LubriMist Oil Mist Lubrication

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1 1 LubriMist Oil Mist Lubrication

Colfax Businesses World leader in the development, engineering, manufacturing, distribution, service and

Approximate Historical Annual Revenue: $690 Million Excellence in welding and cutting solutions for

Approximate Historical Annual Revenue: $1.

2 Colfax Businesses World leader in the development, engineering, manufacturing, distribution, service and support of fluid-handling systems for critical applications in key industries. Approximate Historical Annual Revenue: $690 Million Excellence in welding and cutting solutions for manufacturing, fabrication and maintenance applications across a broad spectrum of industries. Approximate Historical Annual Revenue: $1.7 Billion Precision air and gas handling equipment for challenging applications, from heavy duty fans to rotary heat exchangers to process gas compressors. Approximate Historical Annual Revenue: $900 Million 2

3 Colfax Businesses RELIABILITY SERVICES COLFAX PUMPS DIVISION COT-Puritech Clarus Lubrication Systems Company Allweiler Houttuin Imo Pump Tushaco Imo AB Rosscor Warren Pumps 3

4 In absence of Oil Mist

5 Typical Sump Lubrication Trico Oiler Plug on Top Slinger Rings 5

6 Why Pumps Fail? Static Joints 2% Hydraulic 12% Coupling 2% Other 1% Bearings 40% Seals 43% 6

7 Why Bearings Fail Corrosion 4% Overloading 4% Other 5% Disassembly 15% Particle Contamination 48% Misalignment 13% Insufficient Lubrication 11% 7

8 Why Mechanical Seals Fail? 8

9 Oil Mist Generation & Delivery

54 Kg/cm 2 - Humidity: Maximum recommended dew point -4 C below minimum all-year

10 What do you need to generate Oil Mist? Instrument air, i.e. dry air: - Minimum supply pressure: 40 PSI, 2.81 kg/cm 2 - Maximum supply pressure: 150 PSI, Kg/cm 2 - Humidity: Maximum recommended dew point -4 C below minimum all-year temperature. Paraffinic or synthetic oil ISO VG No EP Additives or Viscosity Modifiers 10

11 What is Oil Mist? AIR AIR AIR Mist Out Instrument Air AIR AIR 5 ppm oil in air Oil Mist Oil Mist Pressure Is 20 H2O or Approximately 0,05 kg/cm 2 Oil Vortex Oil lifted by vacuum AIR AIR OIL MIST Oil mist will not support combustion or explode. 11

12 What is Oil Mist? Oil Mist Density: 1 part oil of 200,000 parts air (5ppm) Very homogeneous particle size Oil particles are 3 microns maximum (Dry Mist) Generator outlet pressure 20 water column (50mbar) Average temperature 17 C Clean mixture Non flammable Non toxic Ability to convey 150m with minimum condensation 12

Repair Simple Manual Controls Oil Tanks Main

Bulk Storage 285 ltr (75 USG) Oil Filter,

13 IVT Oil Mist Generator Embedded PC Monitoring +/- 50 Set Points Common Alarm to DCS Simple Switch-Over from Main to Auxiliary Oil Tanks for Maintenance or Repair Simple Manual Controls Oil Tanks Main - 34 ltr (9 USG) Auxiliary - 34 ltr (9 USG) Bulk Storage 285 ltr (75 USG) Oil Filter, Pressure Gauge, Oil Tanks Sight Gauges, Drain & Fill Connections 13

14 Oil Mist Delivery Oil Mist Particle Sizes Application & Lubrication Generation & Distribution 15 Microns Above Wet Mist For Lubrication 3 Microns Below Dry Mist For Conveying 14

Micron Lubricating) Oil Mist particles impinge on each

15 Converting Oil Mist Oil Mist Lubrication Dry Mist In (1 to 3 Micron Conveying) Orifice Wet Mist Out (up to 30 Micron Lubricating) Oil Mist particles impinge on each other causing them to grow in size and become wetter. 15

16 Oil Mist Benefits

The impact of Oil Mist Oil Mist is the Ultimate Oil Filter Typical cleanliness level ISO 4406 16/13/10 Beyond pre-filtrating the

17 The impact of Oil Mist Oil Mist is the Ultimate Oil Filter Typical cleanliness level ISO /13/10 Beyond pre-filtrating the oil and the air in the mixture, the cyclone generated in the Vortex separates the particulate from the Oil Mist fed to the system. 17

18 The impact of Oil Mist Oil Mist is the Ultimate Bearing Protector Positive Pressure 50mbar 18

19 The impact of Oil Mist 19

20 Superior Cleanliness Levels Oil Mist Lubrication Oil Mist Lubrication Filtration (β 5 >200) 20

21 Temperature Benefits Bearing temperatures decline typically 8-10 degrees Celsius with pure oil mist versus liquid oil lube For every 10 degree drop, the bearing L 10 life increases 11% 21

