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WELCOME TO THE WORLD OF LUBRICANTS
                           THIS SESSION IS
                            PURPOSEFUL
                            STRATEGIC (kausal)
                            ALL ABOUT SAVING MONEY
                            INCREASING MACHINE
                             RELIBILITY
PRES BY –   P. C. MISHRA    ABOUT SERIOUS BUSINESS OF
                             ORGANIZING
                            PLAN TO LEARN FROM OUR
                             MISTAKES
                            BENCHMARK TO OTHERS
                             SUCCESS
WE ALL ARE COMMITTED TO OUR
GOAL
BASICS-
FRICTION- FORCE THAT RESISTS RELATIVE MOTION BETWEEN TWO SURFACES IN CONTACT



                                        DRY – BETWEEN TWO SOLIDS
                                        LUBRICATED- BETWEEN TWO
                                        SOLIDS SEPERATED BY LAYER OF
                                        GAS OR LIQUID
                                        FLUID- BETWEEN LAYERS WITHIN
                                        THE FLUID RELATIVE TO EACH
                                        OTHER
                                        SKIN-BETWEEN SOLID BODY
                                        THROUGH A FLUID
                                        INTERNAL-BETWEEN ELEMENTS
                                        MAKING UP A SOLID MATERIAL
                                        WHILE IT GOES UNDER
                                        DEFORMATION
STATIC- BETWEEN TWO SOLID OBJECTS NOT MOVING TO EACH OTHER, THIS
PREVENTS OBJECT FROM SLIDING. LIKE CAR TYRE AS IT ROLLS ON GROUND
MAX. STATIC FRIC= COFECIENT OF STATIC FRICTION X NORMAL FORCE ( VARIES FROM
0 TO MAX )
KINETIC- BETWEEN TWO OBJECTS ARE MOVING . COFFECIENT OF KINEMETIC
FRICTION IS LESS THAN STATIC COFFECIENT OF FRICTION
Lubrication
SLIDING
ROLLING                 FRICTION
BOUNDARY                 LUBRICANT




          SLIDING
        SOLID          SEMISOLID     FLUID
                                      LIQUID   BOUNDRY GASEIOUS


SUBSTANCE CAPABLE OF REDUCING FRICTION BY MAKING SMOOTH OR
SLIPPERY
SOLID
• ICE, TALC, GRAPHITE
• MOLYBDENUM DISULPHIDE, POLY TETRA FLUOR
  ETHYLENE(PTFE)/ TEFLON,


LIQUID/ SEMISOLID
• CREAM , GEL, GHEE, GREASE , PETRLEUM JELLY
• WATER, VEGATIBLE OIL, OIL FROM ANIMAL SOURCES,
  MINERAL OIL(DRIVED FROM CRUDE OIL), SYNTHETIC OIL


GASEEOUS
• AIR, STEAM
• TECHNICAL GASES, LIQUID METAL VAPOURS
Function of lubricant
      REDUCE FRICTION
      REDUCE WEAR
      DISSIPATES HEAT
      PREVENTS RUST
      PREVENTS CORRISON/
       OXIDATION
      ACTS AS SEAL TO OUTSIDE
       CONTAMINANTS
      FLUSHES CONTAMINANTS
      REDUCE NOISE
HOW DOES IT DO IT ?
 SEPERATION OF MOVING PARTS
 HYDROSTATIC LUBRICATION:-
  HIGH ONLINE PREESURE DRIVES LUB IN THE SPACE CAUSES
SEPERATION BY HYDROLIC FORCE
 HYDRODYNAMIC LUBRICATION:-
  IN THIS MODE A “A FULL FLUID FILM” SEPERATES THE
METALIC CONTACT. MECHANICAL FRICTION IS SUBSTITUTED BY
FLUID FRICTION


