTANCY ( NLGI NO)
NLGI ASTM PENITRATION GRADE 60 STROKES
000 445 - 475 00 400 - 430 0 355 - 385 1 310 - 340 2 265 - 295 3 220 - 250 4 175 - 205 5 130 - 160 6 085 - 115
AS NLGI GRADE DECREASES, GREASE WILL BE SOFTER
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DIFFERENT OILS
AUTOMOTIVE OILS INDUSTRIAL OILS SPECIALITY OILS GREASES TRANSFORMER OILS
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OILS BEING USED
ENGINEOIL-CF4/ CH4 HYDRAULICOILS -SYSTEM OILS RAILROAD OILS AUTO-HYDRAULIC OILS- ULTRA SERIES GEAR OILS- MESH , SYNTHETIC, MESH
PLUS TURBINE OILS- PRIME SERIES
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OILS BEING USED-
GREASES – GEM SERIES GENERAL MCHINERY-LUBREX 22 FIRERESISTANT-HFB68/ HFDU68
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FUNCTIONS OF ENGINE OIL
REDUCE FRICTIONAL RESISTANCE PROTECT AGAINST CORROSION & WEAR ASSIST SEALING ACT AS A COOLANT KEEP THE SLUDGE IN SUSPENSION
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ENGINE PARTS LUBRICATED
main bearings connecting rod bearings cylinders, pistons and rings camshaft bearings cams and valve tappets timing gears valve gears
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ENGINE LUBRICATION SYSTEM
one or more oil pumps outlet relief valves internal and external ducts for conveying the
oil under pressure to the points requiring lubrication.
oil filteration system oil cooling system
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Engine Principles and Layout
Timing Gears
Valve Lifter
Camshaft
Valve
Push Rod
Rocker Arm
Cams
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Approximate Temperature of Internal Surfaces
Exhaust Valve Head 650-730Exhaust Valve Stem 635-675Combustion Chamber Gases 2300-2500Combustion Chamber Wall 204-260Piston Crown 204-426Piston Rings 149-315Piston (Wrist) Pin 120-230Piston Skirt 93-204Top Cylinder Wall 93-371Bottom Cylinder Wall Up to 149Main Bearings Up to 177Connecting Rod Bearings 93-204
Area of the Engine Temperature Range (OC)
Engines and Lubrication
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ENGINE LUBRICATION MECHANISM
thick film lubrication (bearings)
mixed film lubrication (piston skirt)
boundary lubrication (top ring zone area)
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Performance CategoriesAPI Performance Categories for Diesel Engine Oils
HD4 2
CI-4 2002 Low Emission, Four Stroke Engine with EGR and Low Sulfur Fuel
CH-4 1998 Low Emission, Four Stroke Engine Both High and Low Sulfur Fuel
CG-4 1994 Low Emission, Four-Stroke Engines Using 0.05% Sulfur Fuel
CF-4 1991 Low Emission EnginesCF-2 Severe Duty Two-Stroke Cycle EnginesCF Turbocharged Engines or High Sulfur Fuel
Obsolete
Category Service Definition
HeavyDuty
12-19-01
CE 1983 and Later Turbocharged EnginesCD-II Two-Stroke Cycle EnginesCD Turbocharged Engines or High Sulfur FuelCC Moderate Duty - Diesel and GasolineCB Moderate Duty or High Sulfur FuelCA Light Duty, Low Sulfur Fuel
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Performance CategoriesRelative Performance of Each API Category
12-19-01 HD4 379
Oxidation
Oil Aeration
Shear Stability
Filter Plugging
Piston Deposits
Corrosion
Soot Thickening
ValvetrainWear
OilConsumption
Ring and Liner Wear
Sludge
Used Oil Viscometrics
CI-4
CH-4
CG-4
CF-4
CF
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SERVO DIESEL ENGINE OILS
Servo Pride 30 / 40 Servo Pride Super 15W40 Servo Premium CF4 15W40 Servo Pride XL( CH4) 15W40 Servo Pride Supreme ( CI4) 15W40
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SYSTEM OILS
USAGE OF SYSTEM HLP OILS SUPERIOR IN OXIDATION LEVELS GROUP- II BASED OILS LONGER LIFE OILS REDUCTION OF GRADES AND INTER
MIXING BETTER DEMULSIBILTY CHARACTERS
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ADVANTAGES OF RR606 MG
CYLINDER LINER WEAR REDUCED BY 13.3% PISTON RING WEAR REDUCED BY 7% CONNECTING ROD BEARING WEIGHTLOSSIS
IS 44% LOWER CARBON DEPOSIT REDUCED BY 21% SFC REDUCED BY 3% HIGHER TBN LIFE MEANS LOWER LUBE OIL CONSUMPTION
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SAVINGS BY RR606MG SFC IS 2.6-3.0 LTRS/ 100KM FROM 4-5
LTRS/100 KM CONSUMPTION 15YEARS BACK- 25000 KL ESTIMATED CONSUMPTION- 32000KL ACTUAL CURRENTCONSUMPTION-17500KL
SAVINGS ON ACCOUNT OF LUBE OIL- 6400KL
