Book Bits

From "Lubrication for Industry":

CASE STUDY III - SYNTHETIC VERSUS MINERAL-BASED LUBRICANTS IN ADVERSE SITUATIONS PRODUCE SIGNIFICANT SAVINGS

For the majority of situations, chemical wear first-generation lubricants perform adequately; for adverse conditions, such as extreme temperatures, the use of premium lubricants really pays off.

A hydro utility study on energy reduction through lubrication engineering studied the use of synthetics in air compressors. The compressed air unit in the study was a 150-hp screw-type compressor that was recently rebuilt and utilized a standard 32 weight lube oil. A compressed air audit company gave the conveyor a clean bill of health. The power was monitored under varied load conditions and its power consumption noted. Because compressors run extremely hot, synthetic lubricants allow the press to run cooler, they also "desludge" or clean the compressor and allow it to run more efficiently, thereby reducing power consumption. Synthetics also allow for extended changeout intervals. The standard lubricant was replaced with a 32-weight fatty acid ester-type synthetic (second generation) lubricant. An energy reduction of 7.3% was gained by changing the lubricant, and the changeover also resulted in a cooler running compressor.

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Today's Tip

• Buffing of cylinder lines in diesel engines can lead to high oil consumption. Three common causes of “buffing” include:
  
  1. Deposits on piston crown land area (just above top ring)
  2. Dirty oil
  3. Fuel dilution

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Q & A

"We are in the process of implementing a contamination control program in our plant. We want to work smart and get the most bang for our limited budget. Any ideas?"

One of the smartest things you can do is to keep contaminant particles from entering your lubricants so that you don't have to remove them. The cost of excluding a gram of dirt is probably only 10% of what it will cost you once it gets into your oil. Some preventable ways that contaminants get into your oil include:

• new oil

• ventilation and breathers

• seals

• wear generation

• service and manufacturing debris

• filter dumping

• wash-down sprays and solvents

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