1000 MW unit at SHANGHAI, CHINA View of the 600 MW Hirono No.5 steam turbine Continuous ship unloader This unloader realizes continuous unloading from iron ore bulk carriers or coal bulk carriers. IHI has delivered the world's largest continuous ship unloader with a capacity of 4,000 t/hour for iron ore carriers, and also has the world's top technologies and delivery record. IHI also offers belt-type unloaders and pneumatic unloaders for various food and feed such as soybeans, wheat grains, and corns. Designs of unloaders will be adjusted to regional characteristics of delivery destinations. For example, the latest seismic isolating device will be used in the unloaders to be delivered to regions where anti-earthquake measures are required. Rotary or Regenerative Air Pre-Heater Turbine Installation. High and intermediate pressure turbine rotor setting on the casing. The 40-inch blade low-pressure turbine with inner casing and 586-MVA generator are shown behind it.
The biggest pump set has a drive rating of 18,000kW and generates a discharge pressure of 320 bar. JOURNAL BEARING Primary Requirement of Lubrication Lubrication is required to reduce the Friction and Wear between two surfaces Moving against each other Regimes of Lubrication BOUNDARY
MIXED
HYDRODYNAMIC
ELASTO- HYDRODYNAMIC decreasing severity HYDRODYNAMIC LUBRICATION Fluid Film Lubrication Surfaces separated by bulk film formed due to motion between surfaces Affected by viscosity, load and speed Film Thickness 20 microns e.g Journal Bearings, Ring/Liner
FULL SPEED CONDTION JOURNAL BEARING MIXED LUBRICATION Mixed film lubrication Both bulk oil film and boundary film play a role e.g. Gear, Valve train ,Ring liner
INTERMEDIATE SPEED BOUNDARY LUBRICATION Surfaces separated by film of few molecular length Protection essentially depended on boundary film e.g. Heavily loaded gears, Ring/liner, Valve train
START STOP SHOCK LOAD CONDITIONS GEAR CONTACTS GEAR GEOMETRY DETERMINES CONTACT DYNAMICS LUBRICATION IN GEARS FILM THICKNESS IS AFFECTED BY LOAD, SPEED AND VISCOSITY ELASTO HYDRODYNAMIC LUBRICATION Surfaces separated by very thin oil film contacting surface elastically deformed. Film Thickness .25 to 2 microns Roller bearings,lightly loaded gears
FILM THICKNESS IN EHD CONTACTS Lambda = Film Thickness/surface Roughness
Proper Film Thickness Begins when Lambda is greater than 1.5 Secondary functions of a Lubricant Corrosion Inhibition Cooling Cleaning Sealant Power Transmission
Properties the Lubricant should have to perform its functions Proper Viscosity Low viscosity dependency on Temperature Viscosity Index Oxidation and Thermal Stability Anti Corrosion Nil foaming tendency Detergency Dispersancy
LIQUID LUBRICANTS SOLID LUBRICANTS
Lubricants can be Composition of a Lubricant Base Oil Performance Enhancing additives Base Oil Mineral Oil obtained from Petroleum Base Oil Imparts basic properties like viscosity, viscosity index, oxidation stability to lubricant The percentage of base oils varies from 80 to 95 % Turbine Oils TURBINE LUBRICATION SYSTEM REQUIREMENTS FROM A TURBINE OIL CUSTOMERs NEED OIL FEATURES REQUIRED
MAXIMUM EQUIPMENT LIFE LEAST MACHINE DOWNTIME GOOD OXIDATION AND EXTENDED OIL LIFE (10-20 YEARS) THERMAL STABILITY
RUST INHIBITION OF THE SYSTEM GOOD ANTIRUST PROPERTY
NO SYSTEM CORROSION GOOD METAL COMPATIBILITY
EXCELLENT SURFACE ACTIVITY ADEQUATE WATER / AIR SEPARATION OF THE OIL TOWARDS ANTIFOAM OF SYSTEM OIL DEMULSIBILITY & AIR RELEASE PROPERTIES
MINIMAL WEAR GOOD ANTIWEAR PERFORMANCE
REQUIREMENT OF A TURBINE OIL
LUBRICATION OF BEARINGS, GEARS, SEALS ETC.
PROTECTION OF THE SYSTEM FROM CORROSION, RUST AND OTHERS.
TO ACT AS A SEALING MATERIAL FOR DUST AND DIRT.
