Oil Mist Lubrication Training

Lubrication Systems Company

Don Ehlert is currently Manager for EPC Sales at Lubrication Systems Co., a Colfax Company, Company, located in Houston, TX. His current responsibilities include providing technical training and sales presentations. He is also responsible for quotation packages for domestic and foreign engineering companies and end user projects. Since joining LSC in 1984, Don has filled positions in equipment assembly, assembly, field maintenance, field installation, installation, field management, sales and sales management. His vast experience allows him to provide technical support to oil mist user’s world wide. He has been instrumental with the development of oil mist related products and accessories for special applications. He has authored numerous articles related to lubrication systems and their applications. Prior to LSC Mr. Ehlert had spent time in the US Navy providing maintenance and operation support for aircraft on the hydraulic and flight control systems.

Pump Retrofit


Trico Oiler Plug on Top

Slinger Rings

Pump Retrofit



Slinger Rings

Topics


Introduction & Evolution of Oil Mist What is Oil Mist Lubrication with Oil Mist Applying Oil Mist To Equipment Retrofitting Pure Oil Mist Purge Oil Mist Applications Justification of Oil Mist


Introduction & Evolution of Oil Mist Lubrication

Introduction to Oil Mist


Oil Mist can be applied to most rolling element bearings Allows use of higher viscosity lubricants. Pure Oil Mist eliminates oil sump issues. Oil Mist is the ultimate oil filter. Oil Mist is contamination control. Wear particles are not re-circulated. Cooling water in bearing jackets is eliminated. Oil Mist Generators are 99.9996% reliable.



Basic Oil Mist System • Air Controls •Mist Generator •Piping System • Applications

Introduction to Oil Mist Large Scale System

3 to 30 SCFM Air Flow Range 2 Gal. Maximum Oil Consumption Serves 15 to 80 Pumps and Drivers



Dry Mist Out


Instrumentation Air In

Vortex Oil Mist Oil



Application & Lubrication ABOVE WET MIST FOR LUBRICATION

OIL MIST PARTICLE SIZES

3 Microns

BELOW DRY MIST FOR CONVEYING

Generation & Distribution



Reclassifier Sizes Bearing Inch 3 6 10 15 20

BI BI BI BI BI

SCFM 0.09 0.18 0.30 0.45 0.60

5 0 2



Standard reclassifier for single or double row bearings. 5 0 2

Double Row Thrust Bearing on 3” Diameter Shaft = 6 BI or .18 SCFM

5 0 1

Single Row Radial Bearing on 3” Diameter Shaft = 3 BI or .09 SCFM


Dry Mist to Wet Mist

Velocity and Turbulence Converts the Dry Mist to Wet Mist



Distribution Header


Reclassifier 502

Mist Manifold

Oil Mist Generator Spent Oil Collection Container

Typical Pump Application

Evolution of Oil Mist


• Oil Mist was develop in Europe; 1930’s. • Introduced to the US Market ; 1948 STLE Mtg. • First HPI system was in Amuay, Venezuela; 1960’s. • First HPI paper on oil mist lubrication published by Mr. Charlie Miannay; 1974 Hydrocarbon Processing. • System reliability improved; early 1980’s. • Pure oil mist became the standard; 1990’s • Closed loop system developed; early 2000.

1960’s System Installation


1960’s Pure Mist


1960’s Purge Mist


One Way System


Pure Mist Per API 610


2010 Purge Mist

Oil Level Is Visual


Closed Loop System Return Header Distribution Header

OMG

Demisting Device



What is Oil Mist?

What is Oil Mist?


• Oil mist systems are centralized lubrication systems that continuously and efficiently atomizes oil into small particles and then conveys and delivers the correct amount of the pressurized oil mist lubricant to bearings and metal surfaces resulting in improved lubrication, fewer failures/repairs, lower life cycle costs and extended machinery life.

