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REFERENCE GUIDE
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5. GREASE
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(I)
Petrol Engine Oils
(ii) Diesel Engine Oils
(iii) Automotive Gear Oils
(iv) Automotive Transmission Fluids
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(v) Brake Fluids & Specialities
(vi) Automotive Greases
(vii) Compressor Oils
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(viii) Corrosion Preventative Fluids
(iv) Cutting & Metal Processing Fluids
(x)
Industrial Gear Lubricants
(xi) Heat Transfer Oils
(xii) Hydraulic Oils
(xiii) Industrial Machinery & Bearing Oils
(xiv) Quenching Oils
(xv) Refrigerator Compressor oils
(xvi) Rock Drill & Pneumatic Machinery Lubricants
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(xvii) Steam Cylinder Oils
(xviii)Textile Machinery Oils
(xix) Turbine Oils
(xx) Electrical Transformer Oils
(xxi) Industrial Greases
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To
To
To
To
To
To
To
To
clean
disperse deposits
fight acids
reduce wear
prevent foaming
reduce friction
improve pourability in cold conditions
give oils multigrade characteristics
3 STAGES OF LUBRICANT
DEVELOPMENT
2. ENGINE
LABORATORY
3. FIELD TRIALS
small scale
screening tests
severe conditions
evaluation of up to 20
candidate formulations
detailed evaluation of
5 candidates
2 - 3 years duration
1. LABORATORY
In conclusion therefore, lubricants differ in terms of their thickness, base oil &
additive combinations. For instance, thicker oils are required in hot working
temperatures & the base oil & additive requirements differ between an engine oil
& gearbox oil. Lubricants are specialised products and the reputation of our
products depends upon Shell recommending the correct lubricant for the
required application.
NEVER RECOMMEND A SHELL LUBRICANT TO A CUSTOMER UNLESS YOU
ARE 100% SURE OF YOU FACTS. ASK IF YOU ARE NOT SURE. SHELLS
REPUTATION DEPENDS UPON YOU!!!!!!
should remain in the machine before its changed. However, these tests are
carried out in ideal laboratory conditions which is often not the case in reality,
conseqently the recommended change period sometimes has to be reduced if
the machine is operating in harsher conditions i.e. dusty/hot climates, high
sulphur fuels or because the machine is old & is therefore not operating
efficiently. The only time Shell would be prepared to allow extended drain oil
periods is when this is linked to oil condition monitoring( i.e.testing the oil in a
laboratory at agreed intervals whilst the oil is in service).
Q. Can Shell Lubricants be mixed with other companies oils?
A. Yes, but only in small quantities( i.e. top ups). However, mixing is not
recommended where Industrial oils are concerned.
3.VISCOSITY
In the common engineering sense, viscosity is the resistance to flow or
thickness of a liquid. Viscosity of oils decreases with increase in temperature,
hence the temperature at which a viscosity is measured must always be
specified.
There are three diferrent international classifications for measuring the viscosity
of oils & those are as follows:
The Society of Automotive Engineers (SAE) for Engine Oils.
The Society of Automotive Engineers (SAE) for Automotive Gear Oils.
International Organisation of Standardisation(ISO) for Industrial oils.
3(i)SAE Engine Oils:
The classification range for these are:
Thick OIL end
SAE 50
SAE 40
SAE 30
SAE 20W
SAE 15W
SAE 5W
SAE 0W
Thin OIL end
The HIGHER the number the THICKER the oil.
W stands for WINTER
3(ii)SAE Automotve Gear Oils:
The classification range for these are:
Thick OIL end
SAE 140
SAE 90
SAE 85W
SAE 80W
SAE 75W
Thin OIL end
The most common used SAE for gear oils in Africa are 80w,90 & 140.
SAE classification is not a measure of performance of an oil but simply a
classification of the oils thickness. Performance of oils will be covered under
section 4. Specifications & Classifications
3(iii)ISO Industrial Oils:
The most commonly used classification range for these are:
VISCOSITY COMPARISONS
C O MP AR IS O N O F IS O AND S AE V IS C O S IT Y C L AS S IF IC AT IO N S YS T E MS
C St at 40oC
cSt at 100 oC
850
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775
40
700
625
38
680
36
550
34
140
500
450
400
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30
460
28
365
26
315
280
24
320
22
240
205
175
90
40
150
100
85
60
68
46
40
32
22
20
10
ISO
VISCOSITY
GRADE
(INDUSTRIAL
85W
80W
75W
SAE
GEAR OIL
VISCOSITY
NO.