                                               R how
GREASE = LUB.OIL(85 TO 95%) + THICKNING
AGENT+PERFORMANCE ENHANCING ADDITIVES
HOW IT WORKS ?
AS MOVING PARTS COME IN CONTACT WITH GREASE LUB
OIL BLEEDS FROM THE GREASE TO PROVIDE EITHER
• FLUID FILM
• BOUDARY LUBRICATION
THE OIL PICKED UP BY MOVING PARTS LOOSE DUE TO
EVOPARATION OR LEAKAGE SO THE GREASE MUST
CONTINIOUSLY BLEED TO PROVIDE SUFFICIENT
LUBRICATION.
GREASE CONSISTENCY:-
IT IS MEASURE OF ITS RESISTENCE TO DEFORM BY APPLIED FORCE
IT IS IN TRMS OF DEPTH IN TENTHS OF A mm THAT A STNDARD CONE WILL SINK
UNDER PRESCRIBED CONDITION REFERRED AS PENETRATION NO.
THE NATIONAL GREASE LUBRICATING INSTITUTE(NGLI)
HAS GRADED IT FROM


000 (SOFT) TO 6 (HARD)

 GREASE SHOULD BE SOFT ENOUGH TO ALLOW EASY
 APPLICATION, PROVIDE ACCEPTABLE LUBRICATION & NOT
 SO SOFT THAT IT MAY LEAK. THE PRESENCE OF ANY
 PARTICLES WHOSE SIZE IS LARGER THEN THE FILM
 THICKNESS CAN BE DETERMINATIVE TO THE SMOOTH
 RUNNING AND SERVICE LIFE OF THE BEARINGS.
Used Grease having contamination
The Graph represents vibration peaks in Contaminated Grease




                                        Not contaminated grease
HANDLING GREASE & PACKING IT IN BEARING
  ENSURE GREASE DRUM IS ALWAYS COVERD.
 LID SHOULD BE OPENED ONLY IN COVERED PREMISES & JUST ENOUGH TO REMOVE
GREASE. THEREAFTER LID SHOULD BE PROPERLY CLOSED.

  DO NOT TOUCH THE GREASE , TO AVOID SWEAT CONTAMINATION.
  USE CLEAN & COVERED GREASE DISPENSING UNIT/CARRY
GREASE FULLY COVERED IN OIL PROOF PAPER.
   REMOVE USED GREASE FROM BEARING COMLETELY.
Lubrication
USE DIESEL/ KEROSENE (NOT PETROL OR
SOLVENT) FOR CLEANING THE BEARING.
 COMPRESSED AIR SHOULD NOT BE USED FOR
DRYING.
  ENSURE CORRECT AMOUNT OF GREASE ( 1/3
TO ½ OF AVAILABLE SPACE)
  OVER PACKING OF GREASE IN CORRECTLY
ALIGNED & LOADED EQUPMENT CAUSES FOR
HOT RUNNING OF BEARING,OILSEAPAGE FROM
BEARING CAKING OF GREASE & DAMAGE THE
BEARING.                      Real grease gun
LUBRICATIG OIL = LUB. OIL BASE STOCK +
PERFORMANECE ENHANCING ADDITIVES


LUB.BASE STOCK:

 PETROLIUM OIL
 SYNTHETIC OIL
 VEGATABLE OIL
Lubrication
CHARACTERSTICS OF LUB OIL

 VISCOSITY: IT IS MEASURE OF A FLUIDS INTERNAL FRICTION OR
RESISTANCE TO FLOW.

HIGH VISCOSITY FLUID HAS GREATER
 INTERNAL RESISTANCE
GREATER LOAD CAPACITY
MORE TEPERATURE RISE
CHARACTERSTATICS
Lubrication
Lubrication
DIFFERENET OILS SHOW VARYING
DEGREES OF CHANGE IN VISCOSITY WITH
TEMPURATURE. IT IS NECESSARY TO DESIGNATE THE RATE OF
CHANGE OF VISCOSITY VARIATION OF OIL .


  VISCOSITY INDEX: IT IS A NUMBER WHICH DESIGNATES
THE VARIATION OF VISCOSITY WITH RESPECT TO TEMPERATURE
TOTAL BASE NO: IT IS A MEASURE OF THE OIL’S ACID
FIGHTING ABLITY. IT IS QUOTED AS NUMBER .
THIS IS THE QUANTITY OF ACID , EXPRESSED IN TERMS OF THE
EQUIVALENT NUMBER OF mg OF POTASSIUM HYDROXIDE, THAT IS
REQUIRED TO NEUTRALIZE ALL THE BASIC CONSTITUENTS
PRESENT IN ONE gm OF OIL.

