LLA – Day 1

Lubricant Base Oil

Chemistry - Expalin

 Crude Oil
 Origins of crude oil
 The Seven Sisters
 What is crude oil
 Crude Oil is a mixture of naturally occurring hydrocarbons that is refined into diesel, gasoline,
heating oil, jet fuel, kerosene, and literally thousands of other products called petrochemicals.
 Variability in crude oil
 Classes of crude oil
 Very Light Crude
 Light Crude
 Heavy Crude
 Heavy Sour Crude

Sweet crude found includes the Appalachian Basin in Eastern North America, Western Texas, the Bakken
Formation of North Dakota and Saskatchewan, the North Sea of Europe, North Africa, and the Far East
including Indonesia. Australia

Sour crude is more common in the Gulf of Mexico, Mexico, South America, and Canada. Crude produced
by OPEC Member Nations also tends to be relatively sour, with an average sulfur content of 1.77%.

Classes of crude oil

Benchmark Crude

• West Texas Intermediate (WTI) – the Gold Standard

• North Sea Brent Blend

• OPEC Basket

Other Lesser Crude

• Dubai & Oman Sour

• Tapis (Singapore)

• Bonny Light (Nigeria)

• Istmus (Mexico)

• Maya

Crude Chemistry
Crude oil is a mixture of different sized hydrocarbons. The exact composition depends upon where the
oil comes from but typically it contains a lot of big molecules.

 Crude oil is composed of the following groups:

 Hydrocarbon compounds
 Non-hydrocarbon compounds
 Organometallic compound and inorganic salt (metallic compound)
 Crude oil composition
 Crude oil composition
 Different types of hydrocarbons make up crude oil. The percentage of each varies from crude
source. The percentage dictates the oil properties.
 Mineral Base Stocks

Lubricating Oil Molecules contain 25 to 40 Carbon atoms, and a complement of Hydrogen atoms in
various structures and shapes.

Mineral Oil Typical Properties

Paraffin: any of numerous saturated hydrocarbons; specifically : any of a series of open-chain

hydrocarbons CnH2n+2 (such as methane and butane)

Aromatic Compound: a compound that contains a benzene ring or has certain benzene-like properties
(but not necessarily a strong aroma).

Naphthenes: cyclic aliphatic hydrocarbons or simply Cycloalkanes.

The general form of the chemical formula for cycloalkanes is CnH2(n+1−r), where n is the number of
carbon atoms and r is the number of rings.

Asphaltics

Asphaltic: a compound mostly organic, carbonaceous matter, mostly in the form of tarry hydrocarbons
which are usually described as bitumen.

Olefins

Olefins: compounds that contain one or more double bonds (unsaturated) between carbon atoms.

Crude Assay

• A compilation of laboratory and pilot plant data that define the properties of the specific crude
oil. At a minimum, it should contain distillation curve and specific gravity curve.

Crude Properties

• The true boiling point curve is a plot of the boiling points of almost pure components, contained
in the crude oil or fractions of the crude oil.
What is in a Barrel of crude

Barrel of Crude

Interesting Facts…

• Only 1% ± of Crude is used to make Lubricants

• Half of that 1% goes to make Engine Oil – the Dominant Market

• The other half goes to make Industrial Products – of which

• Half is Machine Oil / Half is Process Oil

It All Starts with Distillation

Levels of Distillation

Fractional Distillation

Oil is vaporized before it enters the fractioning column

Catalytic Hydrogenation Process

GII, GIII Hydrocracked Stocks

• Long chain paraffin (waxy paraffin) are converted into stocks with more suitable lubricating
properties, including improved low temp. flow performance. Hydro-finishing is used to remove

Mineral Oil (Group I)

 Molecular size varies greatly (Wide MWD)

 Contains sulfur, wax, nitrogen, solids, water and aromatics
 Impurities removed during the Refining Process (Solvent and Hydrocracked)
 Hydrocracked (Group II, III)
 Molecular size varies slightly – tighter MWD
 A few differences in molecular structure
 Contains almost no sulfur, wax, nitrogen, solids, water and aromatics
 Impurities almost completely removed during Hydrocracking

Synthetics (Group IV, V)

