Handling Lubricants

    George Wills dan Dr. A. R Landsdown, dalam bukunya Lubrication Book, menyarankan agar inventory pelumas harus sudah digunakan dalam masa 3 sampai 12 bulan, tergantung dari jenis pelumas ( table 1.1 ).

                                                                     Tabel 1.1 Lubricant storage life limits

I.    Penyimpanan Pelumas

Drum tidak boleh disimpan berdiri, kecuali dalam keadaan tertentu yang tidak mungkin drum disusun dalam posisi “dibaringkan”. Jika memang terpaksa, posisi tutup harus berada bawah dan diberi alas kayu.

Penyimpanan drum dengan cara berdiri boleh dilakukan, asal memperhatikan posisi tutup drum, yaitu lurus searah jam 12 danj am 6,tidak boleh melintang kearah jam 3 dan jam 9 dan drum harus dimiringkan dengan cara diberi alas kayu agar air tidak mengendap diatas drum.

II.        Penanganan Oli

·            Drum tidak boleh dibuka dengan cara membuat lubang besar atau membuka salah satu ujungnya; hal ini dapat memperbesar resiko oli terkontaminasi.

§            Juga tidak dibenarkan menciduk pelumas dengan bejana terbuka, kecuali dengan menggunakan pompa tangan (posisi drum berdiri) atau membuat kran pada salah satu tutup drum (drum dalam posisi dibaringkan/posisi tidur/horizontal).

§             Pelumas sangat rentan terkontaminasi jika disimpan pada tempat yang terlalu panas atau terlalu dingin dalam jangka waktu lama.

§       Sangat dianjurkan untuk selalu menggunakan bejana penampung pelumas yang bersih dan menyediakan lap/majun yang bukan terbuat dari katun atau wol.

§            Sangat dianjurkan untuk selalu menggunakan bejana dan pompa untuk pelumas yang berbeda untuk tiap jenis pelumas.

III.        Unloading drum

Proses unloading drum dari truck / transportasi merupakan cara untuk menjaga kualitas oli.

Gunakan alat bantu yang mudahkan pekerja untuk proses unloading.

Jangan menjatuhkan drum pada proses unloading, kemasan akan rusak dan kualitas oli akan menurun.

                         Jangan mengunakan roll drum untuk  jarak jauh Gunakan handtruck atau forklift.

                                       Penggangkatan dengan forklift, drum harus dilapisi dengan palet.

                                                 Salah satu alternative penyimpanan Drum. ( vertical )

                                                  Penyimpanan secara vertical dan horizontal.

IV.      Management Pengeluaran barang.

F.I.F.O ( first in – First Out )

Barang yang datang pertama harus juga yang pertama keluar. Konsep ini harus diaplikasikan kesetiap produk. Agar tidak ternyata penyimpanan barang yang pertama datang tidak keluar dari gudang dalam waktu yang lama.

Demikian cara penanganan dan penyimpanan oli yang berguna untuk menjaga kemasan dan kualitas oli dari gudang sampai ke end user.

Dengan mengetahui cara penanganan dan penyimpan yang baik kita dapat menambah value lubricants.

Oil Recommendations for Ariel Compressor

Technical Bulletin

Oil Recommendations for Ariel Compressor

By Wanda – Technical Support PT Petrolube Cakra Persada

General

Lubrication is vital for successful operation of a compressor. Adequate lubrication of the proper type in the proper place at the proper time is the key to successful lubrication. Although lubrication is an ongoing concern throughout the life of the compressor, the initial package design is very important and deserves special attention.

There are two independent systems for lubricating the compressor; the frame oil system and the force feed system. The frame oil system is a pressurized circulating system that supplies a constant pressurized supply of oil to the crankshaft, connecting rods and crossheads. The force feed system is a low volume high pressure injection system that supplies small quanti­ties of oil at regular intervals to lubricate the piston rod packings and the piston rings. In many applications these two systems can use the same lubricant, but in some applications the lubri­cants must be different.

Lubrication Functions

Lubrication performs at least six functions in a compressor.

1.Reduce friction:

A lubricant decreases the resistance to movement between contacting compo­nents. The lubricant allows the components to slide on an oil film rather than directly on the component surfaces to reduce friction.

2.Reduce wear:

A proper lubricating film minimizes contact between sliding components which reduces wear to increase equipment life expectancy and decrease maintenance costs.