22 Other benefits Resulting from MTBF increase: Plant availability reduced loss of profit Reduced maintenance costs Reduced insurance premiums Automation of the lubrication process Lower consumption of lube oil, cooling water, energy Increased personal safety Increased asset safety 22

23 23 Distribution System Layout

24 How does an Oil Mist system look like? 24

25 Application Drops Each piece of equipment to be lubricated should be installed with a drop point originating from the upper header and terminating at the mist manifold 25

26 Mist System Designs Closed Loop System Open Loop System 26

27 Oil Mist Installed 27

28 28 Applying Oil Mist

29 Applying Oil Mist Purge Mist Also called wet sump Used to protect the bearing housing Not primary means of lubrication Pure Mist Also called dry sump Oil mist provides lubrication No oil sump for lubrication 29

30 Pure Oil Mist Pure mist lubricates operating equipment and protects and preserves standby equipment Mist Manifold and Reclassifiers Pump inlet connections 1/8 minimum; ¼ NPT is common 30

31 Between Bearing Pump & Motor Driver 31

32 Motors 32

33 Liquid Ring Compressors 33

34 Pillow Block Bearings Oil Mist Inlet Oil Mist Inlet Oil Mist Outlet 34

35 OH Pump, Turbine Driver & Gear Box 35

36 Rotary Lobe Blowers 36

37 Rotary Lobe Blowers Pure & Purge Mist Application Purge Mist Pure Mist 37

38 Cooling Tower Gear Box 38

39 Steam Turbine 39

40 Machinery Storage Machinery Preservation Yard Aerial View of Oil Mist Preservation Yard in Thailand 41

41 Long Term Storage 42

42 43 Economic Justification

43 Data gathering real case studies 44

44 Data gathering real case studies Maintenance Cost Analysis UNIT MAINTENANCE COSTS MAINTENANCE COSTS TAG 2 YEARS BEFORE OIL MIST 2 YEARS AFTER OIL MIST 611-G-1A G-1B G-1C G-2A G-2B G-2C G G-4A G-4B G-3A G-3B G-2A G-2B G-8A G-8B G-1A G-1B G-4A G-4B G-5A G-5B G-6A G-6B G-7A G-7B Total , ,737 Savings % 45

45 Investment calculator Insert Data Clean Form Customer Date Pumps Turbines Motors Total of Equipments MTBF Annual Failures Cost Repair Average Annual Repair Total Costs Lube Failures Oil Lubricats Consuption* Current Situation [Mo] EUR EUR Lt *Calculated for pumps with 5 lt carter and 4 oil changes in a year. **Considering that the shaft diameter average of the equipments is 70mm and have 3 bearings. Situation after Lubrimist System Pumps Turbines Motors Reliability Multiplicator Improvement Percenatge % New MTBF [Mo] Annual Failures Cost Repair Average EUR Annual Repair Total Costs EUR Lube Failures Oil Lubricats Consuption** Lt Oil Recovery (65%) Lt Real Oil Consuption Lt Savings on Repair Costs Annual Failures difference Savings in Oil lubricant Savings in Energy (2%) Savings in cooling water Manpower reduction Estimated Total Savings** Estimated Benefits Benefits EUR/yr % EUR/yr EUR/Lt EUR/kW EUR/h **these are just considerations and estimates and do not commit in anything the Group companies that make use of this projection tool. Lt/yr EUR/yr kw (AVG) EUR/yr m3/yr EUR/yr h/yr EUR/yr EUR/m3 Non Quantificable Benefits Insurance Costs Work place safety Automation Positive Environmental Impact? Investment Calculation Investment Your Investment Estimation Commonly the number of mist distributors is the number of pumps. 46

46 47 Reference Information

References Pure Mist is Preferred The most important characteristics of pure mist is that bearing operating temperatures and friction in rolling element bearings is reduced.

47 References Pure Mist is Preferred The most important characteristics of pure mist is that bearing operating temperatures and friction in rolling element bearings is reduced. Hence a lower operating temperature equates to longer bearing life and lower energy loss equates to savings, page º to 10º C cooler, page % to 25% less friction, page

48 References Pure Mist is Preferred Reliability: Documented evidence proves that pumps can run more than eight hours after the oil mist flow has ceased. Improved reliability of Oil Mist Generators supports pure oil mist. Back-Up Units: Usually installed for emergency purposes when pure mist is used on a large scale

49 Questions? 50

Oilmist Lubrication Applications In Refineries- Installation & Maintenance Issues

Oilmist Lubrication Applications In Refineries- Installation & Maintenance Issues N Laxman Deputy Manager- Maintenance-Rotary Hindustan Petroleum Corporation Limited Visakh Refinery ABSTRACT Oil mist lubrication