 Molecular size varies insignificantly – Very Narrow MWD

 No differences in molecular structure
 Contains no sulfur, wax, nitrogen, solids, water and aromatics
 Performance properties are highly predictable

Synthetic Oils

Chemically synthesized (polymerization)

Designed to have specific properties:

• Low pour point

• High viscosity index

• High flash point / fire resistance

• Oxidatitive and thermal stability

• High shear strength

API Designated Base Oil Qualities

Organic Esters – Monoesters, Diester, Polyolester

GII, GIII Hydrocracked StocksDiester, Polyol Ester

• An Acid – Alcohol Condensation Reaction process.

• Diester - Formed by reaction between an di-basic acid (adipate, azelate, sebacate,

dodecanedioate) and a monofunctional alcohol (hydroxyl) group (Isoheptanol, -octanol,
tridecanol, etc..).

• Polyol Ester – Formed by a reaction between a polyhydric alcohol (one containing two or more
hydroxyl groups) with a mono-basic acid (oleic, steric, isosteric, ethyl hexyl).

Organic Esters – Monoesters, Diester, Polyolester

Phospate Ester

• An Phosphoric (weak) Acid – Alcohol condensation reaction process.

• Formed through a variety of complex reaction process to produce 3 broad classes of fluid that
represent 13 different molecular families. Each family of products has unique properties.
Typically, these classes are mixed to maximize performance capabilities for specific applications.
These are mostly used as elements in a solution. Neutral esters of orthophosphoric acid is the
only class to find wide use as a lubricant base stock.

Polyalphaolefin – (AKA Synthetic Hydrocarbon, Olefin Oligomer)

Ethylene reaction process carried until the by products deliver a planned size (weight).

Viscosities range from 2 cSt @ 40° C to 100 cSt @ 100°C.

Polyalkylene Glycol – Ethylene, Propylene, Butylene Oxides

PAG – Polyethylene, Polypropylene Glycol AKA – Homopolymer of ethylene oxide, polyoxyalkylene

glycol, polyethylene glycol, polyethylene oxide; polypropylene oxide polypropylene glycols, polyalkylene
glycol ethers, etc...

• Formed by polymerizing epoxides. The reaction is initiated by reacting alcohol and metal
alkoxide of potassium or sodium salt, which creates a chain reaction. As long as the materials
are fed, the reaction continues to equilibrium.
Polyalkylene Glycol – Ethylene, Propylene, Butylene Oxides

Ethylene Oxide properties:

10 cSt – 15,000 cSt

Pour Point Varies with Viscosity – Generally Good

VI Dependent on Structure – Generally High (200+)

Temp Stable to 200°C ±

Low Residue and Sludge Formation

Water Soluble, will hide up to 10% Water by Volume

Will soften polycarbonate, polyurethane plastics

Propylene oxide properties:

10 cSt – 15,000 cSt

Pour Point Varies with Viscosity – Generally Good

VI Dependent on Structure – Generally High (200+)

Temp Stable to 200°C ±

Low Residue and Sludge Formation

Water Insoluble, Oil Insoluble

Inverse (to oil) water solubility rules

Will soften polycarbonate, polyurethane plastics

Base Stocks – Performance Comparisons

Synthetic Lubricant Properties

Synthetic Lubricant Properties

Oil Seed Derived Base Oils

Oil Seed Derived Base Oils

Linseed

Sunflower

Safflower

Canola (Rapeseed)
A variety of oil seeds can produce lubricant base oils. These are called natural esters (because they are
‘synthesized’)

Bio-Based Base Oils

The best application for bio-based lubricants is in machinery that loses oil directly into the environment
during use, total loss lubricants (TLLs), and in machinery used in any sensitive areas, such as in or near
water.

Applications for TLLs include two-stroke engines, chainsaw bars and chains, railroad flanges, cables, dust
suppressants, and marine lubricants.

Bio-Based Base Oils

Compared to petroleum-based lubricants, use of bio-based lubricants:

 Produce a cleaner, less toxic work environment and fewer skin problems for those working with
engines and hydraulic systems.
 Offers better safety due to higher flashpoints, constant viscosity, and less oil mist and vapor
emissions.
 Produces fewer emissions due to higher boiling temperature ranges of esters.
 Are highly biodegradable.
 Costs less over the product’s life-cycle due to less maintenance, storage and disposal
requirements.

