TECHNICAL NOTES ON LUBRICATION Cob. BURNS H,S.CLARE & COs LTD. TILE 1 PRINCIPLE OF WEAR AND FRICTION 2 TOR! OF LUBRICATION 3 ‘WYPRS OF LUBRICANTS Solids Fluids Greases Gases "ANDARD, TESTS FOR LUERICATS General Physical Propertiés Oiliness, Boundary Lubricating Ability, Load Carrying Tests Resistance to Adverse Cunditions Corrosive Zffects of Lubricants Specific Application ‘Tests 5 SOLID LUBRICANTS Properties of MoS, Graphite 6 FLUIDS Properties of tiinerel Gils, oly Alkylene Glycols, Esters enc Diesters, Silicones. 7 GASES owe Properties of Difforent Tes of Gronse, Grease mixing and’ filling of bearings.PRINCIPLES OF WEAR AND FRICTION Although friction is sometimes of concern to the engineer, he is much more concerned with wear since this leads to expensive replacement or repair of worn parts. There are four types of wear: 1 Adhesive Wear ‘This takes place when surfaces come into direct contact with micro welding between the surfeces. Some metlas are particularly prone to this, namely, Stainless Steel, copper. The engineer has found, from practice that some metal combinations give little adhesive wear and these are often used as bearing materials, i.e., steel on brass or stainless steel. Clearly, if a lubricant is interposed between the surfaces adhesive wear is reduced. » Abrasive Wear This occurs either when one surface is hard and rough or when haré abrasive particles are introduced between the surfaces. The engineer makes use of abrasive wear as a means of machining, ive., with grinding, either by using a rough hard wheel or an abrasive paste. Lubrication will only reduce abrasive wear if the lubricant film produced is thicker than the diameter of the abrasive particles. ‘The only effective ways to reduce abrasive wear are to a) stop the abrasive particles getting in between the surfaces, b) to usc materials which are harder than the abrasive terial, NOTE: If one hard and one soft material is used in a bearing, the harder material will wear as the abrasive will imbed into the softer material.Corrosive Wear This is where the surface of the metal is changed chenically, usually oxidised (or rusted) and the resultant material does not have the properties of the original metal and is rubbed away from the surface and lost. Generally, the higher the temperature the more significant is corrosive wear. It can, and often is, reduced with lubricants but it can arise from the lubricant if it becomes contaminated with acids or if the lubricant breaks down to form acids. ‘The degree of corrosive wear is also effected by the materials being used. Clearly, stainless steel is less affected than mild stecl. Fatigue Wear The sufaces of bearings are subjected to stress as the load is transferreticfrom one surface to another and the stress can be high, perticularly in rolling bearings and on gear teeth. The stress can be applied and reduee millions of times. Under these conditions the structure of the surface of the metal can break down and the surface will break up or: flake away. Generally, lubricants have Little effect on fatigue wear except to make sure it does not occur prematurely by preventing "hamner" on the surface or preventing wear scars from which the flaking will commence. friction Engineers have learnt to control and use friction. for instance, a high friction is required on brakes and a low friction in the wheel bearings of your car. Generally, where there is a high wear rate the friction will be high as well. In'order to calculate how much power is lost to friction, or how much effort is required to move a party ithen the engineer will use the coefficient of friction (uy) which is independant of the load applied but is dependant upon the materials of the surfaces in contact, their rough- ness, the lubricant used and the epeed. The calculation is made by this very simple equation: Force required to move = Confficient of Friction x Load or Fo = ph Although somet‘mas w will be quoted for a particular lubricant, the materials, surface finish and speed should also be specified to be precise. h may be as low as 0.02 and generally, engineers are not worred, wear can be accepted until u exceeds 0.15 or 9.22- FORMS: LUBRICATION ‘There are two basic forms of lubrication: Fluid Flox or Hydrodynamic This is where pressure is created in the fluid between the two surfaces and the pressure is sufficient to keep then apart. ‘his form of lubrication is characterised by Zero Wear Low Friction (u generally less than 0.05) Friction Increases with Speed ction Decreases with Fluid Viscosity ‘The most important characteristic of the lubricant withethis form gr lubrication is the viscosity and so any liquid can be used, although the most common is mineral oil. Fluid floy lubrication has obvious advantages, giving low friction era bearings which do not wear out. It can rarely be achieved because ~ The bearing has to be full of lubricant, i.e, continuously lubricated. The corract viscosity must be used, oils vary greatly in viscosity with temperature, Fluid Pow lubrication requires a given speed to be reachedy ge tr does not occur on start-up or when running helow this speed. The pressure generated between surfaces is Limited, so the joad which can be taken is limited or low. Boundary Lubrication This 1 the condition the najority of bearings are running under. Th this «se, the surfaces are not completely separated bit are dicing contact with just an oxtrenely thin film ef lubricant presshy pase the boundary fla, since it is stationary and not moving with the main flow of fluid. the friction and wear rate 1s dependant on how effective the lubricant we ch these extrenely thin, alnost molecular ilns and the nature of the bearing materials.In the carly days of engineering, it was soon recognised that natural of18 and fats (Castor Oil, Palm O11, Mutton or Becf Dripping, Butter) were good lubricants. This is because all these contain fats which are very adhesive to the surface and form a good barrier and therefore good boundary lubricants. The limitation of the hatural oils and fate i the low temperature at which they melt and break down chemically (less than 150°C.), so they are only able to withstand compar itively low loads. Mineral oils are far less effective boundary lubricants but are widely used as they are cheaper and far more stable chemically. With modern refinery techniques producing "purer" oils, they are less effective lubricants than the older crudely refined oils and s0 additions are made to improve the boundary lubricating properties. ‘These fall into two categories a) additives which are adhesive to the surface and work by thoir phyusical presence, i.c. fatty oils, graphite, MoS, b) additives which react chemically with the metal surface to form a lubricating film - these are generally termed Extreme Pressure (EP) additiv SP additives are organic materials containing loosely bound chlorine, sulphur or phosphorous and when high temperature is gonerated on the surface they react chemically with the metal to form the chloride, sulphide or phosphide. Clearly, the chemical EP additives cannot be used at high ambient temperature as they will react with the metal and cause corrosion. ‘The chomical EP additives are formulated to work with steels, and show a very good performance on test machines using hard steel test pieces. In practice, this means they are effective - where hard steel runs against hard steel such as on gear teeth, but if more rormal soft to hard bearing metal combinations are used, they are not effective. In short, chemical FP additives have their place but are Limited in application. Of the surface adhesive additives, by far the most effective are the solids Molybdenum Disulphide and Graphite. From the preceeding considerations it is possible to make a list of the desirabie properties of the ideal solid lubricant, namely - Good Bonding High Load Re Low Friction Wide Temperature Rang> Chemically Inert sistanceTYPES OF LUBRICANT SOLIDS Us is not usually recognised that solids can be used as a lubricant, By a solid, we mean material which does not flow and once sheared it breaks down into smaller pieces. nan in the street is ice, and we know how slippery that is! Many types of solids can be used and they fall into three categorie ‘The one most. commonly met by the 1, Lanellar Solids ~ such as MoS,, graphite, tin suiphide, tungsten sulphide and talc. 2. Plastics « PTFE which is a material that does not wot or adhere to surfaces. 