  TOTAL ACID NO: IT IS A MEASURE OF TENDENCY OF THE
OIL TO TURN ACIDIC IN SERVICE .
THIS IS THEWEIGHT IN MILIGRAMS OF POTASSIUM HYDROXIDE
REQUIRED TO NEUTRALIZE ONE GRAM OF OIL .

TAN IS USEFUL FOR MNITORING TURBINE OIL OR
HYDROLIC OIL where as TBN FOR ENGINE OIL.
Lubrication
WHY TO MONITOR?
CONTA MINATION –

 EXTERAL-
OIL CAN GET DIRT, DUST, WATER ,STEAM, METALLIC
PARTICLES FROM MACHINE etc FROM EXTERNAL
SOURCE

INTERNAL-
CONSUMPTION OF ADDITIVES
 CONSUMPTION OF CORROISION
INHIBITORS
 INGRESS OF AIR FORMING SCUM
 OXIDIZATION- IT CAUSES ACID
FORMATION ,SLUDGE FORMATION &
                BLACKENS THE OIL (
METALIC PARTICULATES ACT AS CATALYST FOR
SIDE BY SIDE REACTION)

CONSUMPUTION OF ANTI WEAR
AND TEAR ADDITIVES
DEGRADATION OF DISPERSING
ADDITVES:
SAMPLEING:
IT IS CRITICAL PHASE FOR
DETERMININING THE
HEALTHINESS OF LUBRCANT
AND THE EQUIPMENT OR
MACHINE

LUBRICATING OIL IS THE
LIFE BLOOD OF
MACHINE


 Real oil analysis
CLEAN THE AREA( SAMPLE POINT).
    DISCARD INITIAL VOLUME
    FILL MAXIMUM TO ¾ OF COTAINER
    CHOOSE A CONTAINER WHICH IS –
     NEW AND CLEAN
     INERT AND ODOUR LESS
     HAVE TIGHT ENCLOSURE
  SAMLING POINT – SHOULD REPRESENT THE SYSTEM OIL
IN CIRCULATION . IT SHOULD NEVER BE FROM THE DRAIN
PLUG OF THE EQUIPMENT.
WHEN A SAMPLE
SHOULD BE TAKEN ?
 WHEN THE MACHINE IS
IN SERVICE
 AFTER ADDING MAKE
UP OIL
 IMMEDIATELY AFTER
SHUT DOWN
TEST METHODS AT
                       CSTPS CHANDRAPUR




1 WATER
  ASTM(AMERICAN SOC.OF TESTING &MATERILS)
D-95
 USES DISTILLATION EXPRESSES IN VOLUME %
ASTM – D-1744-KARL FISCHER REAGENT METHOD:
 THIS METHOD IS ACCURATE FOR SMALL QUANTITIES OF WATER AND RESULTS ARE
 EXPRESSED IN PPM
                2. SEDIMENTS
                 OIL SAMPLE IS WASHED WITH SOLVENT IN A SPECIFIED APPRATUS
                ,SEDIMENT SO COLLECTED ARE WEIGHED IN %MASS

                3. TAN

                  ASTM –D974-AN INICATOR SOLUTION IS MIXED & KOH IS
                ADDED TILL COLOUR CHANGES

                  ASTM-D664- HERE ELECTRICAL CONDUCTIVITY IS MEASURED
                AS THE KOH IS ADDED. EXPRESSED IN
                Mg KOH/g


TAN should not be used as sole criterion for
deterioration of oil
4. KINEMATIC VISCOSITY:

ASTM D –445 :
TIME TAKEN FOR A GIVEN VOLUME OF OIL TO PASS THROUGH A SPECIFIED SIZE ORIFICE AT
GIVEN TEMPERATURE IS MEASURED AND IS CONVERTED TO KINEMATIC VISCOSITY IN
CENTISTOKES

  K. VISCOSITY INCREASES
  DUE TO PRESENCE OF OXIDATION
  DUE TO INGRESS OF INSOLUBLE PRODUCTS
  DUE TO CONTAMINATION WITH HIGHER VISCOSITY PRODUCTS
Oil analysis results affects the performance of machine.
Achieving accurate measurement requires great care in
sample handling at each step in the process, including
handling at the laboratory.

