ExxonMobil Egypt

Lubrication
Fundamentals

Walid AbdelAziz
Lubrication Field Engineer
ExxonMobil Egypt

12, Feb 2018

Topics
Lubrication Fundamentals
Lubricant Characteristics & how to read PDS
– Industrial Lubricants classification
– Lubricants manufacturing process
– Synthetic Lubricants
– Additives
– Greases
Lubricants testing & Used Oil analysis
interpretation
 Lubrication
Fundamentals
 Some History Of Lubrication

Historical
documentation of
a Lubricator
applying lube (—)

4
Why do we lubricate?
Prevent wear
Reduce friction
Cleaning
Remove heat
Loads carrying
Decreasing friction between moving parts
Overcoming Wear
Wear Types
Contact Wear: Welds between parts resulting in layer removal
Friction wear: Surface scratches due to contaminants
Rust: Chemical reaction with ambient conditions
Fatigue: Metal surface fatigue due to cycle load
 Lubrication stages

High friction
Oil

Oil film
formation

Complete
separation
Moving Parts Oil film thickness
 Lubrication
Criteria: Availing anti-friction liquid film to overcome
friction under loads between moving parts
 Viscosity
Liquid resistance to flow

Viscosity is depending on…..

Temperature Pressure Shear force

Temperature effect on viscosity

Viscosity decreases Viscosity Increases

 Oil capability to withstands temperature variation

Viscosity Index

VI
High VI = Oil is capable for maintaining is viscosity

VI 100 VI 135
Industrial Oil
Classification
 Based on Oil Viscosity

International Standardization Organization

ISO

Industrial Liquid Lubricants ISO Viscosity Classification

1992
Viscosity Grades

VG

ISO VG
 Industrial lubricant viscosity is measured at 40C

(cst) (Cst) Viscosity @ 40C ISO VG

2,4 1,98 2,2 2

3,52 2,88 3,2 3
5,06 4,14 4,6 5
7,48 6,12 6,8 7
11,0 9,00 10 10
16,5 13,5 15 15
24,2 19,8 22 22
35,2 28,8 32 32
50,6 41,4 46 46
74,8 61,2 68 68
110 90,0 100 100
Upper Limit Lower Limit Viscosity @ 40 C ISO VG
(Cst) (Cst)

165 135 150 150

242 198 220 220
352 288 320 320
506 414 460 460
748 612 680 680
1100 900 1000 1000
1650 1350 1500 1500
2420 1980 2200 2200
3520 2880 3200 3200
Recognizing Viscosity Designations

AGMA
SAE
SUS
ISO VG
cSt
API SER
Can you tell the viscosity of an oil?
By color?
By smell?
 Oil Viscosity
Determined only in lab using special equipment

Viscosity is shown on product label

Mixing or topping different VG is not permitted

Lubricants are stored based on their type, not

viscosity to avoid mixing between different application
 Lubricants
Manufacturing
Mineral Oils
 Distillation and Treatment Towers
Atmospheric

Fuel

Vacuum
*

*
Crude Oil *

RESIDUE Solvents Solvents Base oil

Hydrogen
(Mineral)
Solvents and Wax Naphta
volatile
Asphalt
Viscosity / density/ boiling degree
Mineral Oil manufacturing stages

Distillation Crude oil

Treatment

A
B

+
C
=
Additives Base oils
 Base Oil Characteristics

Stability Oxidation

Viscosity Base oil Demmusibility

Volatility Pour Point

Apperance
 Product formulation
Basic method

??

Mineral Oil Additives

Normal Lubricant

Crude, Distillation & Treatments Quality / Additives / Blending ratios

Technical expertise in Ideal Base Oil

lubrication Ideal additives composition

Leading Lubricant with excellent Huge investments and field trials

performance for customer
satisfaction
 Lubricants
Manufacturing
Synthetic Oils
What is synthetic lubricant?
 Synthetic oils are produced in labs and
don’t depend on crudes

Chemical process between

Synthetic oil
Carbon and Hydrogen
production molecules
Ethylene
Synthetic base oils

Main Types

• API III Group

Hydrogen treated
Synth
Synthetic
• API Group IV
Poly alpha oleifin

• API Group V
- Esters
- Poly-glycols
- Silicon
 Synthetic Vs Mineral oil
Mineral oils
• Characteristics depend on crude quality
• Contains contaminants

Synthetic Oil
• All characteristics are enhanced
• Does not contain contaminants
• Flexibility in production to match field applications
Synthetic lubricant advantages
Higher VI