(AUTOMOTIVE)
20
18
220
140
115
50
30
20
10W
0W & 5W
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14
12
10
8
6
4
2
SAE
ENGINE
OIL
VISCOSITY
NO.
(AUTOMOTIVE)
As you will see from above, at 40 0 c an ISO 150 is the same thickness as an SAE
Gear Oil 90 & an SAE Engine Oil 40.
3(iv)Multigrades:
Multigrades meet the requirement of more than one viscosity classification & are
therefore suitable for use over a wider temperature range than a single grade
oil.
Multigrades are mostly associated with engine oils(i.e. SAE 20w/50) & some
automotive gearbox oils(i.e. SAE 85W/140). Multigrades are very seldom used in
an industrial oil application.
The modern trend is towards using multigrades for the following reasons:
Reduces the number of oils to stock as multigrades can often do the job of
at least two single grade oils.
Multigrades have additives which make them stronger & less likely to be
cut up by the engine. In other words they stay in grade longer.
They give increased engine protection from start up when the engine is
cold even at 30 0c & hot protection at 350 0c(piston top) when the engine is
running at full working temperature.
IT IS NOT TRUE THAT MULTIGRADES ARE NOT SUITABLE FOR AFRICA.
The most commonly used Multigrades in Africa are:
For Engine oils: 15w/40 & 20w/50.
For Gearbox oils: 80w/90 & 85w/140.
Hydraulics - CETOP
- DIN
Electrical - IEC
SH
DIESEL
highest(strongest)
CF -------------
SG
CE for turbo
charged engines
SF
SE
CD ------------CC
SD
SC
SB
SA
Lowest(weakest)
CB
CA
Lowest(weakest)
The LOWER the letter in the alphabet the LOWER the performance
The HIGHER the letter in the alphabet the HIGHER the performance
Respectable oil companies such as Shell do not market oils in the lower category
but concentrate on the better quality specs as highlighted above.
API GL 5
API GL 4
API GL 3
API GL 2
API GL 1
Weakest
The most common API GLs used in Africa are API GL 4 & API GL5.
GL 4 is usually recommeded for gearboxes & the back axle of passenger cars.
GL 5 is usually recommeded for gearboxes of some trucks & most truck back
axles.
5.GREASE
5(I) Manufacture & Function
Thickener (10-25%)
Additives (5-10%)
Grease
What is a grease ?
...... a
a solid to semi-fluid product of dispersion
of a thickening agent in a liquid lubricant.
Other ingredients, giving special properties,
may be included.
covers mineral oils, synthetic lubricants and
all kinds of thickener
excludes products which do not contain
thickening agents e.g. waxes
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Persistence
do not drain away from stationary lubricated surfaces
provide immediate lubrication on start-up
Protection
better sealants than oils
protection against corrosion during shut-down
Cleanliness
less likely to leak and splash than oils
can be used in production of food, drugs, textiles etc.
______________________________________________________________________________
Contamination
care needed to avoid contamination during storage
wear debris is retained in lubricant
contaminants can increase wear and/or damage grease
Design Limitations
cannot be used in very high speed bearings
_____________________________________________________________________________
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______________________________________________________________________________
Corrosion inhibitors
surfactants
reduce corrosion
Anti-wear
zinc, sulphur/phosphorous
reduce wear
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Stabilisers
water, fatty acids, alcohols, glycerine
improve stability
Dry lubricants
MOS2, graphite, powdered metals
improve lubrication at high temperatures/heavy loads
Tackiness additives
polymers
improve adhesion
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3
2
1
0
00
000
Semi Fluid Grease
The most commonly used NLGI in Africa are 2 & 3 i.e. Alvania EP 2 & Alvania
R 3. Retinax A is also NLGI 2. NLGI 3 is designed for higher temperature
applications i.e. electric motor bearings.