PRECISE AND
RELIABLE
CONDITION
MONITORING IS
NEEDED FOR
CORRECT
PREDICTIONS
USED LAB BOTTLES ARE REUSED FOR SAMPLING.
  SAMPLE IS GENERALLY COLLECTED FROM THE
DRAIN OF THE MACHINE.
  OIL REPLACEMENT IS BASED ON PHYSICAL
APPEARANCE OF OIL NOT ON ACTUAL ANALYSIS.
  THERE IS ABSENCE OF PROPER RECORD , PERIOD
, PROCEDURE AND PARTICULAR POINT .
  TEST RESULTS OBTAINED FROM OUR CHEMICAL
LAB GENERALLY DO NOT TALLY WITH THE IOCL.
THERE ARE HEVY LEKAGES IN OUR MACHINES AS
ONLY 3 TO 4% OF WASTE OIL CAN BE GENERATED.
FOR ANY ORGANIZATION LUBRICANT
CONSUMPTION IS THE CRITERIA FOR COMARISION OF
ITS PROPER MANAGEMENT.
LUB.OIL CONSUMPTION RATIO= ANNUAL
PURCHASE IN LITRE/ TOTAL CHARGE IN INSTALLED
VOLUME IN LITRE
HERE IT COMES ABOUT 0.49 WHERE AS COMPARED
WITH WELL MANAGED POWER STATION IS ONLY
0.079.
Lubrication
Lubrication
OIL RESERVOIRS ( LOP TANK ) COVER IS NOT SEALED
GENERALLY LEFT OPEN SO DIRECT WATER AND DUST
MAY FIND WAY INSIDE.
ON LNE FILTERS USED ARE WIRE MESH TYPE AND
ALLOW PARTICLES OF EVEN 60 MICRON.
OIL DRUMS ARE HANDLED MANNUALY.
NO PROPER TOOLS AVAILABLE FOR PROPER
HANDLING.
THERE IS WRONG BELIEF THAT ‘’ HIGHER LUBRICANT
LEVEL SAFER IS THE MACHINE “
EXCESS LEVEL CAUSES LEKAGE OF OIL SEALS , BEARING
FAILURE AND MAINTENANCE VS LEKAS CONTINUE IN
CLSED CYCLE.
Lubrication
Lubrication
THERE IS HIGH TENDENCY OF THROUGHING
AWAY THE CONTAMINATED /USED OIL IN OIL
DRAINS.
THERE IS TENDENCY OF HIDING THE EVENTS
OF OIL LEKAGE AND NO RECORD ARE
MAINTANED .
Lubrication
ENVIRONMENTAL FACTS
•USED OIL ON THE GROUND MAKES IT UNFERTILE
AND KILLS ALL THE VEGITATION THERE.
•IT CAN PERFORATE TO UNDERGROUD STREAM
AND POLLUTE THE WATER.
•ONE LITRE OF USED OIL POLLUTES ONE
MILLION LITRES OF WATER
•ONE LITRE OF CAN FORM 400 SQUARE METERS
SLICK WHICH CAN KILL ALL THE MARINE LIFE
BENEATH THAT AREA.
•BURNING FIVE LITRES OF OIL POLLUTES SAME
AMOUNT OF AIR AS A MAN BREATHS IN THREE
YEARS.
Lubrication
Lubrication
Lubrication
What can be done?
 WE SHOULD EDUCATE AT ALL THE LEVELS
  SAMPLING POINTS,INTERVAL, PROCEDURE FOR EACH EQIPMENT IS TO BE
CLEARLY MENTIONED
 THE DATA BASE IS TO BE MAINTAINED
 RELIBLE LABORATORY HAS TO BE IDENTIFIED
 PERIODIC OIL REPLACEMENT DATA HAS TO BE BASED ON OIL ANALYSIS