ALLOW RAPID SEPERATION OF WATER AND AIR.
COMPATIBILITY WITH METALS.
TO ACT AS A COOLANT.
RETENTION OF ORIGINAL PHYSICAL PROPERTIES FOR LONG PERIOD OF TIME.
DESIRABLE PROPERTIES OF TURBINE OIL
APPROPRIATE VISCOSITY GOOD RUST PREVENTION HIGH OXIDATION STABILITY GOOD ANTI FOAM PROPERTIES GOOD WATER DEMULSIBILITY GOOD AIR RELEASE PROPERTIES GOOD ANTI FRICTIONAL PROPERTIES
VISCOSITY VISCOSITY IS ONE OF THE KEY PROPERTIES AND OPTIMUM VISCOSITY OF TURBINE OIL PROVIDES PROPER THICKNESS OF OIL FILM DISSIPATION OF HEAT REMOVAL OF CONTAMINANTS
TURBINE OILS ARE AVAILABLE IN ISO VG 32, 46, 68 EXAMPLE: SERVOPRIME 46
DEMULSIBILITY INGRESS OF WATER IS UNAVOIDABLE IN TURBINE SYSTEM THE PRESENCE OF WATER CAN CAUSE POOR LUBRICATION RUST FORMATION METAL CORROSION FOAMING & AIR RELEASE INGRESS OF AIR MUST BE AVOIDED IN SYSTEM. THE INGRESS OF AIR IN OIL MAY CAUSE REDUCTION IN TRUE FLOW OF OIL POOR HEAT DISSIPATION REDUCTION IN OIL FILM THICKNESS INCREASE IN OXIDATION RATE OF OIL RUST & CORROSION CORROSION OF FERROUS & YELLOW METALS IS A PERENNIAL PROBLEM SPECIAL ADDITIVES ARE BEING INCORPORATED IN OILS TO RESIST AGAINST CORROSION FOR A LONGER PERIOD OF TIME OXIDATION & THERMAL STABILITY OXIDATION STABILITY OF OIL - DIRECT BEARING WITH THE LIFE OF OIL IN SYSTEM THE OIL IS EXPOSED TO ELEVATED TEMP., INGRESS OF AIR, METAL & WATER DURING ITS SERVICE AND OIL OXIDATION PROCESS INITIATED GENERATION OF ACIDS & INSOLUBLE SLUDGE DURING OXIDATION MAY CAUSE SEVERE DAMAGE TO SYSTEM
DETERIORATION OF TURBINE OILS IN SERVICE
* HOW TURBINE OIL DEGRADE :
- OXIDATIVE DEGRADATION : CHEMICAL REACTION WITH AIR - THERMAL OXIDATIVE : UNSTABLE COMPOUNDS DUE TO CRACKING OF HIGHER MOLECULES - WATER INGRESS GENERALLY : THROUGH COOLING CIRCUIT - LOSS OF ADDITIVES PRESENT IN OIL
* PROPERTIES OF OILS TO BE RETAINED : - VISCOSITY - OXIDATION STABILITY RESERVE - FREEDOM FROM SLUDGE - FREEDOM FROM ABRASIVE CONTAMINANTS - ANTI CORROSION PROTECTION - OTHER PROPERTIES OF USED TURBINE OIL COLOUR / FLASH / FOAMING / ELEMENTS / DEPLETION OF ADDITIVES
TYPICAL TURBINE OIL SPECIFICATIONS Property Test Method UOM Requirement Viscosity DIN 51562-1 ISO VG 46 ASTM-D 445 KV @ 40 deg C DIN 51562-1 ASTM-D 445 KV @ 100 deg C DIN 51562-1 ASTM-D 445 Viscosity Index DIN ISO 2909 95 Min ASTM-D 2270 Density at 15 C DIN 51757 gm/q.cm. s 0.90 ASTM-D 1298 Appearance light and clear Color DIN ISO 2049 2 Max. ASTM-D 1500 Flash Point DIN ISO 2592 C > 180 ASTM-D 92 Flow Point ISO 3016 C (-) 9 Max. ASTM-D 97 Neutralisation Index DIN 51558-1 mg KOH/g 0.15 Max ASTM-D 974 Ash DIN EN ISO 6245 % by wt s 0.01 ASTM D 482 Water content DIN 51777-1 mg/kg s 150 ASTM-D 1744 Water release Property DIN 51589-1 seconds 300 Max ASTM-D 1401 Air release property at 50 C DIN 51381 minutes 5 Max ASTM-D 3427 Emulsion Test @ 82 Deg C, D-1401, 40-37-3, Minutes, Max ASTM-D 1401 minutes Corrosive effect of Copper DIN EN ISO 2160 s 2100 A3 ASTM-D 130 Corrosion protection for steel DIN 51585 s 0A ASTM-D 665 Solid foreign matter DIN ISO 