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.

25. WHY TO MONITOR?

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

61. RE REFINIING OF OIL