 ON LINE FILTER UNITS OF 4 MICRON MAY BE USED
OFF LINE FILTER SUCH AS SHOWN HERE MAY BE
USED
OIL RESERVOIR SHOULD BE COMLETELY SEALED WITH INSTALLATION OF SUITABLE
CAPACITY
COALSCENCE
             SAMPLING VALVE FIXING
FILTER
MODERNISATION OF LUB ROOM, HANDLING TOOLS
Lubrication
Lubrication
Lubrication
6*600MW = 3600 MW TUTUKA POWER STATION HAVING LUB
   OIL CONSUMPTION RATIO= 0.074
SKILLS AND ATTITUDES CAN GO ALONG WAY TOWARD ENSURING
THAT THE BEST LUB PRACICES ARE IMPLEMENTED & EFFECTIVE
Lubrication
Lubrication
Lubrication
Lubrication
Lubrication
RE REFINIING OF OIL
Lubrication
Lubrication
Lubrication
Lubrication
Lubrication

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Lubrication

  • 1. WELCOME TO THE WORLD OF LUBRICANTS THIS SESSION IS  PURPOSEFUL  STRATEGIC (kausal)  ALL ABOUT SAVING MONEY  INCREASING MACHINE RELIBILITY PRES BY – P. C. MISHRA  ABOUT SERIOUS BUSINESS OF ORGANIZING  PLAN TO LEARN FROM OUR MISTAKES  BENCHMARK TO OTHERS SUCCESS
  • 2. WE ALL ARE COMMITTED TO OUR GOAL
  • 3. BASICS- FRICTION- FORCE THAT RESISTS RELATIVE MOTION BETWEEN TWO SURFACES IN CONTACT DRY – BETWEEN TWO SOLIDS LUBRICATED- BETWEEN TWO SOLIDS SEPERATED BY LAYER OF GAS OR LIQUID FLUID- BETWEEN LAYERS WITHIN THE FLUID RELATIVE TO EACH OTHER SKIN-BETWEEN SOLID BODY THROUGH A FLUID INTERNAL-BETWEEN ELEMENTS MAKING UP A SOLID MATERIAL WHILE IT GOES UNDER DEFORMATION
  • 4. STATIC- BETWEEN TWO SOLID OBJECTS NOT MOVING TO EACH OTHER, THIS PREVENTS OBJECT FROM SLIDING. LIKE CAR TYRE AS IT ROLLS ON GROUND MAX. STATIC FRIC= COFECIENT OF STATIC FRICTION X NORMAL FORCE ( VARIES FROM 0 TO MAX ) KINETIC- BETWEEN TWO OBJECTS ARE MOVING . COFFECIENT OF KINEMETIC FRICTION IS LESS THAN STATIC COFFECIENT OF FRICTION
  • 6. SLIDING ROLLING FRICTION BOUNDARY LUBRICANT SLIDING SOLID SEMISOLID FLUID LIQUID BOUNDRY GASEIOUS SUBSTANCE CAPABLE OF REDUCING FRICTION BY MAKING SMOOTH OR SLIPPERY
  • 7. SOLID • ICE, TALC, GRAPHITE • MOLYBDENUM DISULPHIDE, POLY TETRA FLUOR ETHYLENE(PTFE)/ TEFLON, LIQUID/ SEMISOLID • CREAM , GEL, GHEE, GREASE , PETRLEUM JELLY • WATER, VEGATIBLE OIL, OIL FROM ANIMAL SOURCES, MINERAL OIL(DRIVED FROM CRUDE OIL), SYNTHETIC OIL GASEEOUS • AIR, STEAM • TECHNICAL GASES, LIQUID METAL VAPOURS
  • 8. Function of lubricant  REDUCE FRICTION  REDUCE WEAR  DISSIPATES HEAT  PREVENTS RUST  PREVENTS CORRISON/ OXIDATION  ACTS AS SEAL TO OUTSIDE CONTAMINANTS  FLUSHES CONTAMINANTS  REDUCE NOISE
  • 9. HOW DOES IT DO IT ? SEPERATION OF MOVING PARTS HYDROSTATIC LUBRICATION:- HIGH ONLINE PREESURE DRIVES LUB IN THE SPACE CAUSES SEPERATION BY HYDROLIC FORCE HYDRODYNAMIC LUBRICATION:- IN THIS MODE A “A FULL FLUID FILM” SEPERATES THE METALIC CONTACT. MECHANICAL FRICTION IS SUBSTITUTED BY FLUID FRICTION R how