3. Soft Inert Powders ~ such as zinc oxide, chalk and Hi-load solids. To understand their use, we need to know the properties, particularly Of MoS,, graphite, PTFE ‘The general properties are in the following table: S01 SOURCE Mos, Natural = Mainly U.S.A. Graphite Natural - Ceylen Synthetic 0£1/ Coxe PTFE Synthetic Watural UK STRUCTURE Lamellar Lamellar Polymer. (Piastic) Carbonates PURITY Over 9% varies ~ From 60.0% To 99.5% 100% 98% HARDNESS Very Soft Sort Soft to Medium Medium Solids, when used on their own, will give a completely dry film, yet they mix quite greatest quantity is used. ily as an addition to oils and greases and this is how theEuuros We all know in our own minds what a fluid or liquid is. However, scientifically it is a material which obeys Newton's law of fluids, which is that the force required in shearing is directly proportional to the rate of shear (see appendix for graph ~~ Mineral Oils ‘These consist of a mixture of very large numbers of hydrocarbons which are obtained by refining crude oil. The lighter products are taken avay first with the heavy bitumens and tars being last. Mineral oils would come about’ half-way in this process. ‘The change of viscosity of mineral oil when subjected to temperature is reasonable and accetpable, but it has only a medium resistance to both high and low temperatures. Synthetic Fluids Synthetic fluids, for example, esters, diesters, polyalkylene glycols, are man made fluids that are built up chemically fron raw materials extracted from mineral oil, so mineral oil is not conserved by using them, Unlike mineral oils, they are pure substances and not 2 mixture so they are not such good boundary lubricahts. As thin films ttisy do not haves load carrying properties. They are able to cope better with extreme temperature or wide temperature range. However, being synthetic they will invariably be more expensive - up to 15-20 tines more for silicones. water Not many people realise that water is used as a lubricant, probably the main application that springs to mind is on turbines. Clearly, water is of a very low viscosity and does not contain any boundary lubrication properties. For this reason bearings using water have to be very carefully designed and to precise tolerances. ‘The properties of mineral oils, synthetic fluids and water are compared in the following table, with regard to high and lov texcerature resistance. Viscosity Change high ‘ow with Fluid Temperature Temperature Temperature ost Mineral 011 Good Hediun Medius Medium synthetic : Good noe Very:Good: Medium S004 Righ Diester Poonr Very Good Good High Polyalkylene Glycol Good Very Good High Silicones Excellent Excellent Extra High Water Poor Very Good Low >Greases Grease is a semi-fluid solid which resists the initial load before shearing occurs. As the speed of shear increases, the force required increases linearly. Grease has a base fluid with a thickening agent and to increase performance various additions are made to increase load capacity, oxidation resistance and corrosion protection. It’ is possible to use the fluids mentioned earlier, such as mineral oil, synthetics and their derivatives, as a base fluid. ‘The thickening agents are of two types: 1, Soaps made from Vegitable and animal fats, similar to hand soap, which hasa 3D web-like structure to hold in the ofl. 2. Extremely small inert powders with high surface adhesion to the fluid. Grease is made by initially mixing the.base fluid and the thickener The additives used to increase load carrying ability can be in the form of solids or chemical EP agents containing sulphur, chlorine or phosphorus, Oxidaiton inhibitors are used to increase the Life of the grease at high tempergturs. Corrosion protection is particularly important in ball bearins and powerful corrosion inhibitors are used in this type of grease. With grease manufacture, not only the component raw materials are important but the techniques and know-how on manufacturing and blending, are juat as important if the greases specification is to be net. Gase! When we talk of gases as a lubricant, we really mean ‘dry air’ (oxygen and nitrogen). ‘This is a fluid with extra complications in that it {2 compressablo, ‘so:hat pressure increases the voblme decreases. This poses extra problems in the design of bearings. This is a field we are not concerned with as there is no opportunity to make and sell air!oe aa STANDARD TESTS FOR LUBRICANTS Tests for lubricants can be divided into five groups: 1. General Physical Properties. 2. Oiliness, Boundary Lubricating. Abilify or Load Carrying Tests. 3. Resistance to Adverse Conditiona. 4. Corrosive Effects of Lubricants. 5. Specific Application Tests. GENERAL PHYSICAL PROPERTIES Solids ‘These measurements are often made on solids although the method of measurements has not been standardised, namely, hardness, density and particle size. Hardness is measured by comparison with other solid materials, by means of the Mohrs Scale. This is a rating from one to ten, with ten being the hardest, namely a diamond, and one the softest with talc. Various materials are used as intermediarios and it is really a Geologists scale for rocks. Density is simply measured by weighing in and out of water (or other Liguid of known density) and is quoted as being relative to water. Solids are used in powder form, often incorporated in oils or greases and the particle size is important. Where this is fairly large, it is measured by sieving through a given mesh oP screen, and measuring the percentage which goes through, or expressing the particle size as "All through"a given mesh size if 100% goes through, This, of course, only defines the msxinum particle size. For measuring th> average particle size, or assessing powders so fine they all go through the finest sieve, the particle size can be measured with a microscope or by more sophisticated techniques of passing air through the powder om light through a suspension of the powder and measuring how muca goes through. These techniques are always used where Pouters with an average particle size of less then 10 microns are used. Clearly, the purity: of the solid lubricant is important, especially With naturally occurring materials such as graphite or MoS,, This is determined chemically and a purity in excess of 98% must be used to avoid the inclusion of foreign matter which may be abrasive.small amount of working or shearing - 60 strokes with a grease worker - which is, essentially, a plate-like piston with small holes in it. To really determine to what extent a grease softens when subjected to a greater degree of shearing, such as found ina small gearbox or when being pumped through an automatic grease system, the Prolonged Worked Penetration needs to be measured. This is done in the sane way as Worked Penetration, but instead of using just 60 strokes with the grease vorker, 10,000 strokes are made and sometimes even 100,000 strokes. ‘The result is generally quoted as the increase in penetration, a grease giving less than 30 increase is considered very resistant to shear. A more sophisticated shear stability test is the Roll Stability {ASTM D1@31) illustrated in the Appendix. With this test, the pene~ tration being measured before and after shearing, The increase in penetration is expressed as a percentage and should not exceed 15-20% for a good grease. This can also be done at elevated temperature where greases are expected to operate at high tenperature. ‘The National Lubricating Grease Institute has classified greases according to their penetration from: '0G0* which ts so soft. as to be almost liquid, through to '6", which is hard as butter from the refrigerator. The most commonly used creases are grades '1' and '2'. ‘The penetration range for each N.L..G.1. will be found in the Appendix. This like the 180 VG numbers is boing used internationally. As you have seen from the above, it is necessary to consider three properties; viscosity of base oil, penetration or hardnoss and change in penetration when looking at. the general physical properties of a grease, in order to onsure similar punping characteristics and o film thickness within a bearing OULINESS, BOUNDARY LUBRICATING ABTLITY, OR LOAD CARRYING TESTS Many machines and tests have been devised to measure this most important of properties. When the oil film becones so thin that it is pierced so that metal to metal contact occurs, with oniy a molecular film of lubricant present, the ability of that lubricant to prevent wear, by adhesion, can make the difference between success and disaster. Clearly, in this situaiton the properties of the metal surfaces, which are in contact, must be taken into account and what may be an