3.Remove heat:

Frictional heat is generated between the moving parts and the lubricating film. Circulating oil allows for heat removal to maintain working tolerances and extend oil life.

4.Prevent corrosion:

Keeping air and moisture from the surfaces reduces corrosion to decrease debris particles, frictional heat, and component wear. Corrosion prevention is generally provided by additives rather than the base lubricant.

5.Seal and reduce contaminant buildup:

A liquid lubricant fills small spaces to improve the gas seal on piston rings and packing rings, and flushes away contaminants from moving parts.

6.Dampen shock:

A lubricant of a proper viscosity helps to cushion shock loads or pulsations to reduce vibration and noise, and increase component life.

Lubricant Formulations

R&O Oil

Rust and oxidation inhibited (R&O) oil is a very simple oil comprised of base stock, corrosion inhibitors, anti-wear and antioxidant additives. The viscosity of the base stock determines the viscosity of the finished product. This oil is a very good selection for use in the compressor frame and for most force feed systems.

Engine Oil

Engine oil is formulated for use in internal combustion engines. Its purpose is to counteract the negative effects of combustion and help keep the products of combustion (heat, soot, water, CO2) away from the moving parts of the engine. It is designed to attract water and soot and help keep it in suspension until it can be removed by the filter. These qualities are not required in the compressor frame and in fact may prove detrimental to the lubrication of the cylinders and packing.

Engine oil will work satisfactorily in the compressor frame and in many force feed systems in gathering or transmission applications since viscosity is the most important aspect of com­pressor lubrication. Although engine oil is generally not the best choice for compressor lubri­cation, operational aspects such as previous experience, inventory control, or simplicity of maintenance practices may outweigh the benefits of using a different type of oil.

Emulsion

One common problem with engine oil is the formation of emulsions in the compressor and/or downstream equipment. The detergents in the oil allow the oil and water to mix. If the gas con­tains enough water, it will mix with the detergents in the oil and emulsify. Usually the emul­sions will accumulate in the downstream equipment such as the scrubbers, but can also be found in the cylinders and coolers.

To eliminate an emulsion problem, the emulsions must be completely removed and all equip­ment thoroughly cleaned. Re-start the compressor using a R&O oil or some other appropriate non-detergent based oil.

If used engine oil is supplied for lubrication of the cylinders and packings, it must meet the listed requirements for cylinder and packing lubrication. The oil must be appropriately filtered (ß5=10 and ß12=75 and have an ISO 4406 cleanliness code of 17:16:14 ). Oil viscosity must be monitored and tested to be sure of adequate quality.

Reference: SECTION 4 LUBRICATION – ARIEL COMPRESSOR

For additional information, please contact:

PT. PETROLUBE CAKRA PERSADA

The Promenade Building 2^nd Floor, H2

Jl. Warung Buncit Raya No. 98 Jakarta 12510

Tel.: (62)-21-7048 1177/88

Fax.:(62)-21-7919 1336

Email: info@petrolube.co.id

Email: technical@petrolube.co.id

Soluble Cutting Oils

Technical Bulletin

Soluble Cutting Oils

By Wanda – Technical Support PT Petrolube Cakra Persada

What is a Soluble Oil?
Soluble Oil are water-soluble products used in conjunction with selected additives to provide maximum tool life and fine finishes. Soluble oil form an emulsion when mixed with water and the concentrate consists of a base mineral oil, extreme pressure additives and emulsifiers which help produce the stable emulsion.

What are Soluble Oil Used For?
Soluble Oil Lubricants are most commonly used for heavy-duty metalworking operations where die life is the first priority but added protection for lubrication and rust protection are needed. Because they are diluted, they provide good lubrication and heat transfer performance.

TOTAL offers a wide range of soluble fluids: macro-emulsions with LACTUCA, micro-emulsions with SPIRIT and synthetic fluids with VULSOL. In order to minimise health and safety concerns for operators, all the fluids comply with international regulations such as the Dangerous Products Directive (DPD) 1999/45/EC or Biocidal Products Directive BPD 98/8/EC. In particular, they are free of formaldehyde, chlorine (except one), nitrite, diethanolamine, and other substances that are regarded as being of concern to individual health, safety or the environment. In addition, Total has taken a lead and has been at the forefront in developing products that are formulated without Boron, in anticipation of the use of boric acid and its salts being added to the list of Substances of Very High Concern (SVHC) under REACH and possible subsequent restrictions that may be imposed as a result of this.