  • 10. GREASE = LUB.OIL(85 TO 95%) + THICKNING AGENT+PERFORMANCE ENHANCING ADDITIVES HOW IT WORKS ? AS MOVING PARTS COME IN CONTACT WITH GREASE LUB OIL BLEEDS FROM THE GREASE TO PROVIDE EITHER • FLUID FILM • BOUDARY LUBRICATION THE OIL PICKED UP BY MOVING PARTS LOOSE DUE TO EVOPARATION OR LEAKAGE SO THE GREASE MUST CONTINIOUSLY BLEED TO PROVIDE SUFFICIENT LUBRICATION.
  • 11. GREASE CONSISTENCY:- IT IS MEASURE OF ITS RESISTENCE TO DEFORM BY APPLIED FORCE IT IS IN TRMS OF DEPTH IN TENTHS OF A mm THAT A STNDARD CONE WILL SINK UNDER PRESCRIBED CONDITION REFERRED AS PENETRATION NO. THE NATIONAL GREASE LUBRICATING INSTITUTE(NGLI) HAS GRADED IT FROM 000 (SOFT) TO 6 (HARD) GREASE SHOULD BE SOFT ENOUGH TO ALLOW EASY APPLICATION, PROVIDE ACCEPTABLE LUBRICATION & NOT SO SOFT THAT IT MAY LEAK. THE PRESENCE OF ANY PARTICLES WHOSE SIZE IS LARGER THEN THE FILM THICKNESS CAN BE DETERMINATIVE TO THE SMOOTH RUNNING AND SERVICE LIFE OF THE BEARINGS.
  • 12. Used Grease having contamination
  • 13. The Graph represents vibration peaks in Contaminated Grease Not contaminated grease
  • 14. HANDLING GREASE & PACKING IT IN BEARING ENSURE GREASE DRUM IS ALWAYS COVERD. LID SHOULD BE OPENED ONLY IN COVERED PREMISES & JUST ENOUGH TO REMOVE GREASE. THEREAFTER LID SHOULD BE PROPERLY CLOSED. DO NOT TOUCH THE GREASE , TO AVOID SWEAT CONTAMINATION. USE CLEAN & COVERED GREASE DISPENSING UNIT/CARRY GREASE FULLY COVERED IN OIL PROOF PAPER. REMOVE USED GREASE FROM BEARING COMLETELY.
  • 16. USE DIESEL/ KEROSENE (NOT PETROL OR SOLVENT) FOR CLEANING THE BEARING. COMPRESSED AIR SHOULD NOT BE USED FOR DRYING. ENSURE CORRECT AMOUNT OF GREASE ( 1/3 TO ½ OF AVAILABLE SPACE) OVER PACKING OF GREASE IN CORRECTLY ALIGNED & LOADED EQUPMENT CAUSES FOR HOT RUNNING OF BEARING,OILSEAPAGE FROM BEARING CAKING OF GREASE & DAMAGE THE BEARING. Real grease gun
  • 17. LUBRICATIG OIL = LUB. OIL BASE STOCK + PERFORMANECE ENHANCING ADDITIVES LUB.BASE STOCK: PETROLIUM OIL SYNTHETIC OIL VEGATABLE OIL
  • 19. CHARACTERSTICS OF LUB OIL VISCOSITY: IT IS MEASURE OF A FLUIDS INTERNAL FRICTION OR RESISTANCE TO FLOW. HIGH VISCOSITY FLUID HAS GREATER  INTERNAL RESISTANCE GREATER LOAD CAPACITY MORE TEPERATURE RISE CHARACTERSTATICS
  • 22. DIFFERENET OILS SHOW VARYING DEGREES OF CHANGE IN VISCOSITY WITH TEMPURATURE. IT IS NECESSARY TO DESIGNATE THE RATE OF CHANGE OF VISCOSITY VARIATION OF OIL . VISCOSITY INDEX: IT IS A NUMBER WHICH DESIGNATES THE VARIATION OF VISCOSITY WITH RESPECT TO TEMPERATURE