effective lubricant on very hard, polished stes! surfaces, may not be 2ffective if one of the surfaces is a comparatively soft brass or bronze. The three machines considered here use very hard steal surfaces and generate extremely high surface pressures, which can only be produced, in practice, if similarly hard mateials are used. These tests arenost coinmonly used for measuring the extreme pressure properties of the lubricant arising from the use of chemically active additives which areeffective by ‘etching’ or reacting with the metal surface to form the chloride, sulphide or phosphide of the steal. ‘hey can, and are, also used in assessing the lubricaitng properties of Solid lubricants and fatty acid and ester additions, but the resultsShell 4rBatl Machine The 4-ball machine is a simple test rig for testing the extreme pressure and anti-wear properties of oils and greases. Several types of test procedure can be employed, but the most conon used is as layed out in tne Friction and Wear Tests for Lubricants ~ 1P239, ‘This method covers the determination of lead carrying, anti-friction and anti-wear properties of lubricating oils and greases. ‘The precise contact conditions existing in the 4~-Ball configuration are rarely reproduced in practical applications and therefore care should be taken in the interpretation of results. The 4~Ball machines consist, assentially, of @ device by means of which a bearing ball may be rotated in contact with three fixed balls which are emersed in the sample. Different loads ave applied to the bails by means of weights on a load lever. Provision can be made for the control of the ambient temperature. The upper rotating ball is held in a special chuck at the lower end of tne vertical spindle of a constant speed, electric motor, operating at 1450-1500 r.p.m. The lower balls are held in position, against each other, in the steel cup by meana of a clamping ring and lecking nut and are securely fixed so they cannot rotat. The cup is supported to allow horizontal displacement and alignment of the bearing, so there is an automatic alignment of the three lower balls against the upper ball. The tebt is usually run for sixty seconds and then the wear scars of the three lower balls are measured, by means of a microscope and the scar diameter, in millimatres, averaged. A number of test runs ar? made, commencing at 49 kilogratene load (using new balis for each test run), until a load is reached at which welding and seizure occurs within the minute's running. This is reported as being the Weld Load in Idlogramnes The Mean Hertz Load is also reported ~ this is a single number reported as a load in kilogrammes, which is used to express the overall wear load diangram for twenty tests made below tre Weld Load. Tt is, in fact, the average load in these tests corrected for the deformation of the balls due to the loading and the actual wear scar dianeters measured. In this way, the ability to reduce waar 4s taken into account. It is possible, therefore, to have lubricants with the sum weld load but difforent Mean Hertz Load, and the lubricant with the higher Mean Hertz Load will nave produced, on average, smaller wear scar diameters and therefore is better at preventing ‘earken Wear and Lubricant Testing Mach Extreme pressure properties method 1P240. The principle of this machine is the application of a pivoted test block (steel) °to a rotating cup (the outer ring of the Tinken bearing) in such a way that tne pressure of application and the frictional drag between the test cup and block can be measured. The cup is rotated at 800 r.p.m. znd the of] on grease, wing tested, is continuously fed onto the ring. The test is run for ten minutes and the wear scar on the flat test piece examined. The test is run at successively higher loads (at 51b. increments) until scoring takes place, or until the edges of the wear scar become uneven, showing that metal pick-up has occurred. This is termed the Score Value, The test is then repeated for the load preceeding the scone value and providing on this second test no scoring is in evidence, this is termed the 0-K. value (see Appendix for illustrations of wear scars at 0.x, and Scoring Values) . ‘alley Machine sure test IP 241, ‘the test pisces used in this aachine ft of a quarter inch dianeter steel journal and tw> ‘V' blocks. The steel journal is held in a vertical shaft by a brass shearing pin inserted through a hole and the jjdurna?, the vertical spindle being driven at a standard speo¢ of 200 r.p.ri. by an electric motor. ‘Two lever arms, separately pivoted behind tha vertical spindle, have selfaligning recesses in then and take'Y blocks, which are aligned vertically and clamped around the steel journal, he lead is applied by spring loads? mechanisus consisting of a horizontal spindle with a right and left hand thread at opposite ends. At the centre of the spindle is a large eatchet wheel, which, on rotation increases the load by squeezing the twolever arma tozether. ‘The load applied is registered on a loading dial which records the load applied to the blocks. an accentric driving paul can be used for turning the ratchet wheel and so applying the load at a standard rate; it may also be turned by hand. As wear takes place, it is necessary to aove the two ‘V’olociss closer together to maintain the specified applied load. The distance of movenent, expressed in Wear Teeth (one wear tooth is equivalsnt to 2.00141 iss.} is a measure of the amount of wear, Tha torque set up by the journal rotating against the 'V blocks is indicated by a hydraulically operated pressur2 gauge, ta2 ‘VY! blocks and the entire load mechanism being free to tnen about the axis of sho test journal. The two 'W! blocks and the journal are enersed in oi in the metal oil cup, which is supported on a metal tray incorporating an electrical heater, A general arrangement of the machine is given in the appendix. The test is carried out by running the rachine for one minute at successively higher loads, the increments being 250 lbs. The torque is measured and the test is continued until there is either seizure ov a very sudden increase in torque, The load st which this cccure in reported as the load carrying capacity IP 247, Method §. The change :s weight of the test sournal and 'Y° doc! ir visual appearance, is “ecorded in this Hethot but <% quoted ia speci ication:‘The reproducibility of the results from one machine to another are not as good as with the 4-Ball and the Timlen machine, since the indicated load is subject to variations in manufacture, It is most useful in testing dry film lubricants, but Rocol rarely use it for Company oils or greases. RESISTANCE 10 ADVERSE CONDITIONS ‘three conditions have a great effect on lubricents and are often the cause of lubrication problems these are: High Temperature Low Temperature Water Contmaination High Temperature In all oils, the viscosity falls with increase in temperature. However, there are large variations in the rate at which the viscosity falls with different oils. The Viscosity Index (IP 226) of an of] is an indication according to a standardised (1ST) scale of resistance to change in viscosity with temperature. The scale is based on standard reference oils, a value of 0 Y.1. being adopted for a Sixed rapid rate of fall of viscosity with increase in temperature and a value of 100 V.I. for a certain relatively low fall. A I in excess of 100 can be obtained by the blending of special additives (NT improverts) and will alse be found quoted for synthetic lubricants. ‘the effect, with oils, of different viscosity indices is demonstrated in the following table and in the chart in the appendix. Viscosity Cst Viscosity Cst oun BE HOD en, a SE INORG. vio 952 20 VI 5¢ 452 20 VI 100 250 20 Clearly, if an oil is required to operate over a wide temperature range a high viscosity index is desirable but it should be borne in mind that there is still a large drop in viscosity, even with oils with a high viscosity index. Although the viscosity index gives an indication of tne change in viscosity with temperature, it cannot be used as a method for determining viscosity at a giver temperature since it is an impirical number. vature Charts are available which enable viscosity temperature data to be plotted as a straight ‘ine. These enable the kinematic viscosity of a particular oil to be determined at any given temperature, by plotting on the chart its viscosity at two different temperatures and drawing the straight line for the oil. ‘The viscosity at any desired temperature can thon be read off fron