Principles Of Industrial Maintenance PDF

Course materials provided for personal study only and subject to the disclaimer on the ECU website http://www.ecu.edu.au/supplemental/disclaimer Principles of Industrial Maintenance...

Course materials provided for personal study only and subject to the disclaimer on the ECU website http://www.ecu.edu.au/supplemental/disclaimer Principles of Industrial Maintenance Lecturer: Dr Ana Vafadar [email protected]  This lecture Coverage in this lecture will be largely derived from … McGrory, S. (2001). Lubrication. In R. K. Mobley (Ed.), Plant engineers handbook (pp. 915-960). New-York: The McGraw-Hill Companies, Inc (ISBN 0-7506-7328-1). Content from other sources will be indicated where applicable.  This lecture – the plan Thislecture material is largely based on … Lubrication (CHP 52) (McGrory, 2001) 52.1 Introduction 52.2 Lubrication – The Added Value 52.3 Why A Lubricant? 52.4 Physical Characteristics Of Oils And Greases 52.5 Additives 52.6 Lubricating-Oil Applications 52.7 General Machinery Oils 52.8 Engine Lubricants 52.9 Gear Lubricants 52.10 Hydraulic Fluids 52.16 Greases 52.24 Storage of Lubricants 52.27 Condition Monitoring 52.28 Health, Safety and the Environment  This lecture in a nutshell Thislecture will basically … Identify types of lubrication, major lubricant functions and some (measurable) lubricant properties Identify several lubricant additives and their function Highlight the main methods of applying lubricants Present an overview of lubricants and greases Introduce considerations for lubricant storage, safer application and monitoring its condition  Machine Lubrication Slide 5 Introduction: Lubricants and Lubrication Lubrication is an integral part of (routine) preventive maintenance The accuracy and durability of machine components, like bearings, depends not only on their ‘as produced’ state but on the quality of lubrication during their operational lifetime Source: https://www.indiamart.com/ Costs associated with effective lubrication processes are negligible compared to: gains in production capacity attained through reduced machine downtime money needed to replace worn-out machinery or for repeated (premature) replacement of precision machine components Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 6 Introduction: Lubricants and Lubrication Relative (sliding) motion between dry parts, pressed or assembled together, results in wear and joint damage. Effective lubrication reduces wear Section in surface 1 Section in surface 2 One type of wear, called adhesive wear, is strongly affected by lubrication: Adhesive wear arises from localised bonding across small surface features Asperities, resembling microscale-like peaks, rub against each other. Pressing together at the joint causes localised welding at points. Relative joint motion helps repeatedly break (adhering) peaks but then causes detrimental abrasion (another form of wear). If such welding occurs on a large scale it leads to joint seizure and cessation of motion. An example is seizing of engine components from lack of lubrication or overheating. Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 7 Introduction: Lubricants and Lubrication A lubricant can serve multiple functions which include: Removal of heat from components Attaining correct alignment and joint separation Providing corrosion resistance … and reducing friction To achieve its functions, a lubricant needs some qualities (properties) like: Having the viscosity needed to reduce friction Containing additives for meeting special functions Physically and chemically stable: wont’ break down … and being non-toxic Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 8 Types of Lubrication: The Two Extremes Consider the interface across a lubricated joint. If a section is taken across the joint (and magnified) surfaces will show numerous peaks and valleys. The degree of separation can indicate the type of lubrication: Types of Lubrication Boundary Lubrication Full Fluid-Film Lubrication  Surfaces are lubricated but lubricants  Surfaces are completely separated. Separation is achieved form a film (or layer) so thin that lubricant by a pressurized lubricant. Pressure can be obtained either viscosity is not a major influencing factor. through relative movement (of surfaces) or external pumps.  Lubricant type as well as contact surface  In the ‘hydrodynamic’ variant of this type of lubrication, quality (e.g., roughness) are influencing relative motion between surfaces helps raise this pressure and factors in this type of lubrication. forms a separating (fluid) wedge at the interface.  Chemical additives can be included to  In the ‘hydrostatic’ variant of this type of lubrication, a fluid improve the lubricant function. Some of is pumped to the interface to achieve surface separation. This these work by reacting with surfaces to does not rely on getting a specific speed of relative motion and produce thin, solid layers of lubricant. can be more effective at start-up periods or during low speeds.  