TOPIC 2 : LUBRICATION

CLO 1 : Students should be able to

classify clearly the basic concept of
mechanical components (C4)

This topics explains the lubrication

principle, fluid management,
lubrication protection, lubricating
devices and system, application of
lubricating program plan and its
implementation.

2.1 Understand lubrication

principle

FIGURE 2.1 Oil molecules

cling to metal surfaces but
easily slide against each other.

Lubrication
between two
moving surfaces
results from an oil
film that separates
the surfaces and
supports the load.

2.1 Understand lubrication

principle
FIGURE 2-2 Wedgeshaped oil film
developed below a
moving block.

If oil were put on a flat surface and a heavy block were pushed across the
surface, the block would slide more easily than if it were pushed across a dry
surface.
The reason for this is that a wedge-shaped oil film is built up between the
moving block and the surface.
This wedging action is called hydrodynamic lubrication and the pressure
depends on the force applied to how fast the speed between the objects and
the thickness of the oil.
Thickness of oil is called the viscosity and is defined as the ability of the oil
to resist flow.

2.1 Understand lubrication

principle
hadis

FIGURE 2-3 Wedgeshaped oil film curved

around a bearing
journal.

Hydrodynamic
lubrication occurs
when a wedgeshaped film of
lubricating oil
develops between
two surfaces that
have relative
motion between
them.

2.1.1 Lubrication system

FIGURE 14-4 Typical
V-8 engine lubrication
system. Oil is stored in
the oil pan (sump),
drawn into the oil
pump, and moves
through the oil filter
and on through the oil
passages (oil galleries).

OIL SUMP

OIL PUMP

OIL FILTER

2.1.1 benefit implement

lubrication system.

Improved maintenance planning

Increased equipment reliability
Increased fluid life ( in some instances)
Fewer unscheduled shutdowns
Reduce catastrophic failures
Overall improvement in product quality
Improved inventory control
Energy savings

2.1.2 Several term and principle to

understand and select proper lubrication.
Several term and principle
1.
.

Viscosity
Viscosity is the property of fluid, semifluid or
semifluid substances that cause it to resist flow.
Temperature increase, a lubricants become
thinner or less viscous.
The ideal lubricant is the one with the lowest
viscosity that maintain an oil film between and
the operating temperature of the machine.
Lower temperature : lighter loads and high speeds
= lower viscosity lubricant

2.1.2 Several term and principle to

understand and select proper
lubrication.
2.
.

3.
.

Viscosity Index
The viscosity Index is a measure of the rate
at which the viscosity of a lubricant changes
as the temperature changes.
Flash point and fire point
Flash point a lubricant is the minimum
temperature which not enough to burn only
the vapor or flames.
Fire point - a lubricant is the minimum
temperature at which the lubricant will burn
continously.

2.1.2 Several term and principle to

understand and select proper
lubrication.
4.
.

5.
.

6.
.

Pour point
Lubricant becomes so thick that is no longer
flows.
Oxidation Inhibitors
Additives that slow the rate of the lubricants
natural tendency to oxide.
Rust and Corrosion Inhibitors
Additives that improve a lubricants ability to
stick to metal surfaces (as a coating protect
the metal surface from oxidation and rust).

2.1.2 Several term and principle to

understand and select proper lubrication.
7. Detergent and Dispersant Additives
Detergent Additives to help keep metal
surface clean by preventing deposit formation.
Dispersant Additives assists detergent by
keeping these contaminants suspended in the
oil until the next change.
8. Extreme pressure (EP) Additives
. Commonly found in almost all gear lubricants.
9. Antifoam Additives
. Break up the air bubbles, preventing the oil
from foaming.

2.1.2 Several term and principle to

understand and select proper lubrication.

Select Proper Lubrication

The key requirement for selecting the
proper lubricant is the base oil viscosity. In
order to select the appropriate viscosity,
will need to gather information including:
1. operating speed (variable or fixed)
2. specific type of friction (e.g., sliding or
rolling)
3. load and the environmental conditions
4. industry standards.

2.2 Understand fluid

management.

1.
.

hadis

2.2.1 Apply essential components in a

fluid management program.
Selection and purchase of lubrication
Fluid management begins with
purchasing the correct lubricants
Purchasing should carefully consider the
supplier, products and services.
A supplier should be chosen on the basis
of quality of lubricants and services
offered rather than on price alone.

2.2.1 Apply FOUR essential components in

a fluid management program.
2.
.

Lubricant Monitoring Programs

Monitoring program used to determine
the condition of the lubricant and to
detect early sign of equipment failure.
Oil analyses used to extend lubricant life
and establish oil change out.
The properties that should be monitored
are dependent on the application and
environment.

2.2.1 Apply FOUR essential

components in a fluid
management program.
Lubricant Maintenance
. Closely associated with the monitoring program.
. Used oil test results exceed the condemning
limits and corrective action needs to be taken.
4. Disposal
. Last step in fluid management when the
monitoring results indicate that the oil is
severely degraded of additives that cannot be
restored.
. The most appropriate method of disposal
depend on local, state and federal regulations.
3.