the line, These are accurate over a very wide temperature rangs from the cloud point of the ofl, to at least 280°C. Viscosity TemHigh temperature causes oil to oxidize which produces an increase in viscosity and the formation of acidic materials. Cleariy, the rate of oxidation will effect the life of the oi} as the reason for changing en oil when it is used at a nigh temperature is that oxidation has occurred. Many factors besides the oroperties of the oil and temperature can affect the oxidation: rate, the degree of exposure of the oil to air, the presence of iron or non-ferrous metals which can act as catalysts. ‘The Oxidation Test for Lubricating Oil (IP148) makes an assessment by bubbling air through a sample of oil heated to 200°C. for a period of 12 hours, the viscosity (at 40°C.) being measured before and after the test, the increase in viscosity being quoted as a ratio. Although this test is at a very high temperature over 2 comparative)’ short period, it is useful in assessing oils where ovidation is Likely to occu and is of much more general application than the very longer term teat (IP280), used for assessing the Oxidation Stability of Mineral Turbine Oils. ‘The base ofls in greases are subject to the same thinning with increase in temperature and oxidation as oils. And, although greasesbecome softer with increase in tenperature, this effect is not measured. Many greases, all soap thickened, become liquid at high temperature. ‘This tenperature is not sharply defined as with pure substances but it is assessed by the Drop Point (IP31} test. This is the temperature at which a grease will drop through a small cup, having a 3nm. diameter orifice in the bottom, and is generally taken as the temperature at which the grease becomes liquid. Clearly, the grease cannot be used as a grease above this temperature and in practice it is found that the maximum temperature at which a grease can be used is 20 or 30°C. below the Drop Point, due to excessive loss of oii from the grease by bleeding or separation. Bleeding of oil from a grease can occur under non-extreme conditions and the test used to measure this is the Oil Separation on Storage (IP 121), where 2 sample of grease is supported on a metal gauze cone and a light pressure is applied. The quantity of oil separated through the gauze cone is then sieasured end expressed as a percentage. The standard test calls for it to be done at 40°C. for a period of 42 or 168 hours. ‘The test can easily be done at higher temperatures and for special high tempeature greases this js often done. Low Temperature It is well know, chat at low temperatures both oils ané greases becone thicker and this can lead te excessive drag or friction. The use of the Tomperature/Viscosity Chart will give a measure of viscosity of the of1 whilst it is still liquid. Unlike pure liquids oils do not have precise freezing points as the different fractions will solidify at different temperatures and so a sponge-like structure is formed.The minimun temperature at which an oil can be used an 2 liquid is assessed by tie Pour Point (iP 15) which is the temperature at which the oil wil! just flow in a tube 30 nm, in diameter. By careful control of the cooling vrocedure, good repeatability is achieved and it has been found in practice that this gives a good assessment of the minimus temperature at which an oil can be used, provided the high drag erising from the very high viscosity of the oil just above the Pour Point is acceptable. ‘There is really no comparable test for greases, consideration of the viscosity and pour point of the base oil will give some indication of the lowest temperature a grease is suitable. This information is not generally included in specifications for greases but it should be obtained when operation at a particularly low temperature is required. ‘The Low Temperature Torque Test ~ Lubricating Greases (IP 168) is really a functional test, the starting or initial breakaway terque and the running torque (at 1 r.p.m.) being measured at a given temperature. fon 20 mn. bore ball bearing. The torque is quoted in Nn (1kg. = 9.806) or gn. cms. This test can be useful in comparing one grease with another and ensuring consistency of performance at low temperature, but cannct be interpreted to predict torques for different bearings. Water Contamination It is said that o11 and water donot mix. This, however, is true only if one is gently poured into the other at normal ambient temperature. If the mixing is violent and the temperature high, emulsification will occur and the time required for separation to occur can vary over a wide range. It is well appreciated that contamination of oils with water should be avoided but on some machines, such as steam turbines or rolling mills, this is bound to occur and thea it is important to use an oil which will quickly separate, so that oil only is recirculated fron the oil reservoir and provision can be made for draining off the water from the system. The avility of an oil to separate quickly is measured by its demulsifica- tion number (IP 19). In this test, oil is emulsified with an equal volume of steam condensate by passing dry steam into the oii, the time for the two to separate (at 95°C.) is measured and the denulsification number is that tine in seconds. This test 1s conmonly applied to turbine oils (both new and used) and should be considered for oils used for other applications where emulsification i likely to occur. ‘The twomost important considerations when creas? is contaminated with water are; is it going to be easily washed away, and secondly, will it prevent corrosion. ‘The Water Hash vit Characteristics of Lubricating Greases, IP 215, gives a good measurs of the former. The grease is packed in a ball bearing inserted into a houning and rotated at 600 r.p.m. Water at the test temperature impinges on the housing at the ratio of 5 cc. per second. ‘The amount of grease washed out in one hour is measured and expressed as a percentage of the total fill. A good water resistant grease will give 2% or less. =16-‘The Dynamic Anti-Rust Test, IP 220, is very searching, especially with regard to thin films of grease as found in anti-friciton bearings and the method ro assessment is simple and meaningful. With this test, a ball bearing is greased up in the normal way and 20 ml. cf distilled water is introduced into the plummer block. The bearing is then run, under no load, at 80 r.p.m. for eight hours and then allowéd to stand for sixteen hours. This is repeated three times, the last standing period being 1CShours and the outer ring track examined for corrosion. This is assessed fro m0 (no corroyion) to 6 more than 10% corrosion), see appendix for details of rating. ‘The intermittent running is to simulate running conditions often met in machines running for only 8 to 10 hours a day and a good rating of 0 to 2 ensures that failure of bearings does not occur due to corrosion from water condensating within the bearing, when the machine is stopped and therefore cooling down. CORROSIVE EFFECTS OF LUBRICANTS Mineral oils, in themselves, are not corrosive tometals, and in fact provide a protection from the normal process of oxidation by excluding both air and moisture. Oils and greases can have a corrosive effect if they are: with acidic materials. 1. Con! 2. Blended with chencially active #P additives. 