UNDERSTANDING OIL MIST - Home - Calgary Pump · PDF fileB.Sc. in Mechanical Engineer in 2009 and recently ... Mechanical Seal MTBR is 2x over sump lubricated pumps; ... PowerPoint

Calgary Pump Symposium 2013

UNDERSTANDING OIL MIST

DON EHLERT

TOTAL LUBRICATION MANAGEMENT CO.

Calgary Pump Symposium 2015 1

Calgary Pump Symposium 2013 Calgary Pump Symposium 2015

DON EHLERT 40 years of working with and promoting oil mist lubrication. Prior to oil mist Don was on flight decks of air craft carriers in the worlds largest Navy.

Mariana Flores Mariana Flores is the EPC/OEM Project Manager at Total Lubrication Management, with 5 year experience in Oil Mist / Purification Projects . Mariana graduated with a B.Sc. in Mechanical Engineer in 2009 and recently accomplished the PMP Certification. Mrs. Flores worked for our subsidiary in Mexico serving Latin America projects, and moved to the United States on 2012 to develop Oil Mist Projects for EPC’s. Always focus on results, Mariana is constantly seeking process improvements.

Presenters

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WHAT IS OIL MIST?

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• Is a centralized system that provides an efficient lubrication technology to different classes of rotating equipment widely dispersed at a physical location.

• Instrument air is used to produce and convey Oil Mist through a piping distribution system and then injects the oil mist into bearing cavities for lubrication.

• This equipment may be operating, on standby or in storage conditions.

• Some conditions that affect the system design are: Ambient Temperature, Area Classification , Project Specifications, and/or location and arrangement of equipment.


WHERE CAN OIL MIST BE APPLIED?

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• Common applications are pumps, motors, gearboxes, turbines.

• Industries such as HPI, CPI, Power, Steel, Pulp & Paper.

• Most anti friction bearings can be pure mist applications.

• Sleeve type bearings and gear boxes are purge mist applications.


SUMP LUBRICATION

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Trico Oiler

Slinger

Rings &

Dirty Oil


WHY PUMPS FAIL

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Bearings

40%

Static Joints

2%

Hydraulic

12%

Coupling

2% Other

1%

Seals

43%


WHY BEARINGS FAIL

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Disassembly 15%

Misalignment 13%

Insufficient Lubrication

11%

Particle Contaminatio

n 48%

Corrosion 4%

Overloading 4%

Other 5%


WHY MECHANICAL SEALS FAIL

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WHY OIL MIST WORKS

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Oil Mist Is The Ultimate Oil Filter

Typical Filtration 10µ

Oil Mist Filtration is 1 to 3µ


HOW OIL MIST WORKS

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Fresh clean oil is applied; outside contamination is excluded

Clean oil delivered in particle sizes of 1 to 3 microns

Wear particles migrate with mist flow

Bearings operate in clean oil and run cooler

Calgary Pump Symposium 2013

HOW OIL MIST WORKS


SUPERIOR OIL CLEANLINESS

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• Temperature Benefits;

• Bearing temperatures decline typically 10-20 degrees Fahrenheit with pure oil mist versus oil sump lubrication.

• For every 10 degree drop the bearing temperature L10 life increases 11%


GENERATION OF OIL MIST

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Vortex

Oil Mist Pressure Is 20” H2O or Approximately 3/4 PSI

1 Part Oil -------------------

200,000 Parts Air

• How Oil Mist is Generated

• Oil is lifted by vacuum, generated by high velocity air flowing through the vortex chamber. Oil is drawn up the suction tube and through internal passages around the vortex chamber to a point just below the orifice where it mixes with the air to form oil mist.


TYPES OF OIL MIST

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Dry Mist

• Size: Below 3 Microns • Used for Conveying

Wet Mist

• Size: Above 15 Microns • Used for Lubrication


CONVERTING DRY MIST TO WET MIST

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Oil Mist Generation Reclassification

Dry Mist In

(1 to 3 Micron Conveying)

Wet Mist Out

(30 Micron Lubricating)

Increase Velocity and Turbulence causes the Oil Mist

particles to impinge on each other causing them to

grow in size and become wet mist.

Orifice


LUBRICATION WITH OIL MIST

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Standard reclassifier for single

or double row bearings.

Single Row Radial Bearing on

3” Diameter Shaft = 3 BI or

.09 SCFM

Double Row Thrust Bearing on

3” Diameter Shaft = 6 BI or

.18 SCFM

5

0

1

5

0

2


LUBRICATION WITH OIL MIST

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• Vent/Drain of bearing housing is

very important

• Oil mist flow is required to apply

oil to bearings

• Restricted flow reduces the

amount of oil applied to bearings

• Bearing housing vent/drain

must be adequate to vent SCFM

flow entering from reclassifiers


SINGLE ROW BEARINGS

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Mist Flow for Bearing Lubrication

Vertical

Applications

Motor Brgs. &

Radial Brgs.

Flow through is always preferred.