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High Performance
__________________________________________________________________________________
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Turbocharger Failures
DIESEL ENGINES
Differences to gasoline engines:
compression ignition, not spark ignition
operate at higher temperatures and pressures
heavier fuel, containing sulphur, but no lead
usually heavier, more rugged, and longer
lasting
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DIESEL ENGINE
DEVELOPMENTS
Historical developments have been
evolutionary rather than revolutionary
turbochargers
intercoolers
combustion chamber design
injection systems
fuel economy
progressively increasing demands on the
lubricant
INCREASING DEMANDS ON
DIESEL ENGINE LUBRICANTS
Higher temperatures
Chemical stress
Physical stress
Reduced oil consumption
Extended oil drain
Thermal stability
Depletion / degradation
Film strength
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__________________________________________________________________________
Advantages of gears
compact
can transmit high forces
can operate at high speeds
are very efficient
run smoothly
do not slip
are often available off the shelf
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Disadvantages of gears
______________________________________________________________________________
Gear Types
Gears transmitting
motion between
parallel shafts
Spur gears
Helical gears
Double helical gears
Gears transmitting
motion between
intersecting shafts
Gears transmitting
motion between
non-intersecting shafts
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_________________________________________________________________________
Hypoid gears
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Cooling
particularly important in enclosed gears
Protection
against corrosion
Maintaining cleanliness
removal of wear debris or external contamination
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Viscosity
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6.(iv) Hydraulics
Load
Hydraulic Medium
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Differential
Control Valve
Flexibility
Hydraulics can:
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Economy
Hydraulic equipment is:
compact
simple
often cheaper to manufacture than electrical,
electronic or mechanical systems that achieve the
same result
Power Transmission
must be able to flow easily and resist compression
Lubrication
has to lubricate all moving parts to minimise friction and
wear
Cooling
has to dissipate any heat generated in the hydraulic
system
Sealing
has to be sufficiently viscous to provide a good seal
between the moving parts in pumps, valves and motors
has to minimise leakage
has to be compatible with seal materials
Filterability
the fluid must be easily filterable
suitable viscosity
so that it can flow easily around the system and yet be
sufficiently viscous to provide adequate lubrication
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HYDRAULIC FLUIDS
critical performance considerations
Viscosity (Viscosity
Index)
Air Release
Foaming
Corrosion
Protection
Water Separation
Seal compatibility
Filterability
Water Tolerance
Oxidation Stability
Thermal Stability
Anti- wear
Stick Slip
Fire Resistance
HYDRAULIC OILS
viscosity selection
Oil viscosity must be matched to the needs of
the equipment
particularly system pumps and valves
HYDRAULIC OILS
Oxidation & Thermal Stability
Dictates oils service life
Poor Thermal Stability
Breakdown of additives
Degradation
Oil thickening
Solutions
Oxidation Inhibitors
Thermally stable additives
Quality base oils
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Refrigeration Compressors
Basic Principles of
Compression (1)
Heat is produced during compression
Energy is required to compress a gas. Normally, some
of this energy is dissipated as heat.
When gas is compressed by a moving piston, and
molecules colliding with the piston will have their
kinetic energy increased. The gas therefore gets hotter.
If the compression takes place very slowly, or in a
cooled container, so that the temperature remains
constant, it is said to be an isothermal operation.
If the compression takes place rapidly, or in an
insulated container, so that no heat is lost, it is said to
be an adiabatic operation.
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Basic Principles of
Compression (2)
Cooling during compression increases
efficiency
Less energy is required to carry out an isothermal
compression than an adiabatic compression, since in
adiabatic compression some of the energy is used to
heat the gas, the container and the piston.
Industrial compressors operate at conditions closer to
adiabatic than isothermal.
In order to keep temperatures within acceptable
values, compression of a gas is often carried out in
several stages, with cooling of the gas between stages.
This intercooling also minimises the work done during
compression and improves the efficiency of the
operation.
Basic Principles of
Compression (3)
Evaporation
Evaporation is the escape of molecules from the
surface of a liquid into the gaseous state.
A liquid takes up heat as it evaporates. This heat is
required to increase the thermal energy of the
molecules in the liquid and enable them to overcome
the cohesive forces holding the liquid together.