3, Subjected to temperatures high enough to break down the additives used to form acids. inal ‘Two tests are widely used to assess the corrosive effect, the Copper Strip Tarnish Test (IP 154) for oils (it can also be used for solvents as well) and the Copner Strip Test (IP 122), for greases. iis you will guess from these titles, the assessuent is made in relation~ ship with copper, which is a metal susceptible to oxidation and staining and gives a result which is very easily visually assessed. The procedure in each of the tests is basically the sams, being to take the strip of copper and to carefully polish it and clean the surface 20 that there is no oxide present, and then to enierse the copper strip in the oil or grease being tested. Neither the temperature nor the duration o° the test is specified, but in quoting the results from the test these conditions are invariably siven. with tne Copper Strip Test for grzases the result will either be auotad as being negative, or the degree of discolouration obtained, given either black, g ay or not black or grey. The CopperStrir Tarnish Test for otis has a classification system from 1 to 4, according to the amount of tarnisaing seen on the strip at the completion of tie test. The designation and description of the degree of tarnish will be found in the appendix. Although these teats ere generally used for assessing new lubricants, there is no reason why these tests should not be used with used oils or greases if thare is reason for thinking that a used of} hy‘This technique of testing for the corrosive effect of lubricatns can, of course, be adopted for different metals or even different metal combinations. This has, in fact, been done by David Brown Gears, who have developed their own test which examines the effect of the lubricant, when steel and phosphor bronze are in contact. With this test the staining on the phosphor bronze surface is assessed, using a classifica- tion systen similar to that used in IP 154, Details of this test method will be found in the appendix. SPECIFIC APPLICATION TESTS ‘The only way to be one hundred per cent sure that a lubricant will give satisfactory service on a particular machine, is to test the Subricant on the machine in question and the operating conditions which can be expected. This, of course, is enormously expensive because one or two examples Of the machines would have to be run until they are worn out, but more importantly because to run many machines under carefully controlled conditions for the very long periods of time necessary, will involve an’ expenditure many times the cost of the machine itself. This procedure does, however, sometimes have to be resorted to, especially if the machine is going to b2 mass produced and is going to be sold on a world wide basis and used by completely unskilled operators. Tests of this nature would never become accepted as a test procedure for specifying oils but there are a number of tests where the individual elements of the machine.are used as the test specimens. Two such tests are worth considering; one using steel spur gears and the second ball bearings. Load Carrying Capacity Test for Oils IAE Gear Machine IP 166. This method of test may be used to assess the relative load carrying capacities of oils when used to lubricate steel/steel spur gears. The results are genreally presumed to be appiiceble also to steel/steel helical gears. A special gear rig is operated for a series of: short periods, at increasing loads, the oil under test being used to lubricate the test gears. The performance of the oil fsevaluated by the load at which the scuffing, or scoring on the gear faces occurs. ‘The gear test rig is a power circulating type of gear test rig, of the type developed by the Institution of Automobile Engineers employing special test gears, and is known as the IAE Gear Lubricating Testing Machine. The rig consists of two gear boxes containing, respectively, the test gears and the power return gears, coupied in parallel by two- portion shafts, one of which carries a split coupling so that the torque can be applied to the system. The machine is capable of accepting loads up to 209 lbs. on the loading lever, which corresponds to 300 1b/ft. torque and approximately 12000'1b. per inch tooth face pitch line loading. Tests are carried out under five different conditions, with the speed varying fron 7000 to 6000 r.p.m. and the oil temperature from 60 to 100°C.‘SOLID LUBRICANTS Molybdenun disulphide is the ideal solid lubricant as it has the follow- ing properties: Low Friction igh Pressure Resistance Bonds to all Metals Wide Temperature Range Chemically Inert why do we use other solids as well. The anow2r lies in the drawbacks of MoS, which ares iiigh Cost Plack Colour Not. Approved for Incidental Contact with Food Graphite is not able to withstand such high pressures as MoS, and it does not bond az well to metal surfaces. It is considerably cheaper and it does have advantages at high temperature in that it can stand a higher température ~ 609°C. and the oxtdation products CO and CO, are harmless gases. Jt is generally used where pressures are not particularly high and where very high temperature lubrication is required. Graphites can vary very greatly in quality, tie low purity graphites being very cheap always use. high purity or as it is termed, high carbon graphites, but it snould be borne in mind that competitors may well use cheaper graphites and clearly poor performance will result. PTFE, (Polytetrafluoroethylene) is a slippery plastic with a very low coefficiont cf friction. It is most commonly met on non-stick frying, pans and baking tins Due to its poor bonding it will not withstand high pressure and cannot be used over 259°C. It is white, clean and non-toxic so car be used for food Lubricants. If burnt, PYPE forms toxic fumes resulting in polyner fever with symptoms similar to severe influenza. Clearly, it cannot be “sed anyshere near tobacco and contamination of cigarettes must be carefully avoidedPLUIDS Everybody is familiar to some extent with mineral oils. sven the non-technical motorist will know what it looks like from pouring it into his car enginees.and will know that oil becomes thick on a cold morning. ‘The nunber of diffecent mineral -6ils available for lubrication runs into dozens. Besides different viscosities, variation in properties occurs according to the source and the distillation and refining techniquos used. This is to be expected with a material shich occur's naturally. Minera? oil based lubricahts are used in over 90% of applications and the reasons for this can be surmarised as follous: They 1, Have moderately good boundary lubricating properties. Are chemically stable and prevent corrosion in a wide range of viscosity. d over a fairly wide temperature range. 2, Availeb! 4, Can be 5. ihre moderately priced. ‘This means that: with the aid of modern additive technology to improve particular aspects of these properties, mineral oils can be used over a very wide field of application « in spite of additives to improv the viscosity indexes of mineral oils, they have tuo major disadvantages: 1, Pelow 19°C. tho viscosity increases at an enormous rate with drop in temperature. Ab high temperature, say over 180°C., the oils become almost as shin as water and thay very quickly oxidise to form, at the best, gums and the worst hard carbon deposits which can only be removed by chipping. Almost without exception, synthetic fluids are used to make up for these deficiencies. ‘The very much better viscosity/temperature characteris tics of synthetics can be seen in the graph included in the appendix. ‘The aynthetics also have their drawbacks, Because they are pure materials and not a mixture of complex molecules, as are mineral of}s, they do not give as goed boundary lubrication. This, of course, we compensate by using solid lubricants.TYPES AND PROPERTIES A grease is a base fluid, thickened with 5 to 30% gelling agent, usually a metallic soap, clay or’ inert ponder, ‘The bese fluidsused at present 2) iineral O11, b) Mineral Oi1/Synthetic oil blend, ¢) Hydrocarbon Polymer, @) Silicone ofl, e) White oil, By varying the tase fluid we ean alter the greases characteristics, Also by varying the viscosity of the base fluic we can influanes the greases tenperature cupabilities, ie,, a thick base fluid will give good adhesion ard better high’ temperature perfomence, The save happens in reverse with thin base fluid being better for lov tameratures, but we mist realise that it is the nse fluid vhich provides the lubriestion of the grease, The thickeners are purely a medium to hold and release the base fluid as required during working. Mineral cils have the advantage of being miscible with ell the thickeners ve use, whereas synthetics and silicones are limited to lithium or silica, but thoy have a definite advantage of wider temerature range, Fron the slide beloy it is easy to see the advantages of Bentone, Lithiun and Silica thickeners over the others. Grede ‘Tyne Drop Point Max, Teipernture Water For Long ‘torm Resistance Use Aluniniun tiotal Soop g0%c, som, Good Boriun in 130°, 20°C, Sood Caleturs " 100°C, eve, Good Lithium " 170%, 3e5~290°C, Cood tua an 160°C, z00%, Poor Pentone Clay Over 250°C, 30%, Very Good Silics Inert Powder Over 300°C, 230°C, oorADHESIVE WEAR Severe with: Less severe with: Similar Metals Bearing Metal Soft Ductile Combinations Metals Low Temperature Metals resistant Oxidising to Oxidation Atmosphere Vacuum or Low Loads Inert Atmosphere High LoadsAbrasive Wear OS icv et Sa Severe with: Less severe with: Hard, Sharp Soft Particles Particles Hard Surfaces Soft/Hard Metal _ ittle Abrasive Combination Wear with Retention of Frequent Flushing aa asive Wear Less Sticky Se Lubricants Highly Sticky LubricantsFatigue Wear ttt at tH eley ROLLER BEARING GEAR TEETH SURFACE BREAKING UP Wace To = Lubricant has less effect than correct material selectionBOUNDARY LUBRICANTS SURFACE ADHESIVE —O_ 2 —WLdnenveee Soft Solids Fats - Fatty Esters SURFACE REACTIVE Cra -CL ears Ss | Nas | ———_-8es according to their c ried penetration. the measure: thod ASTM D21/-1? 