5884 mg/kg 300 Max Fouling Class ISO 4406 s 20/17/14 Foaming Characteristics, Foam formation Seq I/seq II/ Seq III DIN 51566 ASTM-D 892(Seq 1- 3) s 50/50/50 Foam stability (10 min.) 0/0/0 Load carrying ability (Fail load stage) FZG/SRC standard test 7 Min DIN 51534-02-A/8,3/90 TOST aging stability DIN 51587 Hours 4000 Min ASTM-D 943 RPVOT aging stability ASTM-D 2272 Min. 350 Min. Testing of low-viscosity lube oils for oxidation and corrosion preventing properties DIN 51394 FTN791B-5308.6 Visc. Change: 20 to 5% TAN change: 2.0 Max Sludge to be indicated Zinc Content Nil Nil HYDRAULIC OILS FUNCTIONS OF HYDRAULIC OILS SMOOTH AND ACCURATE TRANSMISSION OF POWER LUBRICATION OF ALL RUBBING SURFACES TO REDUCE WEAR & FRICTION HEAT REMOVAL FROM HIGH FRICTION SPOTS PROTECTION OF THE EQUIPMENT FROM RUST & CORROSION SEPARATION FROM WATER & AIR KEEPING THE SYSTEM CLEAN FROM CONTAMINANTS INERTNESS TOWARDS ALL NON-METALLIC PARTS INCLUDING PEOPLE RETENTION OF ALL THE ABOVE PROPERTIES FOR A LONGER PERIOD OF TIME HYDRAULIC OIL REQUIREMENTS PROPER VISCOSITY WEAR PROTECTION OXIDATION & THERMAL STABILITY CORROSION PROTECTION GOOD FOAM RESISTANT CHARACTERISTICS RESISTANT TO AIR ENTRAINMENT NON-COMPRESSIBLE GOOD DEMULSIBILITY ADEQUATE FILTERABILITY IN USE INDUSTRIAL GEAR OILS
FUNCTIONS OF GEAR OILS
CONTROL FRICTION AND WEAR REMOVE HEAT GENERATED BY FRICTION PROTECTION AGAINST DIRT&RUST CLASSIFICATION OF GEARS ENCLOSED OR OPEN
SPUR/HELICAL - REFERRED TO AS STEEL ON STEEL TEETH ARE HEAVILY LOADED TOOTH CONTACT IS A MIXTURE OF ROLLING &SLIDING LITTLE ENERGY DISSIPATION(2%) GEAR CLASSIFICATION WORM GEARS- STEEL WORM AND BRONZE WHEEL USED FOR HIGH SPEED REDUCTION LARGE AREA OF CONTACT,LESS TOOTH LOADING HIGH ENERGY DISSIPATION(25%) LOADING TYPE ONLY SLIDING. CHARACTERISTICS OF GEAR LUBRICATION PRESSURE INVOLVED BETWEEN MATING SURFACES ARE VERY HIGH SLIDING ACTION WIPES OUT OIL SUDDEN LOADING GEAR OIL PROPERTIES EP PROPERTY- ESSENTIAL IN SPUR & HELICAL GEARS DUE TO ROLLING MOTION EP ADDITIVES ARE S/P BASED S- CAUSES CONTROLLED CORROSION OF METAL SURFACES AT HIGH TEMPERATURE WHILE ROLLING P- ACIVE AT LOWER TEMPERATURE WHILE SLIDING- BY ADSORPTION GEAR OIL PROPERTIES ANTI OXIDANT- LIFE, SLUDGE ANTI RUST- MORE TAN IN FRESH OIL ANTI FOAM- CALCIUM & RUST INHIBITORS CAUSES FOAMING. DEMULSIBILITY LUBRICATION METHODS SPLASH SPRAY(JET) OIL MIST SPALSH/SPRAY METHODS NEDD OIL TIGHT HOUSING SUMP MUST BE FILLED TO SPECIFIED LEVEL. OIL MUST BE BROUGHT EFFECTIVELY TO GEAR TOOTH SURFACES. SAME OIL MAY LUBRICATE SHAFT BEARINGS. SPLASH LUBRICATION OIL FROM SUMP IS CARRIED UP BY TEETH OF LARGER GEAR DIPPING IN TO OIL. OIL LEVEL IS MAINTAINED SO THAT TEETH ALWAYS DIP INTO OIL. IF OIL LEVEL TOO LOW- POOR LUBRICATION. IF OIL LEVEL TOO HIGH CHURNING WILL CAUSE RAISE IN TEMP. FIXED VOLUME OF OIL IS SUBJECTED TO SEVERE SERVICE. THERE IS NO COOLING AND NO WAY TO FILTER THE OIL CONTINUOUSLY. SPRAY LUBRICATION CIRCULATING SYSTEM MOST OFTEN USED IN LARGER GEAR SETS AND HIGH SPEED