Sicelub Iberico SL

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In absence of Oil Mist
Typical Sump Lubrication

Trico Oiler Plug on Top

Slinger Rings

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Why Pumps Fail?
Static Joints
2% Coupling
2% Other
Hydraulic
12% 1%

Bearings
40%
Seals
43%

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Why Bearings Fail
Overloading
4%
Corrosion Other
4% 5%
Disassembly
15%

Misalignment
13%
Particle
Contamination Insufficient
48% Lubrication
11%

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Why Mechanical Seals Fail?

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Oil Mist Generation & Delivery
 What do you need to generate Oil Mist?

Instrument air, i.e. dry air: Paraffinic or synthetic oil ISO VG 32-150
- Minimum supply pressure: 40 PSI, 2.81 kg/cm2
No EP Additives or Viscosity Modifiers
- Maximum supply pressure: 150 PSI, 10.54 Kg/cm2
- Humidity: Maximum recommended dew point -4°C below
minimum all-year temperature.

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 What is Oil Mist?

AIR

AIR AIR
Mist Out Instrument Air
AIR
AIR
5 ppm oil in air

Oil Mist AIR AIR

Oil Mist Pressure Vortex
Is 20” H2O or
Approximately Oil
Oil lifted
0,05 kg/cm2 by vacuum

OIL MIST

Oil mist will not support

combustion or explode.

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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

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IVT Oil Mist Generator

Simple Switch-Over
from Main to Auxiliary
Embedded PC Monitoring Oil Tanks for
+/- 50 Set Points Maintenance or Repair
Common Alarm to DCS

Simple Manual Controls

Oil Tanks Oil Filter, Pressure

Main - 34 ltr (9 USG) Gauge, Oil Tanks Sight
Auxiliary - 34 ltr (9 USG) Gauges, Drain & Fill
Connections
Bulk Storage – 285 ltr (75
USG)

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Oil Mist Delivery
Oil Mist Particle Sizes
Application & Lubrication Generation & Distribution

15 Microns 3 Microns
Below
Above Wet
Mist For Dry Mist For
Lubrication Conveying

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Converting Oil Mist

Oil Mist Lubrication

Dry Mist In Wet Mist Out

(1 to 3 Micron Conveying) Orifice (up to 30 Micron Lubricating)

Oil Mist particles impinge on each other causing

them to grow in size and become wetter.

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Oil Mist Benefits
The impact of Oil Mist
Oil Mist is the Ultimate Oil Filter

The vortex acts as a cyclone

expelling the particles while
generating the mist

Typical cleanliness level

ISO 4406 16/13/10

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The impact of Oil Mist
Oil Mist is the Ultimate Bearing Protector

Positive Pressure 50mbar

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The impact of Oil Mist

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Superior Cleanliness Levels

Oil Mist Lubrication

Oil Mist Lubrication

Filtration (β5>200)

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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 L10 life

increases 11%

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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

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 Distribution System Layout

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How does an Oil Mist system look like?

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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

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Mist System Designs

Closed Loop System Open Loop System

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Oil Mist Installed

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 Applying Oil Mist

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Applying Oil Mist

Purge Mist Pure Mist

• Also called “wet sump” • Also called “dry sump”
• Used to protect the bearing housing • Oil mist provides lubrication
• Not primary means of lubrication • No oil sump for lubrication

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

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Between Bearing Pump & Motor Driver

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Motors

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Liquid Ring Compressors

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Pillow Block Bearings
Oil Mist Inlet Oil Mist Inlet

Oil Mist Outlet

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OH Pump, Turbine Driver & Gear Box

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Rotary Lobe Blowers

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Rotary Lobe Blowers
Pure & Purge Mist Application

Purge Mist

Pure Mist

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Cooling Tower Gear Box

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Steam Turbine

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Machinery Storage
Machinery Preservation Yard

Aerial View of Oil Mist Preservation Yard in Thailand

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Long Term Storage

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 Economic Justification

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Data gathering – real case studies

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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 14.868 € 6.936 €
611-G-1B 11.242 € 8.814 €
611-G-1C 463 € 0€
611-G-2A 10.909 € 0€
611-G-2B 267 € 0€
611-G-2C 14.463 € 601 €
611-G-6 7.256 € 0€
611-G-4A 6.753 € 6.365 €
611-G-4B 1.915 € 310 €
611-G-3A 27.441 € 19.438 €
611-G-3B 24.715 € 321 €
651-G-2A 147 € 257 €
651-G-2B 0€ 5.991 €
651-G-8A 10.124 € 842 €
651-G-8B 234 € 10.097 €
652-G-1A 10.500 € 9.302 €
652-G-1B 15.683 € 1.889 €
652-G-4A 8.136 € 0€
652-G-4B 0€ 0€
652-G-5A 0€ 3.689 €
652-G-5B 0€ 0€
652-G-6A 467 € 6.716 €
652-G-6B 27.884 € 4.796 €
652-G-7A 4.739 € 11.562 €
652-G-7B 7.496 € 6.961 €

Total 205.704 € 104.887 €

4114,0822 2097,737

Savings 100.817 € 49%

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Investment calculator
Insert Data Clean Form

Customer Situation after Lubrimist System

Date Pumps
Turbines
Current Situation Motors
Pumps Reliability Multiplicator
Turbines Improvement Percenatge %
Motors New MTBF [Mo]
Total of Equipments Annual Failures
MTBF [Mo] Cost Repair Average EUR
Annual Failures Annual Repair Total Costs EUR
Cost Repair Average EUR Lube Failures
Annual Repair Total Costs EUR Oil Lubricats Consuption** Lt
Lube Failures Oil Recovery (65%) Lt
Oil Lubricats Consuption* Lt Real Oil Consuption 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.

Estimated Benefits
Benefits
Savings on Repair Costs EUR/yr
Annual Failures difference %
Lt/yr
Savings in Oil lubricant
EUR/yr EUR/Lt

kW (AVG)
Savings in Energy (2%)
EUR/yr EUR/kW ?
m3/yr
Savings in cooling water
EUR/yr EUR/m3

h/yr
Manpower reduction
EUR/yr EUR/h

Estimated Total
EUR/yr
Savings**
**these are just considerations and estimates and do not commit in anything the Group companies that make use of this projection tool.

Non Quantificable Benefits

Insurance Costs
Work place safety
Automation
Positive Environmental Impact

Investment
Calculation

Investment Estimation
Your Investment

Commonly the number of mist distributors is the number of pumps.

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 Reference Information

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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 217.

8º to 10º C cooler, page 218

20% to 25% less friction, page 218

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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.

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 Questions?

[email protected]

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