SISTEM PELINCIRAN
(LUBRICATION)
INTRODUCTION TO LUBRICATION
INTRODUCTION
Wear is a major cause of material wastage, so any reduction of wear can effect considerable saving.
Friction is a principle cause of energy dissipation and considerable savings are possible by improved friction control
Lubrication is the most effective mean of controlling wear and reducing friction.
Lubrication as part of tribology, which is the science and technology of friction lubrication and wear
LUBRICATION PRINCIPLE Lubrication is introduced between two sliding solids by
adding a gaseous, liquid or solid lubricant at the sliding interface.
Lubrication is the process, or technique employed to reduce wear of one or both surface in close proximity
Make possible by interposing a substance calledlubricant between the surface
Function: To reduce friction and wear To carry away heat generated during the sliding process To carry away debris generated during the sliding process
FLUID MANAGEMENT
FLUID MANAGEMENT
Fluid management programs are being used to extend lubricant life and reduce disposal costs.
Four essential components in a fluid management program: Selection and purchase of the lubricant Lubricant monitoring during use Lubrication maintenance using processing
and refortification techniques Disposal of the spent lubricant
FOUR COMPONENTS IN FLUID MANAGEMENT
LUBRICATION SELECTION & PURCHASE
CRITERIA:a) Correct lubricant for applicationb) Premium lubricant is recommendedc) Lubrication meet equipment manufacturers’
recommendations and specifications.d) Good quality, reliable and proven lubricante) Good services from lubricant supplier
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FOUR COMPONENTS IN FLUID MANAGEMENT
LUBRICATION MONITORING PROGRAM
a) The purpose is to evaluate the condition of the lubricant and to detect early signs of equipment failure.
b) Analysis of the used oil can be used to extend lubricant life and establish oil change interval
c) This program mostly for large volume application of industrial lubricant. Example:
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Turbine / circulating CompressorsHydraulic Gear oils
FOUR COMPONENTS IN FLUID MANAGEMENT
LUBRICATION MONITORING PROGRAM
d) Small volume or once-through applications, need no monitoring
e) Result of monitoring tests can be used in some cases to correct conditions that are contributing to degradation of the lubricant.
f) Results of monitoring program should be assess dependent on the application and environment. Table 2.1 shows properties and condemning limit for most large volume application
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FOUR COMPONENTS IN FLUID MANAGEMENT
LUBRICATION MONITORING PROGRAM
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TABLE 2.1 – Condemning limits for used oil
FOUR COMPONENTS IN FLUID MANAGEMENT
LUBRICATION MAINTENANCE
a) Closely related with the monitoring programb) Can be define as corrective action when used oil
analysis show results exceed condemning limit (Table 2.1)
c) Some maintenance action is, filtration, additive replenishment or lubricant cooling system.
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FOUR COMPONENTS IN FLUID MANAGEMENT
DISPOSAL
a) Last step taken when monitoring results show oils is severely degraded and cannot be restore.
b) Option of disposal could be, recycling, burning, land-filling and re-refining.
c) Method of disposal will depend on local authority
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LUBRICANT PROTECTION
LUBRICANT PROTECTION
1) Protection of lubricant to ensure its longevity and satisfactory performance by proper handling and storage of lubricants.
2) Protection practice to prevent:a) Contamination of dirtsb) Contamination with excessive moisture or waterc) Exposure to extreme temperature
5 WAYS OF LUBRICATION PROTECTION
LUBRICATION PROTECTION
LOCATION & PERSONNEL
FACILITIES
LIGHTINGBULK STORAGE
FIRE PROTECTION
LOCATION AND PERSONNEL
Provide clean and well-lighted room
Provision for heating if expose to cold weather / environment
Assign trained personnel for inventory and dispensing
Provide clear label for each type of lubricant
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FACILITIES FOR HANDLING
Facility to ensure easy handling and proper storage arrangement
Facility design so that various type of lubricant is mixed
Handling equipment must keep clean and well maintained.
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Figure: Parallel rail for handling both full drums and empties
LIGHTING
Proper lighting ensure healthy and comfortable working environment
Proper records and monitoring can be done
Promote safety
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BULK STORAGE
Benefits:Improved efficiencyReduced handling costsReduced risk of contaminationSimplified inventory
Expensive investment:Each products required its own dedicated system
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BULK STORAGE
Bulk shipments can be done with tank trucks, car or tote bins.
Products should be inspected visually for clarity and cleanliness and viscosity check prior to unload.
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FIRE PROTECTION
Enforce strict rules for safety: No smoking area Allow specific trained personnel to have access Allow the used of sparking or arcing producing tool only
under the conditions of good ventilation Only allow minimum quantity of waste or wiping rags and
stored in metal container Oil dripped is prevented or cleaned up properly
Good safety features: Suitable fire extinguishing equipment are available Clean area
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LUBRICATION DEVICES AND SYSTEM
“ GOOD LUBRICATION IS SIMPLY PLACING THE RIGHT AMOUNT OF THE RIGHT LUBRICANT INTHE RIGHT PLACE AT THE RIGHT TIME ”
Manual lubrication
LUBRICATING SYSTEM
Automatic lubrication
MANUAL LUBRICATION
Grease gun
Spraying type lubrication
Apply by hand
Compressed air / electrically powered lubrication equipment
AUTOMATIC LUBRICATION
Efficient
Reduce man-hours
Precise control lubrication application
Reduce material consumption
CENTRALIZED AUTOMATIC LUBRICATION SYSTEM Centralized automatic lubrication system can be
readily justified for the following reasons:
SAFETY
MORE EFFICIENT
LUBRICATION INCREASED
PRODUCTIVITY REDUCED
OPERATING COST BETTER
HOUSEKEEPING
SAFETY
• No climbing around machinery• No excess spillage around machines to
cause slippery• Difficult to access area due to location gas,
fumes or height
TYPES OF AUTOMATIC LUBRICATION SYSTEMS Automatic lubrication system generally fall into
below categories:
Oil mist system
Orifice control system
Injector system
Series- progressive
system
Twin lineDuoline system
Pump to point
systemZone control
system
Ejection system
Injection system
OIL MIST SYSTEM
Mostly used in high-speed precision service
Example:Grinding machineryWoodworkingAir craft compressor
Working principle: Injecting oil drop by drop into a stream of low
pressure air to circulate just enough oil to wet the operating surface
ORIFICE-CONTROL SYSTEM Use only oil as a lubricant with viscosity usually
limited to 300 SUS or less Orifice used to control the amount of lubrication
going into a bearing Best for small, single purpose machinery in a stable
environment. Generally cheap, and simple to design and install. Additional point can be added without disrupting the
original system Not suitable for area has vary temperature,
viscosity change as temperature change viscosity Single broken line will disable complete system.
INJECTOR SYSTEM
Can be used with oil and light greases,, usually limited to NLGI 1.
Working principle: Quickly pressurized main system line so that the lubricant on the discharge end of a spool can be injected into a bearing.
Pump capacity usually sized four times higher than the system’s requirement.
Easy system to design Additional lubrication point can be added without
disrupting original design. Broken line before any injector will disable complete
system
SERIES PROGRESSIVE SYSTEM
Can operate with either oil or grease (suggested minimum viscosity 100 SUS, maximum NLGI 2)
Provide positive displacement of lubricant by supplying each bearing with predetermined amount of lubricant before lubricating the next point.
Main characteristic, system will disable when a line become plugged.
Tamper resistant Complex design, expensive, require comprehensive
engineering study & required high skilled maintenance personnel
Additional point require re-design system