What is Oil Mist


• Oil Mist is an Aerosol; Not a VOC Oil Mist

• 1 Part Oil & 200,000 Equal Parts Air • Will Not Support Combustion • Dry Mist is Generated for transportation • 20” H2O Pressure

Oil

What is Oil Mist?


Toxicity Considerations of Oil Mist Per the American Conference of Governmental Hygienists “Long term threshold limit of 5 mg/m3 for 8 hours” “Short term exposure limit of 10 mg/m3” The 5 mg/m3 is not commonly exceeded around equipment in outdoor locations. Indoor applications use Closed-Loop Systems. California Rule 1173 Exempts Lubricating Fluids from being a Fugitive Emission or Volatile Organic Compound (VOC

Reference: Oil Mist Lubrication Handbook; Mr. Heinz Bloch

What is Oil Mist?


Flammability of Oil Mist The air-oil mixture is several orders of magnitude too lean to sustain combustion.

Experiments have shown the concentration of oil mist in the header ranges from 0.005 to as little as 0.001 of the concentration generally considered flammable.

The oil/air mixture is substantially below the sustainable burning point

Reference: Oil Mist Lubrication Handbook; Mr. Heinz Bloch

What is Oil Mist? Oil Consumption with Oil Mist • .65 in3 per Hour per SCFM • 10 SCFM = 6.5 in3 per Hour • Typical Pump = 0.27 SCFM • 10 SCFM = 27 Pumps • Max of 30 SCFM = 2 Gallons/Day



Lubrication with Oil Mist



Generate Dry Oil Mist for Conveying; Below 3 microns

Lubricate with Wet Oil Mist; Larger than 3 microns



• Reclassifiers preferred location is on the mist manifold • Locate the reclassifier within 2 meters of bearings • Bearing isolators are preferred to help contain the oil mist in the bearing housing

Reclassifiers


• Vent/Drain of bearing housing is very

important • Oil mist flow is required to apply mist to bearings

• Restricted flow exiting bearing housing increases internal pressure reducing flow of oil mist • Bearing housing vent/drain adequate to vent SCFM flow entering through reclassifiers


Single Row Bearings


Mist Flow for Bearing Lubrication Radial Brgs. & Motor Brgs.

Vertical Applications

Always Flow through is always preferred.

Double Row Bearings


Mist Flow for Bearing Lubrication Vertical Applications Recommended: Brg. Isolators 150 Kw & Up 3000 RPM & Up

Always

Flow through is always preferred.

Triple Row Bearings

Two Points


Two Points

Flow through is required.


Applying Oil Mist

Applying Oil Mist


Two methods of applying oil mist

Pure Oil Mist or Dry Sump No Oil Level

Purge Oil Mist or Wet Sump Oil Level is Maintained

Applying Oil Mist Pure Oil Mist or Dry Sump Common on all rolling element bearings Reduces bearing and mechanical seal failures Eliminates manual lubrication tasks Bearing temperature is reduced Eliminates recirculation of hot contaminated oil Allows removal of cooling water


Applying Oil Mist Purge Oil Mist or Wet Sump Typical on sleeve bearings and gearing. Positive pressure prevents intrusion of air borne contaminates i.e. moisture & dust. Oil level is maintained and must be controlled; Oil mist will increase the oil level. Heavily thrust loaded bearings may require the oil sump


Applying Oil Mist


Reclassifiers For Purge Mist Sleeve, Babbitt or Plain Bearings are typically Purge Mist Applications Purge Mist = Light Service or Low Flow Rate

Oil Mist is not Primary Prevents Intrusion of Air Borne Contaminates

Applying Oil Mist


Sizing Reclassifiers For Pure Mist Anti Friction Bearings are typically Dry Sump Applications Formula

Sf x D x N

Sf = Service Factor D = Shaft Diameter in Inches N = Number of Rows Sf = .009 for Light Loads i.e. Motors .022 for Moderate Service