A lways


DOUBLE ROW BEARINGS

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Mist Flow for Bearing Lubrication

Recommended:

Brg. Isolators

150 KW & Up

3000 RPM &

Up

Flow through is always preferred.

A lways

Vertical

Applications


BEARING CAGES

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INSTALLATION & APPLICATION

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The piping distribution system is the most critical part of any Oil Mist System.

Proper arrangement and slope is the key to proper operation.

Each piece of equipment i.e. pump/motor must have a drop line.

The drop originates from the top of the header and terminating at the mist manifold.


OPEN LOOP SYSTEM

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The Open Loop Systems, are the most commonly used. The coalesced oil and stray mist is routed through the vent drain port to the collection device.


CLOSED LOOP SYSTEM

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A closed loop system collects and reuses approximately 95% of all Oil Mist sent into the distribution system.

All coalesced oil and stray mist is recirculated back to the OMG for reuse.

These systems were designed for environmental sustainability, and for a cleaner work environment.


OIL MIST APPLICATIONS

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Pure Mist

• Also called “dry sump”

• Oil mist provides lubrication

• No oil sump for lubrication

Purge Mist

• Also called “wet sump”

• Used to purge the bearing housing

• Not primary means of lubrication


PUMP EXPERIENCE

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Pure mist lubricates operating equipment and protects and preserves standby equipment


MOTOR EXPERIENCE

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SYSTEM COST

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SYSTEM COST OMG $75K

Bulk Oil Tank $10K

Oil Mist Components $15K

Distribution Piping $15K

Installation $200K

Total Installed Cost $300K

SYSTEM INCLUDES 10 OH2 PUMPS PURE MIST

6 BB2 PUMPS PURE MIST

4 OH3 PUMPS PURE MIST

20 MOTORS PURE MIST

800’ HEADER PIPE


SYSTEM BENEFITS

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BENEFITS Pump MTBR is 2x to 4x over oil sump lubricated pumps; average pump repair is $15K

Motor MTBR is 4x to 6x over grease lubricated motors; average motor repair is $6K

Mechanical Seal MTBR is 2x over sump lubricated pumps; average seal/brg. Repair $10K

Reduced Repair Cost Results

20 pump process unit with 2 yr MTBR; oil mist has 4 yr MTBR

Value of repair cost over 25 yrs discounted 7% per yr is $1.7 M

Reduced Maintenance Cost

Checking, replenishing oil/grease on individual equipment is reduced/eliminated 47%

Assume cost of $2,500 per pump/year on 20 pumps w/o oil mist reduced to $1,000 with oil mist

Reduced maintenance cost over 25 yrs, discounted 7%/yr is $0.6M

Cost vs Benefits

Typical system installation of $300K and present value of benefits is $2.3M


PILLOW BLOCK BEARINGS

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EQUIPMENT TRAINS

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Pure & Purge Mist Combination


PURGE OIL MIST

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Required on sleeve type bearings.

Not as effective as pure mist on rolling element bearings.

Oil sumps benefit from purge mist due to the slight positive pressure and flow reduces/eliminates intrusion from air borne contaminates.

Oil Level

Controller

Mist inlet


AIR COOLER SOLUTIONS

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AIR COOLER SOLUTIONS

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MistLockTM Bearings MistLock Motors

Bearings & Motors Designed for Oil Mist

Oil Mist Inlet

Oil Mist

Vent / Drain

Oil Mist In

Case Drain

Oil Mist

Vent / Drain


MAGNETIC ISOLATORS

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•Magnetic Isolators

•Technology: Latest technology positive seal vs. non contacting device. It utilizes magnetic force to maintain faces in contact.

•Advantages: Positive seal not just a restriction device. It seals the bearing housing preventing leakage to atmosphere and contamination into the bearing lubrication. Enhances Oil Mist Systems and overcomes the potential objection of stray oil mist to the atmosphere.

•Disadvantages: Contacting device can be perceived to have possible wear and heat generation. Higher cost vs single labyrinth.

Positive Seal

Self Aligning

Eliminates emissions during operations and

standby conditions.

Eliminates leakage in all bearing housing

configurations and lubrication methods.

More effectively excludes external

contamination.

Enhances performance for Oil Mist Systems.

Easy installation and independent of machinery

conditions for proper face alignment.


LUBRICANTS FOR OIL MIST

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TYPICAL EQUIPMENT STORAGE

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OIL MIST STORAGE

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Crated Equipment Uncrated Equipment


STANDARD LUBRICATION

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Continuous

Maintenance

Large

Inventories

Many

Containers

Human

Intervention


ANOTHER METHOD OF LUBRICATION

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One OMG Per Unit

Reduced Inventory

Low Maintenance

Continuous 24/7

Limited Human Involvement

Lubricates Operating Equipment

Protects/Preserves Idle/Standby Equipment

Calgary Pump Symposium 2013 Calgary Pump Symposium 2015 40

Thank You

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Documents

UNDERSTANDING OIL MIST - Home - Calgary Pump · PDF fileB.Sc. in Mechanical Engineer in 2009 and recently ... Mechanical Seal MTBR is 2x over sump lubricated pumps; ... PowerPoint