Bigger viscosity range

Higher temperature range

Lower volatility

Longer lifetime

Lower traction index

Energy saving
Synthetic lubricants advantages

Higher range of viscosity

Heavy oil
film
thickness

Lower failure rates

High loads and low speeds
Mobilgear SHC 22M
 Synthetic lubricants advantages

‫ﺻورة ﻣﻛﺑرة‬
60x Higher VI & No Waxes
‫ﻟزﯾت ﺗﺧﻠﯾﻘﻲ ﻣن‬
‫اﻟداي إﺳﺗر ﻋﻧد‬
‫ م‬18-

Thicker oil film at

high temperatures
&
‫ﺻورة ﻣﻛﺑرة‬
60x Better flow at low
‫ﻟﻠﺷﻣﻊ اﻟﺑﺗروﻟﻲ‬ temperatures
‫ م‬18- ‫ﻋﻧد‬

Equipment lifetime increase

Bigger temperature range
Viscosity Index
The rate of change of an oil’s
viscosity with temperature

Viscosity Index
Viscosity

Very High
VI (135)

High VI (95)

Low VI (65)

Temperature
Synthetic lubricants advantages

Lower traction Index

Lower internal friction

Lower temperature

Better viscosity & Energy control

Synthetic lubricants advantages
Oxidation stability
Mobil SHC Conventional
mineral Oil

Lower viscosity
increase rate
Lower contaminants
formation rate

Increase ODI
Lower labor cost
Lower downtime
Lower disposal cost
 Synthetic Lubricants in gears

Mobil SHC 600 Synthetic Oil Mineral

Higher Temperature

Oil tank Temp 167°F 182°F 180°F

Efficiency 76% 74% 74%
Additives
 Additives types
Anti-wear

Extreme pressure

Detergents

Anti-oxidants

Rust / Corrosion inhibitors

Viscosity index improvers

Defoamants

Demulsifiers
 Anti-Wear

Layer formation on metal surfaces to protect against wear

High Temperatures

Moving part

Additive layer
Metal surfaces

Stagnant part
Extreme pressure

EP / XP

Graphite / MOS2

Moving part

Stagnant part
EP additive
 Detergents
Metal surfaces

Oil

Contaminants

Removes sticky contaminants

 Rust / Corrosion inhibitors
• Attracts to metal surfaces

• Leaving part suspended in

oil & other part sticks to
surface Metal surface
• To prevent rust and
Water sources?
corrosion
Viscosity Index improver
Multi-grade and seasonal oil change?

100

90

80

70
Expands in high
60

50

40
temperatures and
overcome viscosity
30

20

10

decrease

100

90

80
Molecules detached for
ease of oil flow with
70

60

50

decrease in temperatures
40

30

20

10

0 to overcome viscosity
increase
 Defoamants & Demulsifiers

Helps in water in oil

separation

Eliminates air bubbles from Oil

Greases
Greases composition
Oil
80-87%
Thickner
Soap material holds the Oil
(Na ،Ca ،Li )
8-15%
Fat + Hydroxide (simple or complex for higher temperatures)

Additives
To provide additional features
5%
Why to use grease instead of Oil?

• Mainly for stable structure

• Also provides adequate covering and easy for use
 Greases classification

National Lubricating Grease Institute

NLGI

Hard grease Soft grease Penetration testing shows if the

grease is soft or hard
Greases classification
Worked
NLGI consistency number
penetration
000 445-475
00 400-430
0 355-385
1 310-340
2 265-295
3 220-250
4 175-205
5 130-160
6 85-115
Greases classification
What is the Dropping Point of a Grease?
Mobil greases – Some types
Mobilux EP 0,1,2,3 Mobilgrease XHP 222
Multi purpose High Temperatures
Li Resists water wash-out
NLGI 0,1,2,3 Li Complex
NLGI 2
Mobilith SHC 460 Mobilith SHC 100
NLGI 1.5 Synthetic
Synthetic High speeds
Li Complex High Temperatures
High Loads NLGI 2
High Temperatures
Used Oil Analysis
Oil Sampling

Why Sample?
To monitor wear of machine components
To check for contamination
To make certain the correct lubricant is in service
To monitor lubricant degradation
To optimize drain intervals
To support other maintenance practices
Oil Sampling
When To Send Sample For Lab Analysis:
As part of a monitoring program
Before and after overhaul or major repair
Noticeable change in color or odor
Major change in operating conditions
Oil Sampling
When Not to Send a Sample
for Lab Analysis:

Visible water in the oil

Visible contamination
Sampling is random or sporadic
Lab reports are not used to advantage
Sampling tips
• Know product to be sampled

• Determine sampling point

• Ensure tools and container is clean before use

• Ensure sample container is not leaking and closed

• Write all sample details on label promptly

Oil type and name
Equipment location and description/name
Equipment/Oil life time
Sampling date
Used Oil Analysis – Mobil Serv

Exxonmobil system for used oil analysis

Better organization for samples process
48 hours lead time
Samples tracking
Lower human errors
Empty sampling containers and tools with labels
Results report receipts via email or fax
Used Oil Analysis – Mobil Serv
Used Oil Analysis – Mobil Serv
Used Oil Analysis – Mobil Serv
Questions?
Thank you