Bio-Based Base Oils

 They have several disadvantages in the use phase of the product life cycle, including:
 Some bad odors if contaminants are present.
 High viscosity at low temperatures.
 Poor oxidative stability at high temperatures, although additives designed specifically for plant-
based lubricants eliminate stability issues related to extreme high and low temperatures.
 Oxidation of Vegetable Oil in Machinery
 Price Comparison of Bio-based Oil v. Petroleum
 The current price comparison between bio-based and conventional lubricants is as follows:
 Vegetable & Mineral Oil Comparison

Vegetable Oil Comparison

DOE – USDA Bio-based Vison Goals

Performance Comparisons
Laboratory Safety

Acronyms

 OSHA – Occupational Safety & Health Administration

 EPA – Environmental Protection Agency

 PADEP – Pennsylvania Department of Environmental Protection

 NIOSH – National Institute of Occupational Safety & Health

 CDC – Centers for Disease Control & Prevention

 NSC – National Safety Council

 Lab Regulations

 Occupational Exposures to Hazardous Chemicals in Laboratories. OSHA Lab Standard

(29CFR1910.1450)

 HAZWOPER (Chemical Spills) Hazardous Waste Operations Standard (29CFR1910.120)

 Noise Exposure Standard (1910.95)

 Personal Protection Equip Standard (1910.132)

 Respiratory Protection Standard (1910.134)

 Lockout/Tagout Standard (1910.147 & 333)

 Toxic & Hazardous Substances (1910.1000)

 Hazard Communication Standard (1910.1200)

 Globally Harmonized System

Globally Harmonized System, also known as “GHS” was created by the united nations. It is a system for
standardizing chemical classification and labeling for world-wide implementation

 Laboratory Personal Responsibility

 Wear personal protective equipment (PPE).

 Follow and enforce safety rules, procedures,

and practices.
 Demonstrate safety behavior and promote a
culture of safety.

 Be proactive in every aspect of laboratory

safety, making safety a priority.

 General Safety

 General Safety

 General Safety

 General Safety-Housekeeping

 Keep work areas neat and free of any unnecessary objects.

 Thoroughly clean laboratory work spaces

 Do not block sink drains with debris.

 Never block access to exits or emergency equipment.

 Inspect all equipment for damage (e.g. cracks, defects, etc.) prior to use.

 Never pour chemical waste into trash cans.

 General Safety-Glassware

 Use caution when inserting/removing glass tubing from rubber stoppers.

 Protect your hands with towels or gloves when inserting/removing glass tubing.

 Chipped, cracked, or scratched glassware should never be used.

 Broken glassware must be placed in a box or hard plastic container with a plastic liner and
appropriate signage.

 Always use glass drying racks to support glassware when drying.

 Personal Protective Equipment

 Personal Protective
Equipment

 Always wear appropriate eye protection in the lab (e.g. chemical splash goggles).

 Wear chemical resistant gloves when handling hazardous chemicals and disposable gloves when
handling other chemicals.

 Wear a full-length, long-sleeved lab coat or chemical resistant apron.

 Wear shoes that adequately cover the whole foot (low-heeled shoes with non-slip soles are
preferred).

 Do not wear sandals, open-toed shoes, open-backed shoes or high-heels.

 Avoid wearing short dresses/skirts, shirts that expose the torso, or shorts.

 PPE: Eye Protection

 Use chemical splash goggles with indirect vents and meeting ANSI impact standard Z87.1 when
working with hazardous liquids or solids.

 Use safety glasses with side shields and meeting ANSI impact standard Z87.1 when working with
solids or projectiles.

 PPE: Gloves

 Use the proper glove when handling chemicals.

 Three materials that are very resistant to chemicals: neoprene, butyl, or nitrile.

 Disposable gloves may be acceptable for certain chemicals – check the SDS and/or
manufacturers specifications.

 Chemical Handling

 Chemical Handling

 Check the chemical label to verify it is the correct substance before using.