GEARS. OIL IS CIRCULATED BY PUMP VIA NOZZLE OR JET TO THE GEAR TEETH CONTACT AREA. OIL IS DIRECTED AT PARTING TEETH. OPERATING TEMP REDUCED BY COOLING VIA HEAT EXCHANGER. FILTERATION IS USED TO REMOVE CONTAMINATION. A CENTRALISED SYSTEM IS USED WHEN MULTIPLE GEAR DRIVES OF SIMILAR DESIGN ARE LOCATED CLOSE TO EACH OTHER. MIST LUBRICATION LUBRICANT ATOMISED IN A MOVING AIR STREAM TO FORM MIST. MIST IS PIPED TO THE POINT OF APPLICATION AND DEPOSITED AS A FINE OIL SPRAY DIRECTED AT ENGAGING AND PARTING TEETH ADVANTAGES-REDUCED OIL CONSUMPTION,ELIMINATION OF CONTAMINATION. USED AT MEDIUM AND HIGH SPEEDS. GOOD COOLING LOW POWER LOSS DUE TO OIL DRAG. OPEN GEAR LUBRICATION CONTINUOUS OPERATION SPLASH LUBRICATION. HIGH VISCOSITY LUBES ARE REQUIRED. INTERMITTENT OPERATION OPERATE UNDER BOUNDARY CONDITIONS. METHODS AUTOMATIC SPRAY,HOT MELT,FORCED FEED,GRAVITY DRIP AND HAND APPLICATION. Typical Gear Oil Specifications Sr. Property Test Method Test Condition UOM Servo Mesh SP 320
1 Viscosity Grade DIN 51562-1 ISO VG 320 ASTM-D 445 2 KV @ 40 deg C DIN 51562-1 305 to 335 ASTM-D 445 3 KV @ 100 deg C DIN 51562-1 24.0 ASTM-D 445 4 Viscosity Index DIN ISO 2909 96 ASTM-D 2270 5 Density at 15 C DIN 51757 gm/q.cm. ASTM-D 1298 6 Appearance 7 Color DIN ISO 2049 ASTM-D 1500 8 Flash Point DIN ISO 2592 C 234 ASTM-D 92 9 Flow Point ISO 3016 C -6 ASTM-D 97 10 Neutralisation Index DIN 51558-1 mg KOH/g ASTM-D 974 11 Ash DIN EN ISO 6245 % by wt 0.003 ASTM D 482 12 Water content DIN 51777-1 mg/kg nil ASTM-D 1744 13 Water release Property DIN 51589-1 seconds ASTM-D 1401 14 Air release property at 50 C DIN 51381 minutes ASTM-D 3427 15 Emulsion Test @ 82 Deg C, D- 1401, 40-37-3, Minutes, Max ASTM-D 1401 minutes 15 16 Corrosive effect of Copper DIN EN ISO 2160 1b ASTM-D 130 17 Corrosion protection for steel DIN 51585 ASTM-D 665 18 Solid foreign matter DIN ISO 5884 mg/kg 19 Fouling Class ISO 4406 20 Foaming Characteristics, Foam formation Seq I/seq II/ Seq III DIN 51566 ASTM- D 892(Seq 1-3) Nil/Nil, Nil/Nil, Nil/Nil 21 Foam stability (10 min.) 22 Load carrying ability (Fail load stage) FZG/SRC standard test 13
DIN 51534-02-A/8,3/90 23 TOST aging stability DIN 51587 Hours ASTM-D 943 24 RPVOT aging stability ASTM-D 2272 Min. 25 Testing of low-viscosity lube oils for oxidation and corrosion preventing properties DIN 51394 FTN791B-5308.6
26 Zinc Content Nil Nil 27 Four Ball Weld Load - Weld Load Kgs - Load Wear index, Kg IP 239 D2783 250 46.4 28 4 Ball Wear Test @ 54 C, 1800 rpm, 20 kg, 1hr, mm D 2266 0.3 29 Saponification Num 30 Rust /test Procedure B D 665 Pass 31 Oxidation Test @95 C for 312 hrs increase in KV, % Precipitatiin No , ml D 2893 %, ml 3.6, Nil 32 Timken OK load test D 2782 lbs 60 33 Sulphated Ash DIN 51575 % mass 0.003
COMPRESSOR OILS
TYPES OF COMPRESSORS BASIC CATEGORIES - * POSITIVE DISPLACEMENT TYPE : AIR IS COMPRESSED BY THE SQUASHING EFFECT OF MOVING COMPONENTS EXAMPLE- * RECIPROCATING: SINGLE ACTING , DOUBLE ACTING * ROTARY : SCREW, VANE, ROOTS etc.
