Lubrication Systems Company
Don Ehlert is currently Manager for EPC Sales at Lubrication Systems Co., a Colfax 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, field maintenance, field installation, field management, sales and sales management. His vast experience allows him to provide technical support to oil mist users 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
Lubrication Systems Company
Trico Oiler Plug on Top
Slinger Rings
Topics
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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
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Introduction & Evolution of Oil Mist Lubrication
Introduction to Oil Mist
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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.
Introduction to Oil Mist
Lubrication Systems Company
Basic Oil Mist System
Air Controls Mist Generator Piping System Applications
Introduction to Oil Mist Large Scale System
Lubrication Systems Company
3 to 30 SCFM Air Flow Range 2 Gal. Maximum Oil Consumption
Serves 15 to 80 Pumps and Drivers
Introduction to Oil Mist
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Dry Mist Out
Instrumentation Air In
Vortex
Oil Mist Oil
Introduction to Oil Mist
Application & Lubrication
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ABOVE WET MIST FOR LUBRICATION
OIL MIST PARTICLE SIZES
BELOW DRY MIST FOR CONVEYING
3 Microns
Generation & Distribution
Introduction to Oil Mist
Lubrication Systems Company
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
Introduction to Oil Mist
Standard reclassifier for single or double row bearings.
5 0 2
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5 0 1
Double Row Thrust Bearing on 3 Diameter Shaft = 6 BI or .18 SCFM
Single Row Radial Bearing on 3 Diameter Shaft = 3 BI or .09 SCFM
Introduction to Oil Mist
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Dry Mist to Wet Mist
Velocity and Turbulence Converts the Dry Mist to Wet Mist
Introduction to Oil Mist
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Distribution Header
Reclassifier
502
Mist Manifold
Oil Mist Generator Spent Oil Collection Container
Typical Pump Application
Evolution of Oil Mist
Lubrication Systems Company
Oil Mist was develop in Europe; 1930s. Introduced to the US Market ; 1948 STLE Mtg. First HPI system was in Amuay, Venezuela; 1960s.
First HPI paper on oil mist lubrication published by Mr. Charlie Miannay; 1974 Hydrocarbon Processing.
System reliability improved; early 1980s.
Pure oil mist became the standard; 1990s
Closed loop system developed; early 2000.
1960s System Installation
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1960s Pure Mist
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1960s Purge Mist
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One Way System
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Pure Mist Per API 610
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2010 Purge Mist
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Oil Level Is Visual
Closed Loop System
Return Header Distribution Header
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OMG
Demisting Device
Lubrication Systems Company
What is Oil Mist?
What is Oil Mist?
Lubrication Systems Company
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
Lubrication Systems Company
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?
Lubrication Systems Company
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
Lubrication Systems Company
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 Systems Company
Lubrication Systems Company
Lubrication with Oil Mist
Lubrication with Oil Mist
Lubrication Systems Company
Generate Dry Oil Mist for Conveying; Below 3 microns
Lubricate with Wet Oil Mist; Larger than 3 microns
Lubrication with Oil Mist
Reclassifiers preferred location is on the mist manifold Locate the reclassifier within 2 meters of bearings
Lubrication Systems Company
Bearing isolators are preferred to help contain the oil mist in the bearing housing
Reclassifiers
Lubrication with Oil Mist
Vent/Drain of bearing housing is very
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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.
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Vertical Applications
Always
Flow through is always preferred.
Double Row Bearings
Mist Flow for Bearing Lubrication
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Vertical Applications Recommended:
Brg. Isolators
150 Kw & Up 3000 RPM & Up Always
Flow through is always preferred.
Triple Row Bearings
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Two Points
Two Points
Flow through is required.
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Applying Oil Mist
Applying Oil Mist
Lubrication Systems Company
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
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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
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Applying Oil Mist
Lubrication Systems Company
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
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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
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Retrofitting Oil Mist
Pump Retrofit
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Trico Oiler Plug on Top
Slinger Rings
Pump Retrofit
Single Lube Point
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Lip or Labyrinth Seals 3000 RPM and Less than 150 Kw
Remove Trico and convert to pure mist
Remove slingers, plug drain back ports when pump is out
Pump Retrofit
Lubrication Systems Company
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
Lubrication Systems Company
Two points required with 150 Kw and operating at 3000 RPM
Field retrofit two points with tap in bearing cap
Bearing isolators often
require a second lube point.
Remove slingers, plug drain back ports when pump is out
Pump Retrofit
Lubrication Systems Company
API Specification calls for two lube points outboard of bearings
No Trico Oiler
No Slinger Rings No Oil Sump
Pump Retrofit
Lubrication Systems Company
Older model between bearing pumps often require directional reclassifiers
Pump Retrofit
Lubrication Systems Company
Bearing arrangement did not allow mist to flow through
Oil mist would not get to inboard brg.
Pump Retrofit
Lubrication Systems Company
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
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Motor Retrofit
Not as easily retrofitted as pumps No defined or sealed bearing housing Grease must be removed completely.
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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
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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
Lubrication Systems Company
Bearings operate 3C to 10C cooler with oil mist
No more over or under lubrication
No re-greasing
No oil changes
No dirty oil
Turbine Retrofit
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Eliminates baking of grease
Mist flows through bearings top to bottom
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Purge Oil Mist & Typical Applications
Purge Applications
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Two Methods to Control the Oil Level
Oil Level Site Assy. Constant Level Oiler
Turbine Application
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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
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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
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Pure & Purge Applications
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Purge Mist on Gearing
Pure Mist on Bearings
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Oil Mist Justification
Oil Mist Justification
Operating Expense Items
Pump Bearings Mechanical Seals Fire Potential
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Reliability Savings Cost & Risk Avoidance
Motors
Man Power Oil Savings Cooling Water
Lost Production
Non-Spared Equip.
Oil Mist Justification
Lubrication Systems Company
Pump Maintenance Experience
Oil Mist Justification
Lubrication Systems Company
Mechanical Seal Experience
Oil Mist Justification
Motor Brg. Experience
Lubrication Systems Company
Oil Mist Justification
Manpower Efficiencies
Lubrication Systems Company
Actual Experience
Maintenance staff no longer changes oil or regreases motors. 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
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
Lubrication Systems Company
Oil Mist Justification
Potential Fire Damage
Lubrication Systems Company
Oil Mist Justification
Lubrication Systems Company
Get the Facts on Oil Mist Lubrication
Published in Hydrocarbon Processing August Issue 2008 Heinz Boch & Don Ehlert
Questions
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Contact Info
Don Ehlert Lubrication Systems Co. Houston, TX USA Phone 1-713-464-6266 Email don.ehlert@colfaxcorp.com