 Always use a spatula or scoopula to remove a solid reagent from a container.

 Do not touch chemicals with bare hands.

 Never use a metal spatula when working with peroxides.

 Hold containers away from the body when transferring a chemical or solution from one
container to another.

 Use a hot water bath to heat flammable liquids, never use a flame.

 Chemical Handling

 Add concentrated acid to water slowly; never add water to a concentrated acid.

 Weigh out or remove only the amount of chemical you will need; do not return excess to
container, dispose of properly.

 Never touch, taste, or smell any reagents.

 Never place the container directly under your nose to inhale vapors.

 Never mix or use chemicals not required in the lab exercise.

 When transporting chemicals: place the container in a secondary container or bucket (plastic,
rubber, metal) designed to be carried and large enough to hold entire contents.

 Never handle bottles that are wet/too heavy.

 Use equipment in the way it was designed.

 Chemical
Labeling

 Chemical Labeling

Labeling Basics:

 Use labels with good adhesive.

 Use a permanent marker (waterproof and fade resistant) or laser (not inkjet) printer.

 Print clearly and visibly.

 Replace damaged, faded or semi-attached labels

 Commercially Packaged Chemicals

Verify that the label contains the following information:

 Chemical name (as it appears on the SDS)

 Name of chemical manufacturer

 Necessary handling and hazard information

Add:

 Date received

 Date first opened

 Expiration or “use by” date (if one is not present)

 Chemical Labeling

Secondary Containers and Prepared Solutions

Label all containers used for storage with the following:

 Chemical name (as it appears on the SDS)

 Name of the chemical manufacturer or person who prepared the solution

 Necessary handling and hazard information

 Concentration or purity

 Date prepared

 Expiration or “use by” date

Containers in Immediate Use

These chemicals are to be used within a work shift or laboratory session.

 Label all containers in immediate use with the following:

 Chemical name (as it appears on the SDS)

 Necessary handling and hazard information

 Chemical Labeling

Peroxide-forming chemicals must be labeled with:

 Date received

 Date first opened

 Date to be disposed of

 Label Information-GHS

Chemical manufacturers and importers must provide a label that includes:

 Harmonized signal word (Danger; Warning)

 Pictogram

 Hazard statement for each hazard class and

category

 Precautionary statements must also be

provided as well as product identifier and
supplier information

 Pictograms - GHS

 Different symbol on white background with red square frame set on point

 Eight pictograms are required by OSHA

 The ninth one dealing with the environment is not within OSHA’s jurisdiction

 Labels - GHS

Information required on a GHS label:

1. Product identifier

2. Pictograms

3. Signal word

4. Hazard statement

5. Precautionary
statement

6. Supplier information
 Chemical
Waste

 Chemical Waste

All containers used for chemical waste should be labeled with:

 “WASTE” or “HAZARDOUS WASTE”

 Chemical name (as it appears on the SDS)

 Accumulation start date

 Hazard(s) associated with the chemical waste

 Chemical
Storage

 General Rules

Criteria for Storage Area:

 Store chemicals inside a closeable cabinet or on a sturdy shelf.

 Shelf should have a front-edge lip to prevent accidents and chemical spills (recommended ¾-
inch high).

 Shelving should be secured to wall or floor.

 Ensure that all storage areas have doors with locks.

 Keep chemical storage areas off limits to all students.

 Ventilate storage areas adequately.

 Chemical Storage

 Chemical Storage

 Chemical Storage- Organization

 Organize chemicals first by COMPATIBILITY—not alphabetic succession.

 Store alphabetically within compatible groups.

 Chemical Segregation

 Store acids in a dedicated acid cabinet.

 Nitric acid should be stored alone unless cabinet provides a separate compartment for nitric
acid storage.

 Store highly toxic chemicals in a dedicated, lockable poison cabinet that has been labeled with a
highly visible sign.
 Chemical Storage

 Chemical Segregation

Store volatile and odoriferous chemicals in a ventilated cabinet.

Store flammables in an approved flammable liquid storage cabinet.

Store water sensitive chemicals in a water-tight cabinet in a cool and dry location segregated from all
other chemicals in the laboratory.