.045 for Heavy Service

Oil Mist is Primary Lubrication with NO Oil Sump Lubricates and Prevents Intrusion of Air Borne Contaminates


Retrofitting Oil Mist

Pump Retrofit



Slinger Rings

Pump Retrofit


Single Lube Point

Lip or Labyrinth Seals

Remove Trico and convert to pure mist

3000 RPM and Less than 150 Kw

Remove slingers, plug drain back ports when pump is out

Pump Retrofit

Single row bearing receives adequate lubrication


Single inlets and bearing isolators may require additional vent to allow flow through the multiple row bearing

Pump Retrofit

Two points required with 150 Kw and operating at 3000 RPM Bearing isolators often require a second lube point.

Remove slingers, plug drain back ports when pump is out


Field retrofit two points with tap in bearing cap

Pump Retrofit


API Specification calls for two lube points outboard of bearings No Trico Oiler

No Slinger Rings No Oil Sump

Pump Retrofit


Older model between bearing pumps often require directional reclassifiers

Pump Retrofit


Bearing arrangement did not allow mist to flow through

Oil mist would not get to inboard brg.

Pump Retrofit

Oil mist is directed into the rolling elements and passes through to inboard bearing Directional's are not required on current API edition between bearing pumps


1980 Pure Mist


Motor Retrofit


Not as easily retrofitted as pumps No defined or sealed bearing housing Grease must be removed completely. Items of Concern Seal inlet port to junction box Oil Compatible lead wire insulation Oil compatible epoxy coating Case drain required on coupling end; plug fan end drain port Vent lines routed away from fan

Motor Retrofit


Oil mist must pass through the bearings from top to bottom Sealed bearings are not compatible with oil mist lubrication

Low point case drain is required on vertical motors

Pillow Block


Bearings operate 3ºC to 10ºC cooler with oil mist

No more over or under lubrication

No re-greasing No oil changes No dirty oil

Turbine Retrofit

Eliminates baking of grease

Mist flows through bearings top to bottom



Purge Oil Mist & Typical Applications

Purge Applications


Two Methods to Control the Oil Level Oil Level Site Assy.

Constant Level Oiler

Turbine Application


Little or no modifications required when retrofitting purge oil mist to existing equipment.

Prevents intrusion of steam condensate

Helps with lubrication when in slow roll mode

Gear Box Applications


Gear box applications are always purge mist applications. The oil mist prevents intrusion of airborne contaminates, keeps internal components coated with oil when equipment is sitting idle. Purge mist housing must have oil mist vent and level control.

Gear Box Applications Cooling Tower Fan Gear Box


Pure & Purge Applications

Purge Mist on Gearing


Pure Mist on Bearings


Oil Mist Justification

Oil Mist Justification Operating Expense Items


Reliability Savings – Cost & Risk Avoidance

Pump Bearings Mechanical Seals

Fire Potential

Motors

Lost Production

Man Power

Non-Spared Equip.

Oil Savings Cooling Water



Pump Maintenance Experience


Mechanical Seal Experience


Oil Mist Justification Motor Brg. Experience




Manpower Efficiencies

Actual Experience

•

180 Oil Sumps

•

Oil Changes: 2 per year

•

Oil Fills/Checks: 4 per month

•

Time Per Sump: 4.5 hours/year

•

Cost: $67/hour

•

Manpower Credit: $55,000/year

•

.25 Hrs to re-grease mtrs. semi annual

Maintenance staff no longer changes oil or regreases motors.

With 600 Pumps and Motors oil mist redirects 3000 man hours per year to proactive failure avoidance and reliability improvement tasks.

Oil Mist Justification Oil Savings


Oil Mist Justification Potential Fire Damage




“Get the Facts on Oil Mist Lubrication” Published in Hydrocarbon Processing August Issue 2008 Heinz Boch & Don Ehlert

Oil Mist Lubrication Training

Recommend Documents