* TURBO COMPRESOR TYPE : - HIGH VELOCITY OF MOVING AIR IS CONVERTED INTO PRESSURE
EXAMPLES- * CENTRIFUGAL TYPE * AXIAL FLOW TYPE COMPRESSORS PARTS REQUIRE LUBRICATION 1) RECIPROCATING TYPES BEARINGS - MAIN, CRANKSHAFT, PIN BUSHINGS CYLINDERS - WALLS, PISTON, PISTON RINGS, VALVES SHAFT SEALS IN SOME CASES 2) ROTARY VANE TYPE BEARINGS - ROTOR SHAFT CYLINDERS - WALLS ROTOR - BLADES SLOT SURFACES, VANE, SLIDING AREAS WITHIN SLOTS 3) ROTARY SCREW ALL PARTS OF COMPRESSORS UNDER ROTARY ACTION 4) ROOTS TYPE CONNECTING GEARS, LOBE SHFT BEARINGS 5) CENTRIFUGAL TYPE BEARINGS, GEARS, SHAFT, SEALS, COUPLINGS etc. WORKING ACTION OF COMPRESSORS COMPRESSOR TYPE OPERATING TEMP,C LUBRICATION PROBLEMS
RECIPROCATING - SINGLE STAGE - VARNISH & CARBON UPTO 270C DEPOSITS - MULTI STAGE - PISTON RING WEAR 160 - 210C INCREASE, LEAKAGE DEPOSITS ROTARY 80 - 120 C - DEPOSIT BLOCK FILTER & SEPARATOR ELEMENTS - VARNISH ON BEARINGS SLIDING VANE 80 - 150 C - DEPOSIT BLOCK FILTERS - VANE WEAR INCREASES FILTER DEPOSITS SIGNIFICANCE OF ANTIWEAR PERFORMANCE INCREASE IN PISTON RING GAP DURING COMPRESSOR OPERATION WOULD INDICATE EXCESSIVE WEAR OF CYLINDER BORE / PISTON RINGS
AW PROPERTY IS REQUIRED SPECIFICALLY AT SLIDING / ROTATING SURFACES
CONVENTIONALLY HIGHER LOAD CONDITIONS ARE OVERCOME BY ADOPTING HIGHER VISCOSITY COMPRESSOR OILS
TO ENSURE PROPER LUBRICATION, RECIPROCATING COMPRESSOR OILS MUST HAVE EXCELLENT THERMAL / OXIDATION STABILITY AS WELL AS ADEQUATE AW PERFORMANCE FUNCTIONS OF COMPRESSOR LUBRICANTS ACT AS A COOLANT TO REMOVE THE HEAT OF COMPRESSION TO PROVIDE LIQUID SEAL MINIMISE WEAR IN FRICTIONAL COMPONENTS e.g., PISTON, CYLINDER, BEARING, VANE, SLOTS etc. TO PROVIDE RUST FREE SURFACES TO MINIMISE BUILT UP OF DEPOSITS BY PROVIDING HIGH LEVEL OF THERMAL - OXIDATIVE STABILITY TO KEEP OIL - AIR SEPARATORS CLEAN CHARACTERISTICS OF COMPRESSOR LUBRICANTS CORRECT VISCOSITY AT OPERATING TEMP.TO ASSURE OIL FILM FORMATION ON ALL FRICTIONAL COMPONENTS HIGH OXIDATION-THERMAL STABILITY - RESIST DEPOSIT FORMATION ADEQUATE WEAR PROTECTION GOOD DEMULSIBILITY IN ROTARY FLOODED SYSTEMS TO AVOID EMULSION FORMATION LOW CARBON DEPOSITS ON DISCHARGE VALVES & PASSAGES OF RECIPROCATING COMPRESSORS TROUBLE FREE STARTING AT LOW TEMP. EFFECT OF WATER CONTAMINATION IN LURICATING OIL DIRECTION OF OIL FLOW IN FILTERS Centrifugal Casting up to 120" O.D. The most highly recommended repair procedure for large steam and hydro turbine generator equipment. Centrifugal casting is the method used to obtain maximum bond strength in the recasting process of Babbitt bearings.