 Storage Don’ts

 Do not place heavy materials, liquid chemicals, and large containers on high shelves.

 Do not store chemicals on tops of cabinets.

 Do not store chemicals on the floor, even temporarily.

 Do not store items on bench tops, in laboratory chemical hoods or under sinks.

 Do not store chemicals on shelves above eye level.

 Do not store chemicals with food and drink.

 Do not store chemicals in personal staff refrigerators, even temporarily.

 Do not expose stored chemicals to direct heat or sunlight, or highly variable temperatures.

 Chemical Storage

Proper Use of Chemical Storage Containers

 Never use food containers for chemical storage.

 Make sure all containers are properly closed.

 After each use, carefully wipe down the outside of the container with a paper towel before
returning it to the storage area.

 Properly dispose of the paper towel after use.

 Safety Data
Sheet

 Safety Data Sheet

 Contains information regarding the proper procedures for handling, storing, and disposing of
chemical substances.

 SDS accompanies all chemicals or kits that contain chemicals.

 SDS’s can be obtained from related web sites (e.g. hazard.com) and manufacturers.

 Safety Data Sheet

 Save all SDS’s and store in a designated file or binder.

 Use a system that is organized and easy to understand.

 Place SDS collection in a central, easily accessible location known to all Technicians and
emergency personnel.

 Typically the information is listed in a standardized format.

 Safety Data Sheet Categories

 Section 1: Identification

 Section 2: Hazard identification

 Section 3: Ingredients

 Section 4: First-aid measures

 Section 5: Fire fighting measure

 Section 6: Accidental release measures

 Section 7: Handling and storage

 Section 8: Exposure controls and personal protection

 Section 9: Physical and chemical properties

 Section 10: Stability and reactivity

 Section 11: Toxicological information

 Section 12: Ecological information*

 Section 13: Disposal considerations*

 Section 14: Transport information*

 Section 15: Regulatory information*

 Section 16: Other information

 Spill

 Spill Response

 A chemical spill cart should be available to handle small spills in the laboratory

 Large spills and leaks require:

• Evacuation

• Contact local FD immediately (911)

 Emergency numbers: posted in each laboratory.

 Direct means of communications with front office by phone or intercom

 Spill Kit

Should include:

 Spill control pillows/pads

 Neutralizing agents for acid spills

 Neutralizing agents for alkali spills

 Pick up equipment: brush, broom, pail, dust pan

 Personal protective equipment (PPE)

 Inert absorbents such as sand or kitty litter

 Spill Clean-up

Use appropriate personal protective equipment:

 Gloves

 Apron

 Chemical splash goggles

 Closed-toe foot protection

Clean up small spills with guidance of the appropriate SDS and/or procedures in place within your
system.

 Chemical
Disposal

 Chemical Disposal

 Chemical waste = any chemical discarded or intended to be discarded.

 HAZARDOUS chemical waste (designated by EPA or PA DEP) = waste that presents a danger to
human health and/or the environment.

 According to EPA regulations, there are four characteristics that define a waste as hazardous:

• Ignitability

• Corrosivity

• Reactivity

• Toxicity

 Storing Chemicals for Disposal

 Store all waste in containers that are in good condition and are compatible with their contents.
 Clearly and permanently label each container as to its contents.

 Label as hazardous waste.

 Store waste in a designated area away from normal laboratory operations and to prevent
unauthorized access.

 Store waste bottles away from sinks and floor drains.

 Do not completely fill waste bottles; leave several inches of space at the top of each waste
container.

 Cap all waste bottles.

 Disposal Procedure

 Compressed Gas Cylinders

 Compressed Gas Cylinders

Storage, Maintenance & Handling

 Compressed gases can be hazardous because each cylinder contains large amounts of energy
and may also have high flammability and toxicity potential. Think safety:

• Ensure the contents of all compressed gas cylinders are clearly stenciled or stamped on
the cylinder or durable label.

• Do not identify a gas cylinder only by the manufacturer’s color code.

• Never use cylinders with missing or unreadable labels.

 Compressed Gas Cylinders

Storage, Maintenance & Handling

 Check all cylinders for damage before using.

 Be familiar with the properties and hazards of the gas inside the cylinder before using.