50 465, 400 355 310 265 220 115 130 8 Grease Institute has classified istency as measured by the ‘The classification is as follows: Worked Penetration Ra: 475 430 385 340 295 250 205 160e STB, LUBRICATION BNGHYEERS NaNat, ‘CLOUD POINT cesgunnoy AO) For 5 stconos raga pares He area fae “APPARATUS FOR CLOUD AND POUR TESTS CLOUD POINT The cloud point of a petroleum oil is the temperature at which paraffin wax, or other solidifiable compounds present in the cil, begins to crystallize or separate from solu: tion when the oil is chilled under prescribed conditions. Oils that are nearly or quite wax-free, such as naphthenic types, show no cloud points. To determine the cloud point, a sample of the cil free of all moisture is poured into a test jar and cooled in progressive steps. When inspection first reveals a distinct cloudiness or haze at the bottom of the test jar, the temperature is recorded as the cloud point. Cloud point is useful for es timating the temperature at which filter screens in the fuel intake system of diese! engines might become clogged because of wax separation. The type of wax, micro- rystalline or amorphous, would have a definite bearing on filterability. The amor- phous type would be of a sticky nature and would more easily clog filter screens. POUR POINT The pour point of a petroleum oil is the low. est temperature at which the oil will pour or flow under prescribed conditions when it is chilled without disturbance at a fixed rate, To determine pour point, a sample of oil is cooled in a test jar under specified con: ditions; the temperature is observed in in crements of ~5F until no movement is ap: parent on the surface of the oil when the test jar is held in a horizontal position for 5 seconds. This temperature is recorded as the solid point. By definition the pour point is SF above this temperature Pour point is of importance in establish. ing the lowest temperature at which a diese! fuel is still sufficiently tluid to be pumped or transferred. However, many fuels can be pumped or transferred at temperatures be: low their pour points, Low pour points may atten be obtained by increasing the volatility of the fuel. This reflects itself in 2 lowering of the Btu value om a volume basis and possibly lowering the cetane number.we UNITED STATES STEEL LUBRICATION ENGINEERS MANUAL WHAT IS SHEAR STABILITY? Shear or mechanical stability of grease is its ability to with: stand repeated working with minimum change in its struc- ture or consistency, WHY THE TesT? ‘The shearing action in the test 7 GaAs Noes apparatus simulates the work: De wiaouanceaRt ing of the grease in service. aes service grease. = Moly-Anti-Seize # 2 : High temp. service. -HT-14 #2 : High temp service, Investigate the influence of time for a grease when it starts to evaporate. This information is important for a gas well because after sufficient time, the grease mey dry out totally ane leave behind either the solid lubricant or charcoal-like particles. Review the following important factors which affect valve functional life i ~The wear and friction reduction: especially at the stem to gate thread connection of the manual gate valve. - flow well a grease remains in valve cavity after the valve is cycled many times. - he "sealing" characteristic of the grease when there is small imperfections on valve seal faces. ~ The chemical resistance to H2S and C02, the rust or corrosion preventive characteristics and the oxidation stability. - The effect on grease of low temperature after it has been exposed to high temperatures. 2 OF 16i ENUM WE ePB RH tH BERN. 3 oF le CAMERON IRON WORKS USA, INC. PAS WoustON TEAS PRODUCT ENGINEERING OIL TOOL DIVISION TESTING OF GATE VALVE GREASES AT VARIOUS JUNE 28, 1989 sone: SERVICE TEMPERATURE RANGES one = the effect of a thin grease film between 2 sealing surfaces to see whether it would become a bard film layer when exposed to high and low temperatures. g/ For 2 650F service, it is recommended that only light film of grease be used on parts for valve assenbly. The valve cavity should not be filled with grease, Assenbly procedures should be revised to reflect this, where necessary. TEST PROCEDURE: + (See test results section). TEST SITE = Technical Center. Hillis Flow Control (Gate Valve Engineering test lab) a 10810 Northwest Freeway Fouston, Texas TEST DATE : - 5 tests between 11-8€ WITNESSES: Loc Hoang Jim Rilmoyer arious times : Jay_gprene ~ Rick Barnett ~ Lee Womble - Dave Mefford and 2encicehitc! RBar Rie eae CAMERON IRON WORKS USA, INC. PASE PRODUCT ENGINEERING OIL TOOL DIVISION TESTING OF GATE VALVE GREASES AT VARIOUS JUNE 28, 1989 sunect SERVICE TEMPERATURE RANGES pure Table 1 RECOMMENDED SERVICE TEMPERATURE Grease not exposed to air/orygen No GREASE -75 5G -20 ..0 RM. 250 300 350 400 450 1 Moly 101-H 6 Blue-Pacer 7 BT-14 19 HT-14 #2 23 Moly-Anti $2 # 2 7 HS-LT 12. NS-14 8 TS-41 19 Polymel 422 11 Desco 955 14 s8-14 1g cl-14 #2 25 PS-1603 26 PS-1603 27 88-5/3 enommm ++ amo E E E E E G E od teh) oh te) SP Grease exposed to air/oxygen GRERSE -15 -50 -20 0 RM. 250 300 350 400 450 1 Holy 101-B 7 BS-LT V7 BT-14 8 5-4) > 10 Polymel 422 11 Desce 955 14 88-14 25 PS-1603 26 PS-1603 27 $8-5/3 bs ttt tet et mat Note : Low temperature (-75F to OF) Excellent. Viscosity slightly changed. Good. Hardening but usable. Fair. Bardening but may be usable. Solid hard. temp observation : Acceptable for sealing and pumping. Grease is either too thick or thin. temp test result : (250F to 450P) Excellent. Physical property has only minor change. Good. Losing viscosity or body is broken down. Fair. Fairly liguid or dried out. Totally drieé up (Charecel) or liquefy.GURHLGIPAL ERNe, 5 OF 18 CAMERON IRON WORKS USA, INC. PASE PRODUCT ENGINEERING OIL TOOL DIVISION TESTING OF GATE VALVE GREASES AT VARIOUS JUNE 28, 1989 SERVICE TEMPERATURE RANGES table 2 Service temperature of other greases which were tested but not recommended to be used for CIW gate valves. Note : Low temperature special greases GREASE =15 -50 -20 0 RM. 250 300 380 400 450 Moly 101-8 Lubchem 1606 ci-14 #1 BT-14 #1 Moly-Anti Sz # 1 Ls-239A Silicone Compound X ss-18 tin oe mess pene no es eis ms BO er tt ttt High temp tested w/ opened container GRERSE, -75 50-20 0 RM. 250 300 350 400 450 Lubchem 1606 Hol 4 ‘SP to OF) FE = Excellent, Viscosity slightly changed. ¢ = Good. Hardening but usable F = Pair. Hardening but may be usable x = Solid hard. ‘oom temp observation ¢ E = Receptable for seeling and pumping. Grease is either too thick or thin. temp test result : (250F to 450F) Excellent. Physical property hes some minor change Good. Losing viscosity or body is broken doun. Fair, Fairly liquid or dried out. totally dried up (Charcoal) or liquefied.€ aise ENGINEERING REPORT ue are CAMERON IRON WORKS USA, INC. PASE PRODUCT ENGINEERING OIL TOOL DIVISION TESTING OF GATE VALVE GREASES AT VARIOUS JUNE 28, 1988 SERVICE TEMPERATURE RANGES ome TABLE 3 ACCEPTABLE GATE VALVE GREASES LISTED BY API 6A TEMPERATURE CLASS TEMP. CLASS(ES) TEMP. RANGE (DEG F) ‘ACCEPTABLE GREASES K +75 TO +180 HS-LT L -50 TO +160 HS-LT, NS-14, BLUE PACER P -20 TO +160 HS-LT, NS-14, BLUE PACER, tCI-14 #2 R ROOM TEMP. ALL GREASES IN TABLE 1 8 0 70 150 SEE TEMP. T 0 70 180 SEE TEMP. v 0 70 250 MOLY 101-H, BLUE PACER, MOLY ANTI-SEIZE, HS-LT, NS-14, POLYMEL 422, *C1-14 #2, PS-1603 RD -75 70 250 HS-LT Lev =50 TO 250 HS-LT, NS-14, BLUE PACER Pu =20 TO 250 LS-LT, NS-14, BLUE PACER, : scI-14 #2 x © TO 350 MOLY 101-H, BLUE PACER, MOLY ANTI-SEIZE, HS-LT, aCI-14 #2 0 TO 650 NONE = %CI-14, NLGI GRADE 2 ONLY; CI-14, NLGI GRADE 1 NOT ACCEPTABLE.ENGINEERING REPORT 1798 E.RNo. 9 OF 18 CAMERON IRON WORKS USA, INC. PASE PRODUCT ENGINEERING OIL TOOL DIVISION TESTING OF GATE VALVE GREASES AT VARIOUS cup UNE 28, 1989 SERVICE TEMPERATURE RANGES F TEST EQUIPMENT AND SAMPLES + in can 1.5" dia., 1" high with lid. Heating oven (Room - 500F) Cold box. (Room - ~75F) 7 Grease sample : The tests evaluated many similar greases but the supply sources are different. The purpose woe to check the quality and consistency from one grease m)xi08 batch to another. fo identify the sample, a sample nunber was assigned as shown below : Woly 101-8. CIW grease for high tenperafure werice by Swepco company. Oil base with Solybdenun and graphite solid lubricant. NLGT 42. From Ville Platte assembly line. Moly 101-5. Similar to above. NLGI # 1. Pron gate valve engineering test, lab. Moly 103-B. Similar to sample # 1. Provided from vendor. Sample # 4: Moly 101-8. Similar to sample # 2 From CIK Beziers plant. Sample # 5: PS-1 606. i temperature se by Lubchen company. Not sure ebo sition put likely is an oi) base with molybdenum. NLGI 2 From CIK Beziers. sample # 6 + B ue-Pacer. Synthetic grease by Pacer. NLGI #2 From gate valve engineering test 1ab- semple # 7 : BS= wt. CIR grease for low temperature service by Chemola compan: Synthetic base with Teflon and molybdenum. NLGI # 2. Fron gate valve engineering test lak sample # 8 : TS i. CIW diese resistant grease by Chemola ‘Synthetic base with molybdenum. NLGI 2. From gate vale engineering test jab grease pump ts-4) Similar to above put provided from vendor. Folmmel 422. Diesel resistant and high tenp grease. ‘Synthetic oil base plus high temperature and seas on inhibitor, molybdenum disulfide and graphite, NLGI # 2. Provided from vendor. Desco 955. Diesel resistant service by chemola. 