Other casting methods (Static casting, TIG and Puddling, and Metalizing) are available for: Fan Bearings Motor Bearings Ball Mill Bearings Tilt Pad Bearings Thrust Shoes Pillow Blocks Hydrogen Seals Pivoted Shoe Rotating Thrust Collar Wire Ropes The life of a wire rope can be extended through the proper application of the correct lubricant. The individual wires in a wire rope are subject to abrasive wear as they move relative to each other any time the rope is bent, such as when it goes over a sheave or is wound on a drum. Unless the rope is constructed of stainless steel, it is also subject to corrosion damage. Corrosion is especially a problem for wire ropes that are exposed to the elements. To be effective, the lubricant must penetrate into the rope to provide lubrication between the individual wires and strands. It also must provide lubrication externally to reduce friction between the rope and sheaves or drum, and it should act as a sealant to prevent corrosion. The lubricant coating should not prevent the visual inspection of the rope for broken wires or other damage. Many times, a light mineral oil, such as an SAE 10 motor oil, is used to lubricate wire rope. The advantages of such a light oil is that it can be applied cold and it will penetrate into the rope easily. The main disadvantage is that it will work out of the rope just as easily as it works in, and frequent application will be required. Heavy, adhesive lubricants can provide longer lasting protection, but most require heating before application to provide proper penetration. A heavy lubricant, when properly applied, will not only provide internal lubrication, but also provide a durable outer coating to prevent corrosion and keep dust and abrasives out of the rope. Heavy adhesive lubricants usually must be heated or thinned with a solvent to ensure they provide internal lubrication. The lubricant can be applied by brush, spray, or dripped on, or, preferably, by passing the rope through a heated reservoir filled with the lubricant. Before applying the lubricant, clean any accumulated dirt, dust, or rust from the rope because they can prevent the lubricant from penetrating properly. The lubricant should be applied to the entire circumference of the rope and the rope slowly wound on and off the drum several times to work the lubricant into the rope. If the lubricant is being applied by hand, it may be helpful to apply the lubricant as it passes over a sheave because the ropes strands are spread by the bending, and the lubricant can penetrate
Heavy, adhesive lubricants can provide longer lasting protection, but most require heating before application to provide proper penetration. A heavy lubricant, when properly applied, will not only provide internal lubrication, but also provide a durable outer coating to prevent corrosion and keep dust and abrasives out of the rope. Heavy adhesive lubricants usually must be heated or thinned with a solvent to ensure they provide internal lubrication. The lubricant can be applied by brush, spray, or dripped on, or, preferably, by passing the rope through a heated reservoir filled with the lubricant. Before applying the lubricant, clean any accumulated dirt, dust, or rust from the rope because they can prevent the lubricant from penetrating properly. The lubricant should be applied to the entire circumference of the rope and the rope slowly wound on and off the drum several times to work the lubricant into the rope. If the lubricant is being applied by hand, it may be helpful to apply the lubricant as it passes over a sheave because the ropes strands are spread by the bending, and the lubricant can penetrate more easily.