Rate of evaporation increases with increasing
temperature but decreases with increasing pressure.
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Basic Principles of
Compression (4)
Condensation
Condensation is the change of a substance from a
gaseous to a liquid state.
A gas gives out heat as it condenses
A decrease in temperature will encourage
condensation. Gases can also be condensed by
increasing the pressure on them (providing their
temperature is below a certain critical point).
Vapour at
low pressure
Condenser
Evaporator
condenses the
refrigerant giving
off heat to the
outside
Liquid under
high pressure
evaporates
the refrigerant
extracting heat
from the
refrigerator
Liquid under
low pressure
Expansion Valve
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Sealing
of the compressed gas between the high and low
pressure sides
Cooling
of the compressor bearings and casing
Noise reduction
of noise generated by the moving parts of the
compressor
Electrical insulation
of the motor in hermetically-sealed compressors
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Viscosity
Miscibility
Low temperature properties
Thermal stability
Chemical stability
Compatibility
Miscibility
in sealed systems, the oil must be completely miscible
with the refrigerant
if the oil/refrigerant separates into immiscible layers the
efficiency of refrigeration and lubrication will be impaired
there is a risk that the system will become blocked, and
the compressor may become starved of oil
if the oil and refrigerant are immiscible (e.g. in ammonia
systems), an oil separator must be included
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Thermal stability
although the temperatures in refrigerator systems are not
normally as high as in air compression systems, the oil
must not break down to form coke-like deposits, e.g. on
compressor chambers and valves
Compatibility
the oil must be compatible with the materials used in the
refrigeration system, e.g. electrical insulation, varnishes,
elastomers, polymers etc.
Above
-50C
to
-60C
Below
-70C
use specially tailored
(& expensive)
synthetic lubricants
e.g. silicone oil
and lithium based fluids
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1.
2.
3.
4.
5.
Shell produces lubricants for types of applications & these are categorised into
what are known as PRODUCT GROUPS as follows:
Engine oils(split petrol/diesel)
Automotive Gear Oils
Automotive Transmission Fluids
Brake Fluids & Specialty Products
Automotive Greases
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Compressor Lubricants
Corrosion Preventatives
Cutting & Metal Processing Fluids
Industrial Gear Lubricants
Heat Transfer Fluids
Hydraulic Oils
Machine & bearing Oil
Quenching Oils
Refrigerator Compressor Lubricants
Rock Drilling & Pneumatic Machinery Lubricants
Steam Cylinder Oils
Textile Machinery Oils
Turbine Oils
Transformer Oils
Industrial Greases
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LUBRICANTS
DATA
SHEETS
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MODEL
ENGINE
PETROL
API/SG
API/SG
API/SG
DIESEL
API/CD
API/CD
API/CD
BMW
316i,318i
1983-91
520i
728i,732i,
735
ALL
API/SG
API/SG
API/SG
G5
G5
G5
DAIHATS
U
APPLAUS
E
CHARAD
E
FOURTR
AK
API/SF,S API/CD
G
API/SF,S API/CD
G
API/SF,S API/CD
G
10,000KL 500OKLM
M
10,000KL 500OKLM
M
10,000KL 500OKLM
M
FIAT
UNO
API/SG
API/CD
PUNTO
API/SG
API/CD
TIPO
API/SG
API/CD
CROMA
API/SG
API/CD
10,000KL
M
10,000KL
M
10,000KL
M
10,000KL
M
CITROEN
FORD
PETROL
DIESEL
CCMC
G4,G5
ESCORT
FIESTA
SIERRA
HONDA
HYUNDAI
JAGUAR
LADA
LANDRO
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500OKLM
500OKLM
500OKLM
500OKLM
MAHINDR
A
MAZDA
MERCED
ES-BENZ
MITSUBI
SHI
NISSAN
OPEL
PEUGEO
T
RANGE
ROVER
RENAULT
SAAB
SKODA
SUBARU
SUZUKI
TOYOTA
VOLKSW
AGEN
VOLVO
GOOD STOREKEEPING
New packages should be wiped clean around the bungs, the labeling
checked and any marked variation from the products normal colour, smell or
consistence reported.