Frictional losses arise at interfaces from  Frictional losses arise within the lubricant layer from it (the asperities rubbing against each other. fluid) internally. surface 1 Other types of lubrication separation can exit surface 1 surface 2 between these two extremes (types) surface 2 lubricant Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 9 Key Physical Properties of Oils and Greases To achieve its function, several properties can be considered in the selection of oils and greases. These properties include: Viscosity Viscosity index (VI) Pour point Flash point Drop point (of grease) Penetration (of grease) Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 10 KeyPhysical Properties of Oils and Greases: Viscosity Viscosity is probably the most significant property in any lubricating oil. When a lubricant is trapped at the interface between two moving surfaces, viscosity becomes a measure of the internal friction which the lubricant experiences (should it be allowed to flow across the retaining joint). In simpler terms, viscosity can be taken to give the thickness (stickiness) of a lubricant. Viscosity naturally changes with temperature. To report or specify a viscosity, the relevant temperature also needs to be given. Viscosity can be described in two ways (i.e., two measures can be used). The two ways are related to each other through density (which changes with temperature). The two measures used to describe viscosity are: Kinematic viscosity Dynamic (or absolute) viscosity Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 11 KeyPhysical Properties of Oils and Greases: Viscosity Kinematic viscosity (uses the symbol, ). Units for kinematic viscosity are: (metre2/second) also expressed as (m2/s) (centimetre2/second) also expressed as (cm2/s) A single cm2/s is called a stoke and one hundredth of a stoke (i.e., stoke/100) is a centistoke (abbreviated cSt). Dynamic or Absolute viscosity (uses the symbol, ). Units for dynamic viscosity are: Kilogram/(metre.second) also expressed as (kg/m.s) (Newton.second)/metre2 also expressed as (N.s/m2) (N.s/m2) is equivalent to (Pascal.second) and expressed as (Pa.s) A single (Pa.s) is called poise and one hundredth of a poise is called a centipoise (i.e., Pa.s/100). A centipoise is a special value since it gives the viscosity of water at 20C. If a viscosity value is given but it does not explicitly say whether it is kinematic or dynamic, you can identify the type of viscosity being inferred through the units. Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 12 Key Physical Properties of Oils and Greases: Viscosity Kinematic and dynamic viscosity are related to each other Kinematic Dynamic through density ().   Density is basically the mass of the liquid divided by its volume  (density of water at 20C is about 1000kg/m3). Dashed lines mean the Notes shape of the trends may vary from that shown. Temperature affects the viscosity of gases and liquids viscosity differently. This is related to how viscosity develops in these two different fluids. Liquid Viscosity in gases develops from the occurrence of molecular collisions. These collisions generally increase with temperature and hence, so does gas viscosity. Gas Viscosity in liquids develops from the cohesive forces between molecules. These generally decrease with temperature and hence viscosity follows the same trend in liquids. temperature Both the dynamic and kinematic viscosity are affected by temperature. Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 13 Key Physical Properties of Oils and Greases: Viscosity The kinematic viscosity can be used in some classifications/grades. The International Standards Organisation (ISO) uses kinematic viscosity in identifying viscosity grades. Refer to Table 52.1 for a full listing. The following is a partial extract. Extract from Table 52.1 (ISO viscosity grade chart) Kinematic viscosity limits cST at 40C (104F) ISO viscosity grade Mid-point kinematic viscosity min max 2 2.2 1.98 2.42 3 3.2 2.88 3.52 … … … … … … … … 1000 1000 900 1100 1500 1500 1350 1650 Adapted / Modified from Table 52.1. McGrory, S. (2001). Lubrication. In R. K. Mobley (Ed.), Plant engineers handbook (pp. 915-960). New-York: The McGraw- Hill Companies, Inc Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 14 Key Physical Properties of Oils and Greases: Viscosity Index The Viscosity Index (VI) is used to help characterize the rate at which viscosity changes with temperature. Oil viscosity falls with temperature. VI helps identify how fast an oil looses its viscosity as temperature rises. A high VI means a smaller change in viscosity for a given variation in temperature. In machinery where large variations in temperature occur, the VI is a useful parameter to consider when selecting lubricants. viscosity Slower rate of change with Oil #1 temperature (high VI). Note the relatively smooth change with temperature. Oil #2 Faster rate of change with temperature (low VI). Notice how acute the change is. temperature Principles of Industrial Maintenance Edith Cowan University 2018 Quiz Slide 15  Which of the following lubricant is preferred to be used for lubrication? viscosity o Oil #1. o Oil #2. Oil #1 Oil #2 temperature Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 16 KeyPhysical Properties of Oils and Greases: Pour Point, Flash Point The pour point relates to the low temperature fluidity of lubricants (oils) Operating temperatures should be above the pour point Lubricant oils can emit vapours if their temperature reaches a flash point. With an oxidiser (e.g., air) present the mixtures can become flammable. Key Physical Characteristics of Oils and Greases: Drop Point (Grease) This property “is a very rough indication of grease’s resistance to heat and a guide to manufacture” (McGrory, 2001, pg 919) The drop point identifies the temperature at which a sample of grease, heated using a specific rate, looses a drop through an orifice in the container. The drop point temperature is dependant on the conditions used in the test method. Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 17 Key Physical Properties of Oils and Greases: Penetration (Grease) In greases, consistency is as important a property as viscosity (in oils). Test methods for this include the use of a grease penetrometer that allows an indenter to sink into grease over a given time period. Grease consistency is then related to the depth to which the indenter sinks. One scale for grease penetration is adopted by the American National Lubricating Grease Institute (NLGI). The following is a partial extract. Extract from Table 52.2 (NLGI consistency classification) NLGI number ASTM worked penetration at 77F 000 455-475 00 400-435 0 355-385 1 310-340 … … 6 85-115 Adapted / Modified from Table 52.2. McGrory, S. (2001). Lubrication. In R. K. Mobley (Ed.), Plant engineers handbook (pp. 915-960). New-York: The McGraw- Hill Companies, Inc Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 18 Key Physical Properties of Oils and Greases: Additives Straight (regular) mineral oils might not adequately meet all the functions needed from lubrication. Small amounts of chemical compounds might be added to these oils to improve their characteristics. Different additives exist. Additives Anti- Anti-foam Anti- Anti-wear Extreme Detergent/ VI oxidants corrosion Pressure Dispersant Improvers * Air can be * Oil layers can be entrained into oil. * Boundary squeezed out from * Oils undergo The accumulated * The presence of lubrication * Applied over a air and moisture in interfaces at high *Sludge forms in wide temperature chemical conditions are contact pressure or combustion bubbles gather at lubricating systems more likely to range, mineral oils degradation speeds engines from water the surface and can be detrimental happen during thin at higher when exposed to vapour, unburned form a blanket of to ferrous surfaces start-ups. * High temperature temperatures oxygen. (e.g., steels). causes additives to fuels and (loose viscosity). foam. combustion * Temperature is react with oils, * Additives help * The rise of * Additives allow constituents or products. an influencing reduce this (subsequent) air * Additives that oils to form an substrates to form factor here. particularly where bubbles to the possess an affinity absorbed layer at other compounds. *Acidic bi- for metals help * Additives help systems are surface is the surface. *Extreme break up these reactive to oil products and prevented and form an (absorbed) oil film at the Pressure (EP) deposits and keep viscosity changes sludge result. the oil is aerated. additives help them suspended in (hydraulic surface. * Additives can * Additives help avoid welding of the oil rather than controls). inhibit this in oils bubbles burst at micro-features at agglomerated on * Applied in multi- and greases. the surface. the interface. walls. grade oils. Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 19 Applications Different lubricating oils have qualities that make them more suitable for some applications, but not others. Basic oil grades are produced in plants. Other (different) lubricants are formed by blending mineral oils with additives. Where mineral oils do not satisfy functional requirements, synthetic oils can be resorted to … if these are compatible with machinery (e.g., seals, paints). Applications where specific functional requirements may need to be satisfied in the lubricating oil include: General machinery oils Combustion engine oils Gear lubricating oils Hydraulic fluids Machine tool lubricants Compressors Turbines Transformers and switchgear Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 20 Applications: General machinery oils General machinery oils are used in bearings which can be lubricated by hand, rings or lubricant baths. Such bearings can exist in a variety of uses ranging from shaft support to electric motors. Source: https://www.indiamart.com/ Viscosity of mineral oils used here should minimise (fluid) frictional losses. These lubricants should also have sufficient chemical stability so as to limit oxidation (in the absence of additives). Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 21 Applications: Combustion engine oils Combustion engine oils should be considered when engines are, for example, coupled to compressors or generators or used in heavy vehicles. In addition to (general) functions which lubricants need to provide (remove heat, reduce friction) they should also allow any combustion products that make their way into the oil sump to remain in suspension (instead of being deposited as sludge). Water (from combustion processes) will be in the sump. It will also be acidic in nature due to the presence of dissolved combustion gases. Sludge formation is encouraged in the presence of soot. Corrosion inhibitors (additives) may be used to reduce wear in cylinder bores. Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 22 Applications: Combustion engine oils Some industry info indicates that This type of lubricating oil is classified according to a system viscosity (in cSt) is measured: at 40 C for industrial applications (including some hydraulic oils). devised by the Society of Automotive Engineers (SAE). at 100C for automotive applications. Oil grades are given numeric values to distinguish their viscosity Some exceptions might include differentials on cars using oil with and the temperature for this viscosity. The ‘W’ infers cold start oils. viscosity reported at 40C whilst Refer to Table 52.3 for a full listing (and explanation). differentials on a heavy-duty road vehicles have viscosity reported at 100C (Industry Presentation, 2011) Extract from Table 52.3 (ISO viscosity grade chart) Viscosity (cST) at 100C Maximum Max borderline pumping viscosity temperature Grade cP at C (C) min Max 0W 3250 at -30 -35 3.8 - 5W 3500 at -25 -30 3.8 - 10W 3500 at -20 -25 4.1 - … … … … … 50 - - 16.3 21.9 Adapted / Modified from Table 52.3. McGrory, S. (2001). Lubrication. In R. K. Mobley (Ed.), Plant engineers handbook (pp. 915-960). New-York: The McGraw- Hill Companies, Inc Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 23 Applications: Combustion engine oils The viscosity of lubricating oils change with temperature (oils thicken at low temperature and thin at high temperature). The extent by which these viscosities change (with temperature) varies. Multi-grade oils have high values of VI (i.e., they undergo less changes in viscosity when temperature varies). Multi-grade oils combine the benefits of thinner viscosity oils (useful for low temperature operation and cold start-up) together with the advantages of thicker viscosity oils (useful for high temperature operation). Multi-grade oils are better candidates for all-year use. Key oil characteristics (like viscosity and VI) provide measurable indicators of physical properties. Different applications require varying combinations of physical properties so as to meet performance needs. Some engines will work best with SAE20 oils whilst others need SAE10W oils. This does not mean that SAE20 grades offer better performance than SAE10W. Performance is related to operating the conditions and environmental factors which the engine is subject to. Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 24 Applications: Gear Lubricants Gears are machined in an array of sizes, materials and types: bevel, spur, hypoid, worm, … etc. Gears are subject to varying speeds and loads. This means lubricating requirements also vary. Some gears are overhung whilst others are more rigidly assembled onto shafts. Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 25 Applications: Gear Lubricants Some points to consider: Loads: Increased gear load means greater pressure between meshing teeth and potential reductions in oil film thickness. Thinner lubricant films mean more likelihood of wear on gear teeth surfaces. Source: https://en.wikipedia.org/wiki/Worm_drive#/media/File:Worm_Gear.gif EP additives: react with the surfaces of metallic gears and form a low-friction fluid films. Reactions with gear teeth surfaces mean EP additives can cause corrosion. EP additives eventually break down with ever increasing load. Worm Gears: because sliding is quite pronounced between gear teeth, boundary lubrication is prevalent. If gears are overhung (not sitting in a lubricant bath), lubricating oils need to access meshing zones. The use of thinner oils makes them less likely to remain in meshing zones. Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 26 Applications: Gear Lubricants Gear materials: for the same operational speeds, steel gears are likely to withstand greater loads compared to cast iron or bronze gears. Higher viscosity oils might therefore be needed (because of the load). Friction: because of the meshing (and sliding action), hypoid and worm gears are likely to experience greater friction than other gear types (e.g., spur gears). Oils used in different gear applications are likely to experience different increases in temperature across teeth meshing zones. This also affects the upper temperature expected when gears operate and are lubricated. Spur, bevel, helical gears: oil temperature rise of about 30C and peak oil temperatures is about 70C. Worm, hypoid gears: oil temperature rise of about 40C and peak oil temperatures is about 95C. Oils with EP additives should not exceed 75C. Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 27 Other Types of Oils: Hydraulic Fluids Hydraulic systems are widespread. In addition to functioning as a means for transferring pressure, hydraulic oils need to provide lubricating functionality as well as providing corrosion resistance. Hydraulic oils should retain their properties over a wide temperature range. As such, they should be chemically stable. Mineral oils cannot on their own provide all the functionality needed from hydraulic oils. Therefore, their characteristics are enhanced with the inclusion of additives. Additives may include types specific to: Anti-oxidation Anti-wear Foam-inhibition Anti-corrosion Viscosity Index improvement particularly where temperature stability is important Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 28 Other Types of Oils: Hydraulic Fluids Fire Resistant hydraulic fluids also referred to as FR fluids, resist combustion and the creation of a flame in the presence of ignition sources (but they are not fire extinguishers). FR fluids become more relevant in applications such as: Welding plants (electric) Door actuators (furnace doors) Mining machinery Die-casting and plastic moulding machines Forging plants FR features are particularly important in the above applications because any (high pressure) leakage causes sprays to be ejected and potential fire hazards. Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 29 Other Types of Oils: Hydraulic Fluids Fully synthetic variants from these Fire Resistant hydraulic fluids (McGrory, 2001, Table 52.7) possess better lubrication characteristics compared to water-based variants. While also being available for operation up to 150C, fully synthetic types are however not as likely to be compatible with the conventional type seals and materials (paint) which might be used in systems that operate using water-based types. Water-in-oil Phosphate Mineral oil emulsion Water-glycol ester Fire resistance Another consideration is poor fair that water readily evaporates.excellent This means thatgood water- Relative baseddensity variants (minimum0.87 0.94 of 35% water content, 1.08 see previous 1.14 not table) should be used Viscosity for operation above Index high 60C. high high low Vapour pressure low high high low Special seals no partly partly yes Special paints no no yes yes Rust protection v.good good fair fair Adapted / Modified from Table 52.7. McGrory, S. (2001). Lubrication. In R. K. Mobley (Ed.), Plant engineers handbook (pp. 915-960). New-York: The McGraw- Hill Companies, Inc Principles of Industrial Maintenance Edith Cowan University 2018 Quiz Slide 30  Which of the following item(s) is correct? o Mineral oils can on their own provide all the functionality needed from hydraulic oils. oDifferent lubricants are formed by blending mineral oils with additives. oStraight (regular) mineral oils might adequately meet all the functions needed from lubrication. oViscosity may be considered as a measure of the internal friction which the lubricant experiences. Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 31 Lubrication Methods Lubricants can be applied using different methods. Method of lubrication not only effects how lubricants reach regions of interest (e.g., the meshing zone on gears) but also what happens to the lubricant itself. Splash Lubrication: oil is splashed up from the oil tray or oil pan. Please watch the video. Video URL: https://www.youtube.com/watch?v=eor9KLrnNrs Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 32 Lubrication Methods Splash Lubrication Casing (wall) can be externally finned to increase heat transfer area. A greater area helps Gear 4 Gear 2 dissipate heat transferred from the oil to the case. oil oil Gear 3 Gear 1 Adapted / Modified from Table 52.8. McGrory, S. (2001). Lubrication. In R. K. Mobley (Ed.), Plant engineers handbook (pp. 915-960). New-York: The McGraw-Hill Companies, Inc Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 33 Lubrication Methods Forced Lubrication: Is achieved by pumping the lubricant. The merits of this method include: Controlled flow (amounts) of lubricants ( e.g. to teeth meshing zones on gears). Closer temperature control of oil viscosity through the application of heat exchangers to cool or heat oil. Forced flow through filters helps remove unwanted suspended matter in the oil and any other solid substances. Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 34 Lubrication Methods Oil Mist Lubrication: is a ‘total loss’ lubrication method where finely dispersed oil droplets are carried by (propelled) using compressed air. ‘Total loss’ methods of lubrication mean that the oil is not recirculated or recovered. The merits of oil mist lubrication are: Oil lubricant (in this form) can be transported in pipe work with less frictional losses compared to liquid streams. Additional pumps are not needed and the driving pressure can be obtained though the use of compressed air (readily available in many mechanical workshops). Surrounding atmospheres can be charged with oil mist unless these (oil mist lubrication) systems are totally enclosed. Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 35 Lubrication Methods Engine Lubrication Systems Please watch the video. Video URL: https://www.youtube.com/watch?v=mmmcj53TNic Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 36 Lubricating Greases The advantages of using greases include: More likely to remain where applied (under conditions of shock loading, abrupt changes in direction of rotation, strong centrifugal forces from rotation, contact pressure in joints). Less prone to gravity effects. Performs sealing thereby reducing likelihood of contaminants like water and dust entering systems. Can help prevent corrosion in parts sitting idle for extended periods. Requires less replenishment compared to thinner oils. Helps eliminate dripping (or splashing). May effectively operate over a wide temperature range. ... and lubricates. The disadvantages of using greases include: They do not dissipate heat from areas (as well as oils in general). They exhibit a greater resistance to motion particularly in low-torque joints (than oils). Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 37 Lubricating Greases How greases are produced can be used to classify these important lubricants. Grease Type Some features (+):widely used; smooth texture; good water resistance; inexpensive; lower starting calcium-soap torque. (-): low drop point (~100C) limits max operating temperature to ~50C. greases Listed uses: medium-duty rolling and plain bearings; general duties; central greasing systems; can contain EP additives making them used in steel-mill applications. (+):high drop points (~150C) with max operating temperature ~80C. (-): not very sodium-soap resistive to moisture; unsuitable for wet conditions; some consistency not suitable for greases rolling-contact bearings (fibrous or spongy like greases). Listed uses: plain bearings. (+): operate to max ~120C (continuous use) or higher (intermittent use); satisfactory lithium-soap water resistance. Listed uses: initially developed as aircraft greases now used more greases widely in industry; rolling-contact bearings if they incorporate additives; centralised greasing systems. Other metal-soap (+): operate to max ~ 50C; not soluble in water; adhesive to metals; good where based (e.g., oscillatory motion or vibrations exist. Listed uses: vehicle chassis; rolling mill aluminium) systems; cams. As with all lubricants (oils, greases) and hydraulic fluids, the manufacturers Material Safety Data Sheets (MSDS) should be consulted to identify important considerations prior to use. Technical specifications should also be read to learn more about the specific application scope or characteristics of a particular substance. Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Lubricant Application: Quality Dispensing Considerations Lubricants need to be applied in as clean a condition as they were supplied. Careless application can lead to contaminants such as dust, abrasive particles and water needlessly introduced into machinery. Effective lubricant supply requires at least: Availability of suitable dispensing tools for the specific application Appropriate use of dispensing equipment at the point of application Well organized store/record/data keeping Use of suitable storage environment and facilities for materials Proper training  Machine Lubrication Slide 39 Lubricant Application: Health and Safety Considerations Petroleum based products are wide ranging and continuously being modified or developed. Different handling procedures, specifications and hazards exist with each. Before any handling of lubricants, it is essential that the following are some items that need to be made available: Personal protective equipment/clothing First aid capacity of relevance Detailed information on the product and any remedial actions needed where exposure occurs (e.g., MSDS). Good washing facilities are available with approved skin-cleansers and reconditioning creams. Continued use of some substances may also warrant additional processes and“The precautions. aim is to minimise skin contact, not only because most petroleum products are natural skin degreasing agents, but also because with some of them prolonged and repeated contact in poor conditions of personal hygiene may result in various skin disorders” McGrory, 2001, pg 959 Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 40 Lubricant Application: Health and Safety Considerations Some general precautions when working with lubricants (and other substances like machining/cutting oils): Minimise skin contact through appropriate work methods and equipment and minimise (unnecessary) handling of oily substances. Dispose of wipes after application. Soluble oils as well as synthetic fluids should only be applied as per recommended dilutions. Skin contact with concentrates should be avoided. Other considerations may also need to be considered where oil like mists, vapours or sprays exist. Lubricants Application: Environmental Lubricants will eventually need to be replaced. This raises the issue of disposal. Lubricants should never be discharged into streams or sewage systems. Disposal should be governed by relevant industry practice and local regulations and standards. Principles of Industrial Maintenance Edith Cowan University 2018  Machine Lubrication Slide 41 Lubricant Application: Condition Monitoring Condition monitoring of lubricants forms an important part of predictive maintenance (refer to previous lectures on PDM). Condition monitoring of lubricants can include: Chemical analyses Spectrographic To identify what elements show up in samples and trace back where they may have come from pH monitoring To identify acidity or alkalinity Physical characterisation methods Viscosity testing Principles of Industrial Maintenance Edith Cowan University 2018  Lack of lubrication Example Slide 42  Alaska Airlines Flight 261 Crash The air craft was manufactured and delivered new to Alaska Airlines in 1992. The five crew members and 83 of the Image Source: https://www.deviantart.com/ passengers died. The accident occurred due to the lack of lubrication and the resultant excessive wear. This real-world example will be discussed during next sessions. Principles of Industrial Maintenance Edith Cowan University 2018 Predictive Maintenance Slide 43 Thank you Principles of Industrial Maintenance Edith Cowan University 2018