  • 23. TOTAL BASE NO: IT IS A MEASURE OF THE OIL’S ACID FIGHTING ABLITY. IT IS QUOTED AS NUMBER . THIS IS THE QUANTITY OF ACID , EXPRESSED IN TERMS OF THE EQUIVALENT NUMBER OF mg OF POTASSIUM HYDROXIDE, THAT IS REQUIRED TO NEUTRALIZE ALL THE BASIC CONSTITUENTS PRESENT IN ONE gm OF OIL. TOTAL ACID NO: IT IS A MEASURE OF TENDENCY OF THE OIL TO TURN ACIDIC IN SERVICE . THIS IS THEWEIGHT IN MILIGRAMS OF POTASSIUM HYDROXIDE REQUIRED TO NEUTRALIZE ONE GRAM OF OIL . TAN IS USEFUL FOR MNITORING TURBINE OIL OR HYDROLIC OIL where as TBN FOR ENGINE OIL.
  • 26. CONTA MINATION –  EXTERAL- OIL CAN GET DIRT, DUST, WATER ,STEAM, METALLIC PARTICLES FROM MACHINE etc FROM EXTERNAL SOURCE INTERNAL-
  • 27. CONSUMPTION OF ADDITIVES  CONSUMPTION OF CORROISION INHIBITORS  INGRESS OF AIR FORMING SCUM  OXIDIZATION- IT CAUSES ACID FORMATION ,SLUDGE FORMATION & BLACKENS THE OIL ( METALIC PARTICULATES ACT AS CATALYST FOR SIDE BY SIDE REACTION) CONSUMPUTION OF ANTI WEAR AND TEAR ADDITIVES DEGRADATION OF DISPERSING ADDITVES:
  • 28. SAMPLEING: IT IS CRITICAL PHASE FOR DETERMININING THE HEALTHINESS OF LUBRCANT AND THE EQUIPMENT OR MACHINE LUBRICATING OIL IS THE LIFE BLOOD OF MACHINE Real oil analysis
  • 29. CLEAN THE AREA( SAMPLE POINT). DISCARD INITIAL VOLUME FILL MAXIMUM TO ¾ OF COTAINER CHOOSE A CONTAINER WHICH IS –  NEW AND CLEAN  INERT AND ODOUR LESS  HAVE TIGHT ENCLOSURE SAMLING POINT – SHOULD REPRESENT THE SYSTEM OIL IN CIRCULATION . IT SHOULD NEVER BE FROM THE DRAIN PLUG OF THE EQUIPMENT.
  • 30. WHEN A SAMPLE SHOULD BE TAKEN ?  WHEN THE MACHINE IS IN SERVICE  AFTER ADDING MAKE UP OIL  IMMEDIATELY AFTER SHUT DOWN
  • 31. TEST METHODS AT CSTPS CHANDRAPUR 1 WATER ASTM(AMERICAN SOC.OF TESTING &MATERILS) D-95 USES DISTILLATION EXPRESSES IN VOLUME %
  • 32. ASTM – D-1744-KARL FISCHER REAGENT METHOD: THIS METHOD IS ACCURATE FOR SMALL QUANTITIES OF WATER AND RESULTS ARE EXPRESSED IN PPM 2. SEDIMENTS OIL SAMPLE IS WASHED WITH SOLVENT IN A SPECIFIED APPRATUS ,SEDIMENT SO COLLECTED ARE WEIGHED IN %MASS 3. TAN ASTM –D974-AN INICATOR SOLUTION IS MIXED & KOH IS ADDED TILL COLOUR CHANGES ASTM-D664- HERE ELECTRICAL CONDUCTIVITY IS MEASURED AS THE KOH IS ADDED. EXPRESSED IN Mg KOH/g TAN should not be used as sole criterion for deterioration of oil
  • 33. 4. KINEMATIC VISCOSITY: ASTM D –445 : TIME TAKEN FOR A GIVEN VOLUME OF OIL TO PASS THROUGH A SPECIFIED SIZE ORIFICE AT GIVEN TEMPERATURE IS MEASURED AND IS CONVERTED TO KINEMATIC VISCOSITY IN CENTISTOKES K. VISCOSITY INCREASES DUE TO PRESENCE OF OXIDATION DUE TO INGRESS OF INSOLUBLE PRODUCTS DUE TO CONTAMINATION WITH HIGHER VISCOSITY PRODUCTS
  • 34. Oil analysis results affects the performance of machine. Achieving accurate measurement requires great care in sample handling at each step in the process, including handling at the laboratory. PRECISE AND RELIABLE CONDITION MONITORING IS NEEDED FOR CORRECT PREDICTIONS