2.3 Lubrication Protection.

2.3.1 Organize lubrication protection in term of
hadis
Location and personal
. A clean, well lighted room or building is advisable
(e.g. provision for heating in cold weather).
. One or two individuals are assigned the
responsibility for inventory and dispensing of
lubricants and should be trained on the
importance of protecting lubricant contamination
and commingling with other lubricants.
. Drum should be labeled clearly to ensure
application/use of the correct lubricant.

1.

2.3.1 Organize lubrication

protection in term of:
2.
.

.
.

Facilities for handling container,

Floor level (Storeroom) should be the
same as the delivery truck floor.
The facilities rolling the drum into the
storeroom .
Rack can be arranged along one or more
walls.
Drum can be raise by forklift truck.
Each drum should have its own spigot to
avoid commingling of products.

2.3.1 Organize lubrication

protection in term of:
3.
.
.

Lighting
Relates to good records.
Complete records as to lubricant
consumption per machines per area.
Requires careful inventory (monthly) and
recording of amounts of oil and grease
issued.
If storeroom is painted gloss white, if
light outlets are well located to obviate
glare and comfortable record desk is
installed.

2.3.1 Organize lubrication

protection in term of:
4. Bulk storage

Benefits :
i.
Improve efficiency
ii.
Reduced handling costs
iii.
reduced risk of contamination and simplified inventory.
.
Upon arrival of bulk shipments:
i.
Each product should be inspected visually for clarity and
cleanliness
ii.
Checked the viscosity with handheld viscometer.
iii.
Each tank should be gauged to ensure sufficient room.
iv.
Tank links and valves should be checked to ensure that the product
is being unloaded into the correct tank.
v.
Sample should be obtained from the tank after unloading and
labeled with product:
a.
Name
b.
Invoice number
c.
Batch number
* Samples should be stored at least 6 months.

2.3.1 Organize lubrication

protection in term of:
5. Fire protection.
Storage area is remote
No smoking rules are observed
Visit from other plant personnel are prohibited
Oil drip is prevented or cleaned up promptly
Waste or wiping rags are stored in metal containers
and in minimum quantity
Sparking or arcing tools are used only under
conditions of good ventilation
Insurance regulation required installation of
suitable fire extinguishing equipment and a
sprinkler system.

2.4 Lubricating devices and

system.
2.4.1 Evaluate effectiveness lubricate

NO

TYPE OF
LUBRICANT

USED

ADVANTAGES

SITUATION

Hydraulic Oils
Transmit fluid
power
throughout
hydraulic system

Hydraulic
systems
pump

Minimize wear
An internal seal to
reduce friction
Heat tranfer
medium

Temperature:
-4.4C~100C
Pressure:
1000psi (69 bar)

Gear Oils

Spur,
helical,
bevel,
warm etc.

Rust & oxidation

inhibited

Operating under
light to moderate
load
Improves
lubricity & anti
frictional
properties
Greater stability,
longer life, wider
temperature
range
Slow speed,

Compounded gear
oils
Synthetics
Open gear
compounds

2.4 Lubricating devices and

system.
NO

TYPE OF
LUBRICANT

USED

STANDARD

SITUATION

Turbine Oils
Oil circulation
systems to lubricate
and cool turbine and
generator journal
bearings.

Pump
Hydraulic
governor
Geared
turbine
systems.
compressor

Topped off
rather than
displaced
High level of
oxidation
stability
Rust protection

Temperature:
538C
(1000F)

Compressor Oils

Reciprocatin
g (piston)
Rotary
sliding vane
Straight and
helical
screw.

Minimize
bearing & gear
wear
Remove heat
from
compression
area
To seal
compression
system

Are machines
that draw in
and deliver
gas at higher
than ambient
pressures and
temperatures.

2.4 Lubricating devices and

system.

2.4.2 Lubricating devices system based

on equipment or mechanical
components.

2.5 Apply lubricating program

plan and implement into
mechanical component.
a.
1.
2.
3.
4.
5.

The plant lubrication survey.

Inventory machinery
Machine characteristics
Point of lubrication
Method of lubrication
Frequency of lubrication

hadis

2.5 Apply lubricating program

plan and implement into
mechanical component.
b. Establishment of lubrication schedules
and improvements in selection and
application of lubrication.
1. Identification of equipment
2. Point of lubrication
3. Lubricants
4. Methods
5. Frequencies
6. Name of worker

2.5 Apply lubricating program

plan and implement into
mechanical component.
c. Lubrication analysis
1. Physical and chemical
2. Wear metals
3. Product contamination
4. recommendation

2.5.2 Identify activities required to implement

the lubrication management program

1.
2.
3.
4.
5.
6.
7.
8.

Lubrication surveys
Lubricant consolidation
Lubricant schedules
Lubricant handling and storage
Oil sampling and testing
Evaluation of new lubricants
Lubrication training
Lubrication methods
Quiz 1