lubrication

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intoduction to lubricants

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Presentation Transcript

WELCOME TO THE WORLD OF LUBRICANTS : 

WELCOME TO THE WORLD OF LUBRICANTS THIS SESSION IS PURPOSEFUL STRATEGIC ALL ABOUT SAVING MONEY INCREASING MACHINE RELIBILITY ABOUT SERIOUS BUSINESS OF ORGANIZING PLAN TO LEARN FROM OUR MISTAKES BENCHMARK TO OTHERS SUCCESS

Slide 2: 

LUBRICANTS A SHORT PREVIEW BY P. C. MISHRA Dy. Ex. Er. (G C R)

WELCOME TO THE WORLD OF LUBRICANTS : 

WELCOME TO THE WORLD OF LUBRICANTS THIS SESSION IS PURPOSEFUL STRATEGIC ALL ABOUT SAVING MONEY INCREASING MACHINE RELIBILITY ABOUT SERIOUS BUSINESS OF ORGANIZING PLAN TO LEARN FROM OUR MISTAKES BENCHMARK TO OTHERS SUCCESS

Slide 4: 

HOPE WE ALL BE REMAIN COMMITTED TO OUR GOAL LET US WARM UP OUR BRAIN BY TICK MARKING THE QUESTIONERY & CLAIM THE PRIZE-----

Function of lubricant : 

Function of lubricant REDUCE FRICTION REDUCE WEAR DISSIPATES HEAT PREVENTS RUST PREVENTS CORRISON ACTS AS SEAL TO OUTSIDE CONTAMINANTS FLUSHES CONTAMINANTS

HOW DOES IT DO IT ? : 

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

Slide 7: 

FRICTION SLIDING ROLLING FLUID BOUNDRY LUBRICANT SOLID SEMISOLID LIQUID GASEIOUS

SEMISOLID OR COHESIVE LUBRICANT---GREASE--- : 

SEMISOLID OR COHESIVE LUBRICANT---GREASE--- 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.

Slide 9: 

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.

Slide 10: 

Used Grease having contamination, The graph represents vibration peak in contaminated grease Not contaminated grease

Slide 11: 

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. 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.

Slide 12: 

LUBRICATIG OIL = LUB. OIL BASE STOCK+PERFORMANECE ENHANCING ADDITIVES LUB.BASE STOCK: PETROLIUM OIL (PARAFFANIC/ NAPHTHENIC) SYNTHETIC OIL VEGATABLE OIL 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

Slide 13: 

AN OIL WITH THE CORRECT VISCOSITY FOR A PARTICULAR OPERATION WILL BE: THICK ENOUGH TO SUPPORTHE LOAD BUT NOT SO THICK AS TO CAUSE EXCESSIVE FRICTION IN THE FLUID AND CORRESPONDING INCREASE IN TEMPERATURE DYNAMIC VISCOSITY(ABSOLUTE VISCOSITY): = SHEAR STRSS/SHEAR RATE MEASURED IN POISE OR CENTIPOISE KINEMATIC VISCOSITY =DYNAMIC VISCOSITY/DENSITY OF LUBRICANT MEASURED IN CENTISOKES

Slide 14: 

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.

Slide 15: 

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:

Slide 16: 

SAMPLEING: IT IS CRITICAL PHASE FOR DETERMININING THE HEALTHINESS OF LUBRCANT AND THE EQUIPMENT OR MACHINE LUBRICATING OIL IS THE LIFE BLOOD OF MACHINE

Slide 17: 

HOW TO SAMPLE? 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.

Slide 18: 

WHEN A SAMPLE SHOULD BE TAKEN ? WHEN THE MACHINE IS IN SERVICE AFTER ADDING MAKE UP OIL IMMEDIATELY AFTER SHUT DOWN OUR TEST METHODS AT CSTPS CHANDRAPUR 1 WATER ASTM(AMERICAN SOC.OF TESTING &MATERILS) D-95 USES DISTILLATION EXPRESSES IN vol %

Slide 19: 

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 detoriation of oil

Slide 20: 

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

Slide 21: 

oil analysis tests are run affects the quality of results. 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