APPROXIMATE VALUE- Rs 64 croreSAVINGS ON FUEL IS 5% OF100000 MT
APPROXIMATE VALUE IS –Rs 450 Crore
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NEW GENERATION OILS
RR 606MG PLUS- LUDHIANA
RR 606MG ALTERANATE VII- JHANSI
RR 520 MG
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RR 606 MG PLUS& VII SERIES
TO FURTHER REDUCE SFC, SLC TO SUSTAIN HIGHER LOADS LONGER DRAIN PERIODS HIGHER TBN RETENTION VALUES ASH LESS ADDITIVES
Since trial is under progress detailed data is
not available
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ULTRA SERIES OF OILS
ENHANCE THE DRAIN PERIOD CURRENT RECOMMENDED IS 1000 HRS DRAIN PERIOD TO BE INCREASED TO 1800
HRS
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GEAR OILS- MESH SERIES
SHIFTED TO SYNGEAR OIL- SYTHETIC OILS
CURRENT OTHER GRADES USED IN MESH SP OILS
RECOMMENDED IS SERVO MESH PLUS SERIES OILS – ANTI MICRO PITTING OILS- SEMI SYNTHETIC OILS
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MICROPITTING A new form of tooth surface wear Conventional gear oils are inadequate to control this type of
wear under severe operating conditions Characterized by the presence of fine surface pits, showing Characterized by the presence of fine surface pits, showing
Fractured lower surfaces Fractured lower surfaces Driving stress for micro pitting arises from the Roughness Driving stress for micro pitting arises from the Roughness
of the gear surfacesof the gear surfaces Therefore, surface roughness & lubricant additives have an Therefore, surface roughness & lubricant additives have an
important impactimportant impact
MICROPITTING IS AN UNIFORM ROLLING CONTACT
FATIGUE WEAR PHENOMENON, OBSERVED IN CASE
OF HARDENED GEARS, OPERATING UNDER MIXED OR
BOUNDARY LUBRICATION REGIMES
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SERVOMESH PLUS
• Anti micro pitting resistant industrial gear oils
• Carefully blended with HVI solvent neutral base stocks
• Optimized with tailor made additive package to ensure many
other performance parameters of S-P series oils in addition to
superior antimicropitting and wear protections
• Protects against scuffing without promoting corrosive wear and
fatigue failures
• Passes through special micro pitting tests
THE OILS ARE APPROVED BY M/S FLENDER AG OF GERMANY
COMMERCIALLY AVAILABLE IN ISOVG GRADES OF 220 / 320/460
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TURBINE OILS- PRIME OILS
IMPROVEMENT DONE IS INDEGENIOUS BASE OIL STOCKS
SULPHUR % IS THE ORDER OF 200 ppm AGAINST IMPORTED STOCKS OF 2000 ppm
SEMI-SYNTHETIC IN NATURE SATURATES % IS HIGH LOWER OXIDATION
LEVELS LESS OF ELEMENTAL- METALS
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GREASES
SERVO GREASE WR2- WATER RESISTANCE SERVO PLEX SHC 120- SYNTHETIC GREASE SERVO CHAIN TEXT- SYNTHETIC OILS – HIGH
TEMPERATURE SERVO CHAIN KOTE – CHAIN LUBRICATION
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TRANSFORMER OILS
SERVO ELECTRA BIS335-1993 SPECIFICATION. Approved by
Central power research institution (CPRI) NON CONVENTIONAL-ACID TREATMENT Hydro Catalytic Techniques, which
resulted in high quality base oil with inherent property of low pour point, and superior Hydrophobic
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TRANSFORMER OIL
Kinematic Vis. @ 400 C : 14.84 Density : 0.835 Flash Point : 165 Min. Pour point : (-)10 min Interfacial tension,N/m : 0.050 min Neutalisation value,TAN : nil Corrosive sulphur : non corrosive BD Voltage,ms,KV : 71 Di electic, dissipation factor : 0.0001
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TRANSFORMER OIL
Specific resistance 1012 : 3920 (ohm @27 degreeC)
OXIDATION STABILITY :0.01mgKOH/gm Water content ppm : 14
GASSING TENDENCY IS 1/3 RD OF THE NORMAL CONVENTIONAL OILS
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DISPOSAL OF OILS
BURNING INCERENATING BURYING UNDER GROUND
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Lubrication is any procedure that has theeffect of reducing friction and wear
Friction– resistance to motion encountered
during sliding
Wear– loss or destruction of surface
material
FUNDAMENTALS OF LUBRICATION
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History
• Egyptians used fluids to lubricate sledges as early as 2400 B.C.