  • 35. USED LAB BOTTLES ARE REUSED FOR SAMPLING. SAMPLE IS GENERALLY COLLECTED FROM THE DRAIN OF THE MACHINE. OIL REPLACEMENT IS BASED ON PHYSICAL APPEARANCE OF OIL NOT ON ACTUAL ANALYSIS. THERE IS ABSENCE OF PROPER RECORD , PERIOD , PROCEDURE AND PARTICULAR POINT . TEST RESULTS OBTAINED FROM OUR CHEMICAL LAB GENERALLY DO NOT TALLY WITH THE IOCL.
  • 36. THERE ARE HEVY LEKAGES IN OUR MACHINES AS ONLY 3 TO 4% OF WASTE OIL CAN BE GENERATED. FOR ANY ORGANIZATION LUBRICANT CONSUMPTION IS THE CRITERIA FOR COMARISION OF ITS PROPER MANAGEMENT. LUB.OIL CONSUMPTION RATIO= ANNUAL PURCHASE IN LITRE/ TOTAL CHARGE IN INSTALLED VOLUME IN LITRE HERE IT COMES ABOUT 0.49 WHERE AS COMPARED WITH WELL MANAGED POWER STATION IS ONLY 0.079.
  • 39. OIL RESERVOIRS ( LOP TANK ) COVER IS NOT SEALED GENERALLY LEFT OPEN SO DIRECT WATER AND DUST MAY FIND WAY INSIDE. ON LNE FILTERS USED ARE WIRE MESH TYPE AND ALLOW PARTICLES OF EVEN 60 MICRON. OIL DRUMS ARE HANDLED MANNUALY. NO PROPER TOOLS AVAILABLE FOR PROPER HANDLING. THERE IS WRONG BELIEF THAT ‘’ HIGHER LUBRICANT LEVEL SAFER IS THE MACHINE “ EXCESS LEVEL CAUSES LEKAGE OF OIL SEALS , BEARING FAILURE AND MAINTENANCE VS LEKAS CONTINUE IN CLSED CYCLE.
  • 42. THERE IS HIGH TENDENCY OF THROUGHING AWAY THE CONTAMINATED /USED OIL IN OIL DRAINS. THERE IS TENDENCY OF HIDING THE EVENTS OF OIL LEKAGE AND NO RECORD ARE MAINTANED .
  • 44. ENVIRONMENTAL FACTS •USED OIL ON THE GROUND MAKES IT UNFERTILE AND KILLS ALL THE VEGITATION THERE. •IT CAN PERFORATE TO UNDERGROUD STREAM AND POLLUTE THE WATER. •ONE LITRE OF USED OIL POLLUTES ONE MILLION LITRES OF WATER •ONE LITRE OF CAN FORM 400 SQUARE METERS SLICK WHICH CAN KILL ALL THE MARINE LIFE BENEATH THAT AREA. •BURNING FIVE LITRES OF OIL POLLUTES SAME AMOUNT OF AIR AS A MAN BREATHS IN THREE YEARS.
  • 48. What can be done? WE SHOULD EDUCATE AT ALL THE LEVELS SAMPLING POINTS,INTERVAL, PROCEDURE FOR EACH EQIPMENT IS TO BE CLEARLY MENTIONED THE DATA BASE IS TO BE MAINTAINED RELIBLE LABORATORY HAS TO BE IDENTIFIED PERIODIC OIL REPLACEMENT DATA HAS TO BE BASED ON OIL ANALYSIS  ON LINE FILTER UNITS OF 4 MICRON MAY BE USED OFF LINE FILTER SUCH AS SHOWN HERE MAY BE USED
  • 49. OIL RESERVOIR SHOULD BE COMLETELY SEALED WITH INSTALLATION OF SUITABLE CAPACITY
  • 50. COALSCENCE SAMPLING VALVE FIXING FILTER
  • 51. MODERNISATION OF LUB ROOM, HANDLING TOOLS
  • 55. 6*600MW = 3600 MW TUTUKA POWER STATION HAVING LUB OIL CONSUMPTION RATIO= 0.074 SKILLS AND ATTITUDES CAN GO ALONG WAY TOWARD ENSURING THAT THE BEST LUB PRACICES ARE IMPLEMENTED & EFFECTIVE