The use of clean water of good biological and physicochemical quality is recommended for the implementation and maintenance of soluble fluids. Their formulation guarantees machining performance for any type of metals and severity of operations:

• Reduction in the cutting efforts provides longer tool service life and superior surface finish of the parts,

• Protection against corrosion of machined parts and equipment.

• Resistance to the development of bacteria and yeast and fungi.

• Non-foaming product with no particular odour for convenient use.

• Stability in service ensuring long fluid life.

Total soluble cutting fluids products are supplied as a concentrate. When mixed with water, they are used to cool and lubricate the cutting process and also to flush away waste material. The finished fluid is generally 95% water combined with 5% concentrate.

Product Range – Total Lubricant: Soluble Cutting Oils

Continuous...

For additional information, please contact:

PT. PETROLUBE CAKRA PERSADA

The Promenade Building 2^nd Floor, H2

Jl. Warung Buncit Raya No. 98 Jakarta 12510

Tel.: (62)-21-7048 1177/88

Fax.:(62)-21-7919 1336

Email: info@petrolube.co.id

Email:technical@petrolube.co.id

Turbine Oil Condition Monitoring - Part 01

Technical Bulletin

Turbine Oil Condition Monitoring - Part 01

By Wanda – Technical Support PT Petrolube Cakra Persada

Introduction

Modern steam and gas turbines subject the turbine lubricant to ever greater demands. Higher temperatures are encountered in bearings, smaller reservoirs reduce residence times, and issues with varnish deposits have become critical concerns. Since the oil is the lifeblood of reliable turbine operation, a sound oil condition monitoring is needed to ensure long trouble free operations.

Turbine Oil Degradation

There are four primary reasons that turbine oils degrade in service. First is oxidation. All oils oxidize in service when exposed to oxygen in the atmosphere. And oxidation is not limited to the reservoir as air is dissolved in the oil. With the increasing temperatures found in turbines, increasing flow rates and shorter reservoir residence times, the oxygen and oil have more opportunities to interact.

Second is thermal degradation. The oil can be exposed to temperatures in a turbine that cause base oil and additive molecules to chemically change. The result of this reaction is the formation of materials that are not readily soluble in the oil. The materials then deposit within the oil system causing deposits, and in some cases, equipment failures.

Third is contamination. Turbine oils are subject to a variety of contaminants such as water (especially in steam turbines), dust and other ingress materials, wash down chemicals, and internally derived contamination, such as wear metals. While none of these are a direct result of oil degradation, they often contribute to other degradation issues. Wear metals, such as copper iron and lead, catalyze the oxidation reaction. Water (especially chemically treated water) can have very adverse effects on the ability to dissipate foam and separate from water. Excess foaming can lead to sluggish response from hydraulic control systems, cavitation in pumps and bearings, and safety issues if the foam over fills the reservoir and spills on the floor.

The fourth is additive depletion. Some additive depletion is normal and expected. Anti-oxidant additives are consumed as they perform their function. Demulsifiers help the oil shed water, but if exposed to large amounts of water contamination, the demulsifiers can be removed. Antifoam additives can be removed from ultrafine filtration or can agglomerate when the oil is not circulated for extended periods of time.

All of these factors should be consistently monitored throughout the life of the turbine oil. The following describes the tests most commonly used for used turbine oil monitoring. They can be broken into three categories: Physical and Chemical Properties, Contamination Measurements and Performance Properties.

Continous.........

 For additional information, please contact:

PT. PETROLUBE CAKRA PERSADA

The Promenade Building 2^nd Floor, H2

Jl. Warung Buncit Raya No. 98 Jakarta 12510

Tel.: (62)-21-7048 1177/88

Fax.:(62)-21-7919 1336

Email: info@petrolube.co.id

Email: technical@petrolube.co.id

Coolant for Gas & Diesel Engine

Technical Bulletin

Coolant for Gas & Diesel Engine

By Wanda – Technical Support PT Petrolube Cakra Persada

Improper cooling system maintenance can result in various cooling system problems and failures. Many engine failures (40 % - 60%) are related to the cooling system. The following problems ; overheating, leakage of the water pump, plugged radiators, and cylinder liner pitting.