• Natural oils widely used as lubricants up to the 19th Century
• Mineral oils introduced during 19th century (industrial revolution)
• Additives and synthetic lubricants introduced during the 20th Century, particularly after World War II
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CAUSES OF FRICTION
Molecular attraction between bodies in contact Interlocking of the opposing surface
irregularities Surface waviness
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TYPES OF FRICTION
Static
Kinetic...................
Rolling............................................
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FRICTION & WEAR
Friction regime Coefficient of Friction Wear
Dry Friction (Sliding) 0.3 high
Dry Friction (Rolling) 0.005 very low
Mixed friction (rolling) 0.005 - 0.3 noticeable
Fluid friction 0.005 - 0.1 practically zero
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FUNDAMENTALS OF LUBRICATION
MODES OF LUBRICATION
HYDRODYNAMIC MIXED FILM ELASTO HYDRODYNAMIC BOUNDARY
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Hydrodynamic
Hydrodynamic Pressure
Stationary Surface
Moving Surface
Liquid ‘wedge’ formed under the inclined plate causes lift
FUNDAMENTALS OF LUBRICATION
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Hydrodynamic
static
high speed
Lubricant film thickness greater than surface asperities
laminar flow
Low Load
FUNDAMENTALS OF LUBRICATION
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Mixed
Some surface contact
Lubricant film thickness of similar order to surface asperities
High load
Low speed
FUNDAMENTALS OF LUBRICATION
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Elasto-hydrodynamic
Very thin layer of oilunder extremepressure
Elastic deformationof gear tooth surfaces
W
Example:Loaded Gears
“Model” Gear tooth surfaces
W
Unloaded
Loaded
FUNDAMENTALS OF LUBRICATION
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Boundary
Lubricant film thickness less than surface asperities
Surface Contact
Very High Load
Very low speed
Lubricant Film
FUNDAMENTALS OF LUBRICATION
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1 10 100 1,000 100,000
1.0
0.1
0.01
0.001
Mixed Lubrication
Boundary Lubrication
ZN/P
Coeffi
cie
nt
of
Fri
cti
on
Full Fluid Film Lubrication0.0001
Z= Viscosity N= Speed P= Pressure
Lubrication Regimes
FUNDAMENTALS OF LUBRICATION
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PRIMARY FUNCTIONS OF A LUBRICANT
Reduce Friction Reduce Wear Removal of Heat ( Due to Frictional Work,
Combustion Heat)
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IMPORTANT PROPERTIES
Proper fluidity under operating conditions Film strength to withstand loads Chemical Stability Lubricity or oiliness or slipperiness to the
degree required Adhesiveness to bearing surfaces Purity , freedom from contaminants Noncorrosive characterstics
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IMPORTANT PROPERTIES
Rust proofing capability Resistance to water washout Resistance to foaming Good sealing properties Low change in fluidity due to change in temperatures Fire resistance Low volatility Good emulsifying qualities Availability at reasonable cost
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CLASSIFICATION OF LUBRICANTS
PHYSICAL STATE SOLID : Graphite Powder , Molebdenum
disulphide , Talc Liquid: Mineral Oils, Vegetable Oils, Synthetic
Oils Gases : Air, Helium, Carbon dioxide Plastics: Greases
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APPLICATIONS
Gases : Lighter bearings like gyroscopes , Rotating mount of large telescopes
Solids: They are used of extreme conditions of temperature, vacuum, loads & nuclear radiations.