Gates, Radial gates, Dampers and butterfly valves Grease for the slow moving, highly loaded, bronze bushings such as those found on wicket gates, radial gates, and butterfly valves should be adhesive, water resistant, able to withstand high bearing pressures, and of a consistency that can be pumped at the lowest temperature encountered. Usually, a grease with extreme pressure or antiwear capabilities is specified. It should be noted that the term, extreme pressure, is used fairly liberally by grease manufacturers, and the presence of extreme pressure additives and extreme pressure properties should be verified. Because the grease is lubricating a bronze bearing, it should not be corrosive to copper. TIN BASE ALLOYS FOR BEARINGS Tin base babbitts commonly contain copper and antimony. They have hardness up to 32BHN which gives them excellent load-carrying characteristics. They show low friction resistance, low wear, good run-in properties and good emergency behavior in the absence of adequate lubrication. They wet easily and maintain an oil film, resist corrosion, are easily cast and bonded and retain good mechanical properties at elevated temperatures. STORAGE AND HANDLING OF LUBRICANTS
WHY PROPER STORAGE AND HANDLING ?
TEMPERATURE VARIATION RAINS DUST CONTAMINANTS
WHY PROPER STORAGE AND HANDLING ?
WHY PROPER STORAGE AND HANDLING ?
OIL EXPANDS 20 TIMES MORE THAN STEEL AIR EXPANDS 100 TIMES MORE THAN STEEL
IF STEEL BARREL IS FILLED FULLY & THE BUNG IS TIGHTENED, BARREL WILL BURST IF THE TEMPERATURE INCREASES
WHY PROPER STORAGE AND HANDLING ?
IF SMALL CLEARANCE IS LEFT TO ACCOMOFDATE OIL EXPANSION, THEN ALSO BARREL WILL BURST DUE TO COMPRESSION OF THE CLEARANCE AIR
HENCE ATLEAST 2.5% CLEARANCE IS LEFT. NORMALLY 8-10 LITERS AIR CLEARANCE IS AVAILABLE IN 210 LITER OIL BARREL
WHY PROPER STORAGE AND HANDLING ?
AIR IS TRAPPED NO BREATHING ACTION NO MOISTURE INGRESS
WHY PROPER STORAGE AND HANDLING ?
TO PRESERVE INTEGRITY OF PRODUCT HEAT OXIDATION COLD GELLING WATER AND DUST CONTAMINATION
WEATHERING
OBLITERATE LABELS, BATCH MARKS
AVOID INTERMIXING
PERSONAL SAFETY BY PROPER HANDLING
ELIMINATE WASTE LESS DISPOSAL, NO POLLUTION
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OUTSIDE STORAGE
KEEP BUNGS TIGHT BUNGSI IN 3 OCLOC K - 9 OCLOCK COVER WITH A TARPAULIN
RECOMMENDATIONS FOR WAREHOUSE
SPACIOUS WORKPLACE WITH PUMPS, DISPENSING EQUIPMENT, ETC. GOOD VENTILATION AND LIGHTING DUST FREE FIRE PROTECTION FOLLOW FIFO
ADVANTAGES ORIGINAL PLANT CONDITION OIL: ENSURES RIGH LUBRICATION LESS MACHINERY DOWN TIME ELIMINATION OF WASTE MONITARY SAVINGS DISPOSAL PROBLEM ELIMINATED NO ENVIRONMENT POLLUTION ADVANTAGES SAFETY IS ENSURED GOOD HOUSEKEEPING Performance Enhancing additives Anti oxidants Anti Wear and EP Agents Corrosion inhibitors Foam inhibitors Detergency Dispersancy Viscosity index improvers Pour Point Depressants Friction Modifiers
Physico Chemical Properties of Lubricating Oil
VISCOSITY VISCOSITY INDEX DENSITY AND GRAVITY COLOUR FLASH POINTS NEUTRALISATION NUMBER POUR POINT FOAMING TENDANCY Classification of Lubricants Based on viscosity Example: SAE15w40, ISOVG 68 etc Based on application Automotive oil (engine oil, Gear oil, coolants etc) Industrial Oil: Turbine Oil, Gear oil, Hydraulic oil Based on Performance Example: API SF, CJ etc ADVANTAGES OF GREASES
CAN BE USED IN NON ACCESIBLE AREAS CAN BE USED IN OPEN GEARS ACTS AS A SEALANT/ KEEP DUST/DIRT OUT SOLID ADDITIVES CAN BE SUSPENDED STAYS IN PLACE FOR LONG TIME OR PACKED FOR LIFE APPLICATIONS GREASE IS PREFERRED Thank You