If there is any reason to doubt the good condition of a lubricant, the tank
or packages concerned should be quarantined to isolate the problem and your
Shell Lubricants Sales engineer consulted for immediate specialised advice.
Lubricants must only be dispensed from clean, dedicated containers.
Never be tempted to use ad-hoc oil measures otherwise, for example, tin cans in
a food factory could end up on the production line full of oil.
Spilt oil can cause accidents and should be cleaned up without delay.
Sawdust is effective, but represents a fire hazard and should be removed as soon
as it becomes oily.
Grease guns should be filled cleanly and carefully for grease acts as an
abrasive when mixed with grit or dirt.
When empty, lubricants containers should have their bungs or lids
securely replaced to prevent contamination.
ii)
STORAGE
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Insulating oils
Refrigeration oils
Greases
In all cases where storage of lubricants is considered, attention should be
given to the effects of storage on the condition of the containers. In particular,
prolonged storage may give rise to peeling of paint and obliteration of markings.
iii)
STACKING DRUMS
INDOOR STORAGE
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HANDLING DRUMS
The standard 205 litre barrel weighs about 180 kg when filled with oil. It is
strong being designed to be re-used several times, but is readily damaged by
bad handling.
The barrels must never be dropped when being unloaded or moved. The
impact can burst the seams, causing subsequent leaking or contamination of the
contents.
There are many suitable methods of handling barrels, but the most widely
accepted are:
Manual elevator
FIRE-HAZARDS
HEALTH HAZARDS
41
vapours or mist. To ensure that their use will be safe and without risk to health,
the following guidelines should be followed.
Since lubricants and related products can become contaminated during
service, particular care should be taken to minimise contact with used oils.
It is emphasised that all these risks are virtually non-existent if regular
and prolonged contact with the skin and exposure to mist, fumes and vapours is
avoided. This is
readily achieved by the observance of good working
practices and personal hygiene.
To ensure that workers are not at risk, it is necessary for them to practice
good standards of personal and industrial hygiene.
They should:
a)Use oil impermeable gloves or, if they cannot be used, suitable oil
repellent type barrier creams.
b)Avoid unnecessary contact with oil by using protective clothing and
ensuring that machine splash guards are properly adjusted.
c)Not put oily rags or tools into pockets, especially trouser pockets.
d)Not use dirty rags for wiping oil off the skin. Abrasions may be caused
by metal particles and swaft embedded in the rags and lead to subsequent
infection.
e)Obtain First Aid treatment at once for any injury, however slight.
f)Wash regularly, especially before meals, before smoking, before using
the toilet and after work, to remove oil from the skin. They should use soap or
any special cleaners provided. Solvents such as kerosene (paraffin), gasoline
(petrol), etc. must not be used to remove oil from the skin. Use a conditioning
cream after washing, where provided.
advice
g)Report any Skin abnormality of any part of the body and seek medical
without delay.
viii)
persist
42
refer
ix)
DISPOSAL
an
Spillage
- Spilt product should be absorbed with sand, earth or mineral absorbent
disposed of in accordance with local regulations. In the event of a large
spillage, steps should be taken to prevent pollution of drainage
systems,
rivers and waterways.
and
Disposal of packages
- Used packages should be disposed of safely, preferably to recognised
dealers/renovators. It is dangerous, because of the risk of explosion, to
attempt modification of containers by oxy-acetylene torch or
hammer and chisel etc. If the containers are to be re-used all markings should
be removed or obliterated.
drum
risk
Waste Oil
- Used products should be disposed of, preferably to a licensed collector
or
contractor so
that they do not contaminate drainage systems,
rivers or
waterways in accordance with local legislation.
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THE FOLLOWING TERMS ARE NOT ALL IN THIS GUIDE BUT ARE USED EXTENSIVELY IN THE OIL INDUSTRY
Additive: A chemical substance which, when blended with a petroleum product, has the effect of improving one or more of its
properties or performance characteristics.
API Service Classification: A system of letter designations agreed on by API, SAE, and ASTM to define broad classes of engine
service. Also a system of service classifications for automotive gear lubricants.