Liquids: For most of the Industrial & Automotive application mineral oil based lubricants are used.
Greases: Greases are used for those applications where liquids do not stay in place.
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CLASSIFICATION BASED ON APPLICATION
Engine Oils Gear Oils Hydraulic Oils Compressor Oils Turbine Oils Cutting Oils Circulation bearing oils
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CLASSIFICATION OF LUBRICANTS BASED ON VISCOSITY
SAE Classification for Automotive Engine Oils & Gear Oils
ISO VG Classification for Industrial Oils NLGI Classification for Greases
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SAE CLASSIFICATION - ENGINE OILS
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SAE CLASSIFICATION OF AUTOMOTIVE GEAR OILS
SAE VISCOSITY GRADE
MIN TEMP FOR VISC OF 150000
cP °C
VISC AT 100°CcSt
MINIMUM MAXIMUM
70W -55 4.1 -
75W -40 4.1 -
80W -26 7.0 -
85W -12 11.0 -
90 - 13.5 24.0
140 - 24.0 41.0
250 - 41.0 -
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ISO VG CLASSIFICATION
Min. Max. Min. Max.
2 2.2 1.98 2.42 68 68 61.20 74.80
3 3.2 2.88 3.52 100 100 90.00 110.00
5 4.6 4.14 5.06 150 150 135.00 165.00
7 6.8 6.12 7.48 220 220 198.00 242.00
10 10.0 9.00 11.00 320 320 288.00 352.00
15 15.0 13.50 16.50 460 460 414.00 506.00
22 22.0 19.80 24.20 680 680 612.00 748.00
32 32.0 28.80 35.20 1000 1000 900.00 1100.00
46 46.0 41.40 50.60 1500 1500 1350.00 1650.00
Viscosity Limit cSt
@ 40oC
Viscosity Limit cSt
@ 40oCISO
Visosity Grade
Midpoint cSt @
40oC
ISO Viscosity
Grade
Midpoint cSt @
40oC
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NLGI CLASSIFICATION
NLGI No. ASTM Penetration at 25o C000 445-475
00 400-430
0 355-385
1 310-340
2 265-295
3 220-250
4 175-205
5 130-160
6 84-115
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HOW LUBRICANTS ARE MADE
ADDITIVES: Detergents,Dispersants,Oxidation Inhibitors,VI Improvers,Antifoam,Antiwear
BASE OIL Additives
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BASE OIL PRODUCTION
Base oils are produced from crude Oil. Distillation is done to adjust viscosity & flash point Refining to improve aging tendency & VT
Charactersitics Dewaxing is done to improve low- temperature
properties. Base Oils & Additives blended together to get required
properties for a specific application.
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SERVO NOMENCLATURE
SERVOPRIME – FOR TURBINES ( PRIME MOVER) SERVOSYSTEM- FOR HYDRAULIC SYSTEMS SERVOMESH – FOR INDUSTRIAL GEARS SERVOPRESS- FOR COMPRESSORS SERVOSPIN – FOR TEXTILE/GRINDING HIGH
SPEED SPINDLES SERVOSTEEL – FOR STEEL INDUSTRY BEARINGS SERVOFRIZ – FOR REFRIGERATION COMPRESSOR SERVONEUM FOR PNEUMATIC TOOLS SERVOWAY- FOR MACHINE TOOL GUIDE WAYS SERVOCYL FOR STEAM CYLINDER SERVO SM FOR SUGAR MILL BEARINGS SERVOSHAFT FOR MARINE SHAFT BEARINGS
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SERVO NOMENCLATURE
SERVOCUT FOR CUTTING – CUTTING FLUIDS SERVOTHERM FOR HEAT TRANSFER SYSTEMS SERVOQUENCH FOR QUENCHING OPERATIONS SERVO MARINE FOR MARINE ENGINES SERVO GEM FOR GENERAL ELECTRICAL &
MECHANICAL SERVOCOAT OPEN GEAR COATING LUBRICANT SERVORP FOR RUST PREVENTION SERVOVACUUM FOR VACUUM PUMPS SERVOSYNGEAR FOR GEARS – SYNTHETIC OIL SERVOSYNCO FOR COMPRESSORS- SYNTHETIC OIL SERVO GEAR FOR AUTO GEARS