3G08 synthetic with oxidation and corresion jnhibitors. Provided from vendor. Sample # 1 Sample # 2 Sample # 3 sample # 9 Semple # 10 + Sample # 12ENGINEERING REPORT Siena: CAMERON IRON WORKS USA, INC. PASE HOUSTON TOUS PRODUCT ENGINEERING OIL TOOL DIVISION TESTING OF GRTE VALVE GRERSES AT VARIOUS JUNE 28, 1989 SERVICE TEMPERATURE RANGES ome sample # 12 : NS-14. CIK grease for low temperature service. Sample # Sample # Sample # Sample # Sample # sample ¥ Sample # Sample Sample sample Sample ¢ Sample ¢ Semple ¢ Sample ¢ Sample # 13: ue iss 16: vw: : ES-239%. Proposed by South Coa: : Silicon Compound. KLCI § 2. Pure silicone oi]. NLGI # 1 manufactured by South Coast company. synthetic oi] base, inorganic thickener and graphite solid lubricant. Provided from vendor. Similar to sample ¢ 12 but from CIK stock room, 5-14. Former CIW grease for diesel resistant service. synthetic oi] base with graphite. NLGI # 2. Provided from South Coast products. CI-14 # 1. Special CI standard service grease but with NLGI 1. Oil base with graphite Provided from South Coast vendor. Ci-14 f 2. CIW grease for standard service. NLGI 2. Similar to above and provided from South Coast. HI-14. Former CIW grease for high temperature service. Nanufactured by South Coast Products. Inorganic base With graphite ané molybdenum disulfide solid lubricant. NLGI # 3. From gate valve engineering test lab. Hi-14 #1, Similar to sample 17 but with NLGi Provided fron South Coast Products company. : H-14 #2. Similar te above. NUGI # 2. from South Coast Products. Chemically inert. By South Coast. Moly-Anti Seize # 1 for High tenperature service. by South Coast. Oil bese with molybdenum disulfide. Nc! #1. (claimed to be similar to Moly-101). Moly-Anti Seize # 2. Similar to above. NLGI # 2. S§-18. I-14. For standard service From gate valve test lab. Cl-1s. For standaré service. Sinilar to sample # 1€. Fron gate valve test lab grease pump lar to sample # 16 : 8-5/3. Claimed for diesel resistance service but only suitable for standard service, Likely oil base with molybdenun disulfide an¢ graphite. Manufactured by Rocol company. Provided by CIk Brazil 8 OF 18ENGINEERING REPORT E.R.No. CAMERON IRON WORKS USA, INC. — PASE PRODUCT ENGINEERING OIL TOOL DIVISION 9 OF 18 TESTING OF GATE VALVE GREASES AT VARIOUS DUNE 28, 1989 gustcr SERVICE TEMPERATURE RANGES pare RESULTS : the following sections summarize the behavior at high temperature tf the standard and some new greases which may be suitable for CW oe ene it is important to understand them when selecting 2 greuts the tested samples are grouped into 4 standard CIR grease striret groups. Riso included is a 5th group which is for new and special greases. 1/ LOW TEMPERATURE SERVICE GREASE ¢ (-75F, ~50F te 250F) currently, CIM is using 2 types of low temperature sreete, which certthe HS-LT and the NS-14. The KS-LT was approved 19 1987 and the nscl4 had been approved quite sometime ago. At -75F, only the HS-LT is acceptable. ns-b? (Sample #7) t excellent at -75P. At 250F, the HS-LT becones fairly soft, (NLGI 1), and it starts to evaporate bechry out (NLGI 2). The evaporation helps to bring tock the grease penetration point to an accepteble level. te air or oxygen is present, the oxidation vould occur and cause the HS-LT to burn to charcoal. -14 (sample 12,13) : excelent at -208, starts to harden at -50F. Tie soft at room temperature (NLGI £1). At 250F) ot Hlart to dry out and increzse its penetration. Hovever, the NS-14 will liquefy at 350F. 2) STANDRRD SERVICE GREASE : (OF to 250F) clk hes qualified a few vendors te supply the grease for this service. Rll tested samples were acceptable for its standard temperature niviee rating, OF to 250F. Outside the specified tenperature range, the four tested samples (samples 18) 16, 25, 26) behave hifferently depending upon the mizing batch or vendor. At 2 tenperature higher than 250F, all of ther. will go through the {Sfiening phase, and then either become liquid or ary out.ENGINEERING REPORT 1798 E.R.No. 10 oF 1 CAMERON IRON WORKS USA, INC. PACE PRODUCT ENGINEERING OIL TOOL DIVISION TESTING OF GATE VALVE GREASES AT VARIOUS JUNE 28, 1989 susner SERVICE TEMPERATURE RANGES one 3/ HIGH TEMPERATURE SERVICE GREASE : (OF to 450F) For this service application, CIW is using the HT-14 (sample 17) and the Moly 101-H (sample 1,3). The standard HT-14, NLGI § 3, is too hard to be used with a hand pump. To overcome this problem, 2 new alternate greases were provided and performed well through the test. They are the HT-14-2 (semple 19) and the Moly-Anti-Seize # 2, (sample 23). There was one other sample khich ds being used in CIM valves, the Lubchem 1606 (sample #5), which did not pass the temperature test. MOLY-101-H (Sample 1,3) : is not usable under OF, excellent at room temperature. At 250F to 450F, it increases its hardness slightly and also starts to dry out. This is the biggest "plus" point of this grease since it does not go through the softening phase. If air or oxygen is present, at 400F a thin layer on the outside surface will . burn to charcoal. (Note that Moly-101 has 3 different NLGI grades:1,2,3. The vendor's standard grade is NLGI #1. For gate valve usage, the Moly-101-8 (NLGI # 2) should be specified). MOLY-ANTI-SEIZE — 2, (Sample 23): This is 2 new grease to CIK ‘The chemical composition is similer to the Moly-10] grease. The MOLY-ANTI-SEIZE is acceptable at -20F and excellent at room temperature. Its penetration point decreases at 250F and continues decreasing to 350F. This grease starts to evaporate at 350F and its hardness increases to an acceptable level. The maximun service temperature of this grease is 450F 4 (Sample 17, NLGI 3) : - was not tested at low tenperature. Very thick at roon temperature but its hardness decreases at 350F. Also at 350F, it will start to éry out, The HI-14 is acceptable up to 450F. Note that the previous tests indicated thet at 450F and after a long period of time, it would burn to becone a "solid lubricant" or charcoal-like product.ENGINEERING REPORT Arye E.R.No. 1] oF 1€ CAMERON IRON WORKS USA, INC. PAGE HOUSTON TEAS PRODUCT ENGINEERING OIL TOOL DIVISION ESTING OF GRTE VALVE GREASES AT VARIOUS JUNE 28, 1989 sunecr SERVICE TEMPERATURE RANGES pare pI-14 #2. (Sample 19) : The chemical composition is similar to the HT-14 with lover penetration point. The minimum service temperature of the HT-14 #2 is -20F. It has an excellent penetration point at room temperature, becomes soft at 350P and starts to dry out at this temperature. The maximum service temperature is 450F. 4/ DIESEL RESISTANT SERVICE GREASES : (OF to 250F) the two stendard CIM greases for this service are: 8-41 (Sample 8,9) ine Sold (Sample 14). The tests included the following new samples: Polyme) 422 (Sample 10), Desco 955 (Sample 11). All of these greases passed the diesel resistance test. 1-41 (Sample 8,9) : Becomes hard at OF and solid at -20P- Excellent at room temperature, the 78-41 should stay in the Valve cavity very well. However, at 250F it becomes liquid and would flow out the valve cavity easily. g6-14 (Sample 14) : Similar to the 75-41, it starts to become herd at OF and solid at -20F. Excellent at room temperature, At 250F, the S5-14 becomes soft and starts to éry out. Rt 450F, it changes to e liguid state, after sufficient tine, it will dry out and burn to leave behind the charcoal. polynel 422 (Sample 10) : The Polymel is a nev grease to CIK but has a long successful history in oil field service. 