Demulsibility: Ability of an oil to separate from or shed water as determined by a standard test method. Demulsibility is an
important consideration in lubricant maintenance in many circulating lubrication systems.
Detergency: Property of a lubricating oil to reduce or prevent deposits formed under high temperature conditions or as a result of the
action on the oil of acidic contaminants.
Dispersant: An engine oil additive that helps prevent sludge, varnish and other engine deposits by keeping particles suspended in a
colloidal state (suspension of finely divided particles).
Dropping Point: The lowest temperature at which a grease is sufficiently fluid to drip as determined by a standard test method;
hence and indication of whether a grease will flow from a bearing at operating temperatures.
Emulsifier: An additive that promotes the formation of a stable mixture, or emulsion of oil and water.
Extreme Pressure Additive: Chemical compound imparting extreme pressure characteristics to a lubricant with the objective of
reducing wear under conditions where rubbing or sliding accompanies high contact pressures, as in heavily loaded gears, particularly
of the hypoid type.
Flash Point: The lowest temperature under closely specified conditions at which a combustible material will give off sufficient
vapour to form a flammable mixture with air in a standardized vessel. Flash point test are used to assess the volatilities of petroleum
products.
Foaming: Occurrence of a frothy mixture of air and a petroleum product (lubricant, fuel oil) that can reduce the effectiveness of the
product and cause sluggish hydraulic operations, air binding of oil pumps and overflow of tanks or sumps.
Graphite: A soft form of elemental carbon, grey to black in colour. It occurs naturally or is synthesized from coal or other carbon
sources; widely used as a lubricant alone or added to conventional lubricants.
Grease: Lubricating oil thickened with a metallic soap or a special clay to yield a lubricant in solid form. The action of the
thickening agent may be likened to that of a sponge which holds the lubricating agent in its interstices.
ISO- VG: The ISO viscosity classification system, an international system approved by the ISO, for classifying industrial lubricants
according to viscosity. Each ISO viscosity grade number designation corresponds to the mid-point of a viscosity range expressed in
centistokes at 40 oC. This system is detailed in the ISO Specifications ISO 3448.
Molybdenum Disulphide: Chemical compound of molybdenum and sulphur which has excellent properties as a solid lubricant due
to the type of molecular structure of the particles.
Multigrade Oil: Engine oil that meets the requirements of more than one SAE viscosity grade classification and may therefore be suitable for
use over a wider temperature range than a single grade oil. Multigrade oils have 2 viscosity grade numbers indicating their lowest and highest
classification.
Multipurpose Grease: A lubricating grease suitable for a variety of appellations, such as chassis, wheel, bearings, universal joints, and water
pumps on automotive equipment; usually lithium-based.
Penetration: A measure of the hardness and consistency of bitumen and lubricating greases in terms of the distance in tenths of a millimeter
by which a weighted special needle or cone will penetrate the sample in 5 seconds, the temperature, unless otherwise stated being 25 oC
(77oF).
Pour Point Depressant: An additive which lowers the pour point of petroleum products containing wax by reducing the tendency of the wax to
collect into a solid mass.
Pour Point: Lowest temperature at which a liquid petroleum product will flow when it is cooled under the conditions of the standard test
method.
SAE Number: Number indicating the viscosity range of crankcase, transmission, or rear axle lubricant, according to systems designed by SAE.
Shear Stability: Ability of a lubricant such as a grease or VI improved oil to withstand mechanical shearing without being degraded in
consistency or viscosity.
Soap: General term for the salt of a metal and a fatty acid. Ordinary washing soaps are those of sodium and potassium. The soaps of lithium,
sodium, calcium, barium, and aluminium are the principle thickeners used in grease making.
Sludge: Soft deposits, usually dark coloured formed in lubrication systems, mainly consisting of oxidized lubricating oil components, water
and, in internal combustion engines, carbonaceous residues from fuel combustion.
Viscosity: In the common engineering sense, viscosity is the resistance of flow or thickness of a liquid. Viscosity of oils decreases with
increase in temperature, hence the temperature at which a viscosity is measured must always be specified.
Viscosity Improver: Lubricant additive, usually a high molecular weight polymer, that reduces the tendency of an oils viscosity to change with
temperature.
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13)
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