These failure could be avoided with proper cooling system maintenance. Maintenance of the cooling system is important to engine life and to the performance.

Coolant provides three main functions ;

•         Coolant provides cooling by transferring heat from the engine to the air.
•         Coolant provides corrosions protection.
•         Coolant provides anti-boil protection and antifreeze protection.

Coolant is normally composed of three elements ;

• •         Water
• •         Additive
• •         Glycol

The chart shown below is a listing of the six most common problems seen in heavy duty cooling systems. Along with each problem is a description of how it occurs, how it affects the engine and, most importantly, how to prevent it.

WT SUPRA is a so-called “water treatment” agent: it is an aqueous concentrate of specific organic corrosion and cavitation inhibitors. Its special formula – containing absolutely no phosphates, nitrites, amines, boron, nitrates or silicates – gives it two important properties: first of all WT SUPRA is nonpolluting and, secondly, it is long-lasting.

Typical Characteristic

Typical Characteristic	Methods	WT Supra
Colour	-	Colourless
Density @20 deg C.	ASTM D 1122	1.058
pH	ASTM D 11287	9.4
pHdiluted to 5% by Volume	-	1

Applications

·           As a 5 to 10% solution in water depending on its purpose, WT SUPRA will protect cooling circuits in diesel and gas engines:

-       in combined heat and power plants or electricity power stations requiring no antifreeze protection but needing efficient heat transfer;

-       in ships engines;

-       on the factory test bed during running-in and for the protection of the engine block against corrosion between leaving the factory and entering service. Heat transfer systems (such as heating plant or secondary circuits in cogeneration units) employing an aqueous fluid.

·           It is preferable to use a soft water even if laboratory tests give satisfactory results with water rated at 20° TH (200ppm).

·           It is important that the antifreeze should be mechanically mixed with the water to ensure a uniform mixture.

·           When WT SUPRA is used to flush circuits that have previously contained a different fluid, its minimum concentration should be 5%.

·           When WT SUPRA is used in the cooling systems of stationary engines, its minimum  concentration should be 7.5%.

·           A 10% dilution is recommended when WT SUPRA is used to protect the cooling circuits of engines when these are being run in on the test bed and during periods of storage (2 months).

Advantages

·      WT SUPRA protects circuits much better against cavitation and corrosion than conventional  ‘water treatment" products.

·      The absence of any inorganic ingredients (such as phosphates, nitrites, etc.) means that no hard deposits are formed, especially around the top of liners, cylinder heads, heat exchanger tubes and electric heaters. As a result :

-            heat transfer is sustained,

-            anti-corrosion and anti-cavitation properties are maintained,

-            there is no risk of pipe erosion due to hard particles in circulation,

-            the circuit remains clean.

·      The active ingredients in WT SUPRA are non-polluting, and confer the same properties on the circuit fluid so long as it does not contain any toxic substances such as monoethylene glycol (a routine ingredient of ordinary antifreezes). These properties allow it to be used in domestic heating installations.

·      When no antifreeze protection is needed, filling a heat transfer circuit with WT SUPRA after  emptying out a conventional antifreeze gives better performance – thanks to the fluid’s higher thermal capacity – at lower cost.

•       Optimum protection is obtained when WT SUPRA is diluted in water of hardness below 20° TH, containing no zinc and less than 300 ppm of chlorides and sulphates.

WT Supra Approvals ;

•       DEUTZ AG : Gas engine series 616/620/2020/632 (Deutz Technical Circulation 0199-99-2091, 5^th exchange date 07.01.2004)

•       MAN 248 (start of approval ; 13.01.04~12.01.06)

•       MTU ( MTL 5049) ; date 07.09.04

•       Wartsila ; Wartsila vasa 22/26/32/38/46/64/28SG/34SG/32DF, date 11.10.02

Reference: PDS WT Supra, Article: Cooling System Maintenance for Heavy Duty Engines

For additional information, please contact:

PT. PETROLUBE CAKRA PERSADA

The Promenade Building 2^nd Floor, H2

Jl. Warung Buncit Raya No. 98 Jakarta 12510

Tel.: (62)-21-7048 1177/88

Fax.:(62)-21-7919 1336

Email: info@petrolube.co.id

Email: technical@petrolube.co.id