1t becomes Slightly hard at -20F and solid at -S0F. Excellent at toon temperature and up to 250F. At 350F, the Polymel 422 Gecreages its penetration point and starts to dry out. he dsoF and after sufficient time, it would burn te charcoal. deseo 955 (Sample 11) : Similar to the Polymel 422, this nex grease has been used in oil field equipment. Becones hard at OF and solid at -SOF. Excellent fron. room temperature to 250F. Softens at 350F and alsc starts to dry out. At 450P, the top layer burns to leave behind a hard layer. Similar to all above greases, if air or oxygen is present, the oxidation at 450F causes the Desco 955 to burn to charcoal.ENGINEERING REPORT arse E.R.No. 12 OF 18 CAMERON IRON WORKS USA, INC. PASE PRODUCT ENGINEERING OIL TOOL DIVISION TESTING OF GRTE VALVE GREASES AT VARIOUS JUNE 28, 1989 svewer SERVICE TEMPERRTURE RANGES sre 5/ SPECIAL and NEW GREASE + the test program covered some other greases being used in CIW valves. It also found several samples which have some good points to consider BLUE-PACER (Sample 6). A special synthetic grease which has been used in CI¥ valves, mainly at the valve stem packing. The grease penetration point remains unchanged between OF to 350F. Tt becomes hard at -20F and solid at -S0F. At temperatures higher than 350F, it starts to become soft but still is the best up to 450F when compared to all of the tested samples. 5-5/3 (Sample 27). This grease was claimed to be a diesel-resistant grease and is available in South America. It failed the diese] test but would fit the CIW standard grease type. The $5-5/3 becomes solid at OF; its consistency is excellent to 250F and still within the acceptable range up to 450F, If the grease is exposed to air, the 5-5/3 becomes charcoal at 450F. PS-1606 (Sample £). The PS-1606 name is the CIW purchasing speci fication number for igh tenpersture grease. Lubchem company selected their grease names to be the sane as the CIK PE number, This grease has only now been evaluated, but has been supplied to several CIM plants. The PS-1606 grease is solid at OF and liquefies at 250F if inside an enclosed container. It is not acceptable. The actuel test observations are listed ee follovs, The ranking is: R= Totally dried up, chercoal, Not acceptable B= Hard thin top layer, the portion under is acceptable C= Grease drying but still soft. (NLGI # 3) D = No change. E = Grease becomes soft. (NLGI # 1) F = Softer than E rating above G = Totally became liquid.ENGINEERING REPORT 1798 E.R.NO. 13 oF 1é CAMERON IRON WORKS USA, INC. PASE PRODUCT ENGINEERING OIL TOOL DIVISION TESTING OF GRTE VALVE GREASES AT VARIOUS JUNE 28, 1989 suuect SERVICE TEMPERATURE RANGES oor Test #1 : Heat test - Greases were placed in OPENED tin can, 2" diameter. 3/4" thick. - Emphasis was on the high temperature service greases. Sample GREASE 325F 410F No NAME 72 brs 70 hrs 1 Moly 101-8 c B 2 Moly 101-8 Ez B 3 Moly 101-# c B 4 Moly 101-5 E B 5 Lubchem 1606 B B/B 7 HS-LT B R 8 TS-41 B B a7 BTL ce c 25 P8-1603, B B 26 © PS-1603 a B Test #2: Heat test = Greases were placed in CLOSED tin can. 2" @. 1,5" thick - Emphasis wes on the high temperature greases. Sample GREASE 410 F 450 F No NAME 72 HRS 10 HRS 25 PS-1603 26 = PE-1603 =, 2 Moly 101-8 c 5 3 Moly 103-E ° E 5 Lubcher. 1606 c c 6 —_Blue-Pacer D c 8 oTS-4l G SG a7 oBT-14 c B F E E icENGINEERING REPORT E.R. No. 14 OF 18 CAMERON IRON WORKS USA, INC. PAGE Test $3: Houston TEAS PRODUCT ENGINEERING OIL TOOL DIVISION TESTING OF GATE VALVE GREASES AT VARIOUS JUNE 28, 1989 suste: SERVICE TEMPERATURE RANGES Heat test - Greases were placed both in CLOSED and OPENED container. 2” diameter, 1.5" thick. Emphasis was on diesel resistant greases. Sample No GREASE 250 F 350 F NAME 450 F 72 HRS 100 HRS 70: HRS CLOSED CAN Lubchem 1606 TS-41 Polymel 422 Desco 955 85-14 ss-5/3 vovace owonoa beac ee 27 jesel resi Immerse in diesel oil for 3 days. Lubchem 13-42 Polymel Desco 95! s-14 ss-5/3 Moly 102 FERS! NAME OPENED CAN 1606 € B a G B E/h 422 c B B 5 D c h B B B D ¢ B 6 EB Immerse in diese] oil for 3 DAYS HS-LT fair Ts-4] passed Polymel 422 passed Desco 955 passed ss-14 passed 8-5/3 dissolvedaEPORTIOVG 1798 ENGINEERING REPORT Grito: 35 OF 26 CAMERON IRON WORKS USA, INC. PASE WOUETON TEAS PRODUCT ENGINEERING OIL TOOL DIVISION TESTING OF GATE VALVE GREASES AT VARIOUS JUNE 28, 1989 susiecr SERVICE TEMPERATURE RANGES one test £5 : Low temperature test. - To check for performance at low temp. = Cooled to 0 then to -20, -50, -70 F. 24hrs at each test temperature. Check for each 24 hrs. Ranking : 1 = No change Excellent 2 = Harder Good 3: Increased hardness Poor 4: Hard Wot acceptable 5 = Solid hard Not acceptable Sample GREASE 0 «+2 -=50-75 No NAME ahr 24hr 24br = 24br 2 Moly 101-8 2 5 3 Moly 101-E eer 5 5 Lubchem 1606 5 7 HS-LT 3 SEL aca i 8 = TS-41 4 8 10 Polymel_422 Saeed 5 11 Desco 955 404 5 12 s(NB-14 aa aus 13 NS-14 ae en M4 BB-14 48 u cr-l4 #2 aac ce ie cI-14 2 ee) a5 ye wT-14 $1 Steere ig ET-14 $2 48 20 LS-239h ee 5 21 Silieond eau Compound 1 oN tS 22 Moly-Anti “ Seize #1 1 9 5 23 Moly-Anti Seize #2 Pee 5 24 88-18 3. 8 aoa) 26 PS-1603 AS 2 (88-53 5oy NGINEERING REPORT aise a . E.R.No. 16 OF 18 CAMERON IRON WORKS USA, INC. PASE HOUSTON TEAS PRODUCT ENGINEERING OIL TOOL DIVISION TESTING OF GRTE VALVE GREASES AT VARIOUS JUNE 28, 1989 sunte: SERVICE TEMPERATURE RANGES are Test # 6 : Heat test To test all new samples from various vendors. Sample GREASE 250F 350F 450 F Ko NAME 48hr 72hr 48hr 1 Holy 101-# D D c 2 Moly 101-S D/E D/E c 3 Moly 101-H D D c 4 Moly 101-8 D/E F/G c 5 Lubchem 1606 G - - 6 Blue-Pacer D D/E D/E 7 ORS-LT D/E c c/B 8 TS-41 F/G G w 9 «TS-41 F/G G = 10 © Polymel 422 D E A 11 Desco 955 c B B é 12. NS-14 D/E Gc _ 13° NS-14 D/E c - 14 S$-14 E B c as ci-14. #1 F EF c 16 cl-4 $2 D E B/C 17 OBT-14 D/E E c 18 D F/G B 35 D E c 20 © -LS-2392 D D c 21 Silicon Compound D D D/E wa, 22 Moly-Anti Seize #1 E E/E c 23. Moly-Rati Seize $ 2 E c 24 S8-18 A = - 26 = PS-1603 E F/G E 27 $8-5/3 E/F E cENGINEERING REPORT 1796 E.R.No. 17 OF 18 CAMERON IRON WORKS USA, INC. PACE WOUsTON TEAS PRODUCT ENGINEERING OIL TOOL DIVISION TESTING OF GATE VALVE GREASES AT VARIOUS JUNE 28, 1989 suncet SERVICE TEMPERATURE RANGES eae DISCUSSION + When grease is exposed to a high temperature, being a mizture of lubricating petroleum or synthetic oil, a thickener, and a solid lubricant, grease has no distinct melting point in the way that homogeneous crystalline substances do. During the observation of a tected sample, the grease physical properties will go through one of the 3 following paths: ~ If the grease has a low Dropping Point, it would change from @ semi-solid to @ liquid state. Since this behavior is not favorable for gate valve application where the "liquid" would flon out of the valve cavity, the test did not try to determine how the grease would be at an higher temperature. ~ another path is for the grease to soften to a semi-liguid state. The grease will either remain at this state or start to 4 evaporate to increase its penetration. The determination becomes more difficult because besides the tenperature effect, the exposure time to high temperature, the grease evaporation resistance, the effect of surrounding fluid and the grease onidation resistance ere also important factors. At 2 higher tenperature under the grease Fire Point, it will éry up and leave behind, all or 2 layer, of a solid lubricant or Gharcoal-like residue. These hard perticles or charcoal are hot acceptable because they create a leak path in the valve, especially when the gate/seat bearing stress is not high. € = the third path is the most favorable. Similar to the above path, the grease will dry up, but it does not ge throush the semi-liguid state, so that the grease ret in the valve cavity longer. Again, at @ sufficient temperature and exposure {ine to aiz/ozygen, the grease would become 2 solid lubricant or be burned to charcoal. hough the grease viscosity and consistency are related to temperature, the relationships follow no consistent pattern. The fact that a grease does not liquefy at a particular temperature gives no assurance that its consistency will be suitable at that temperature.ENGINEERING REPORT E.RNo. 98 oF 18 CAMERON IRON WORKS USA, INC. PASE PRODUCT ENGINEERING OL TOOL DIVISION ESTING OF GATE VALVE GREASES AT VARIOUS JUNE 28, 1989 ‘SUBJECT SERVICE TEMPERATURE RANGES —_ a Ae ee Leer:) Loc Hoang, Engineer Dave Mefford, Manager Valve Engineering Valve Engineering ha Ed Szymé , Matager Larry Hoes, Vice Presitient Wellhead Products Engineering Oil Tool Division SS Joe Parris, Manager Patent Services