 Wear appropriate PPE before handling/using.

 Check for leaks after attaching a cylinder by using a soap solution, “snoop” liquid, or gas
detector.

 Label empty cylinders as “EMPTY” or “MT.”

 Always attach safety caps when storing or moving cylinders.

 Larger cylinders should be secured to a wall or lab bench by a clamp or chain.

 Store cylinders by gas type; separate oxidizing gases from flammable gases by either 20 feet or
a 30 minute 5 foot high firewall.
 Store cylinders in a cool, dry, well-ventilated area away from incompatible materials and ignition
sources.

 Do not subject any part of a cylinder to temperatures higher than 125 deg F or lower than 50
deg F.

 Store empty cylinders separately from full ones.

 Ventilation

 Ventilation

 Critical for safe and healthy operation.

 Occupied lab air exchange rates should be 6 to 10 times an hour per applicable standards.

 Unoccupied lab air exchange rates including storerooms should be 4x in 1 hour (NFPA 45).

 Air supplies to labs, storerooms, prep rooms should never be recycled to any other part of the
building, other labs, offices.

 Only conduct experiments the ventilation system can handle without a fume hood.

 HVAC filters should be changed quarterly.

 Fume Hood

 Provides local exhaust ventilation.

 Essential in exhausting hazardous gases, particulates, vapors, etc.

 Use hood to remove airborne chemicals (e.g. aerosols, dusts, fumes, vapors).

 Do not store items within fume hoods.

 Place apparatus far back to rear of hood for efficient air flow.

 Ensure only necessary materials are under hood during an operation.

 Avoid having students work opposite a fume hood.

 Always keep the sash between the face and experiment – sash should be lowered.

 Check air flow before and during operation (face velocity of 80-120 fpm).

 Emergency Eyewash/Shower

 Emergency Eyewash/Shower

 OSHA 1910.151c states:

“Where the eyes or body of any person may be exposed to injurious corrosive materials, suitable
facilities for quick drenching or flushing of the eyes and body shall be provided within the work area for
immediate emergency use.”
 Emergency Eyewash/Shower

 Should comply with ANSI Z358.1: “Minimum performance and use requirements for emergency
eyewash and shower equipment.”

 Should be within 10 seconds walking time from the hazard.

 Must be on the same level as the hazard.

 Path of travel to station should be free of hazards and as straight as possible.

 Emergency eyewash stations should be able to deliver 3gpm of water for 15 minutes.

 Emergency shower should be able to deliver 20gpm for 15 minutes.

 Emergency Eyewash/Shower

 Must have “hands free stay open valve” capable of activation in 1 second or less.

 Area around station should be well lit.

 Must be identified by highly visible sign.

 Emergency eyewash outlet “heads” must be protected from airborne contaminants.

 Stations should be protected from freezing.

 Weekly inspections should be documented

 Should be “flow tested” and checked weekly to ensure:

• Area around station is well lit.

• Identified by a highly visible sign.

• Outlet “heads” are protected.

• Area is not obstructed.

• Control valves are operational.

• Flow activates in 1 second or less.

 First Aid

 First Aid

 First aid kits should be available in each laboratory along with the phone # of medical help.

 PPE for protection against exposure to bodily fluids should be contained in the kits (e.g. gloves,
surgical mask, etc.).

 Management should be contacted for any injury and to provide treatment beyond first aid.

 Basic First Aid Measures

Eye Contact:

Immediately flush eyes with plenty of water for at least 15 minutes lifting the upper and lower eye lids
occasionally. Get professional medical attention immediately.

Skin Contact:

Immediately flush skin with plenty of water for at least 15 minutes while removing contaminated
clothing and shoes. Get medical help immediately.

Inhalation:

Evacuate victim to fresh air and get professional medical help immediately.

 Resources

 Occupational Safety & Health Administration (OSHA) www.osha.gov

 Environmental Protection Agency (EPA) www.epa.gov

 National Institute for Occupational Safety & Health (NIOSH) www.cdc.gov/niosh/homepage.html

 Schools Chemical Cleanout Campaign (SC3)

www.epa/gov/epaoswer/osw/conserve/clusters/schools/index.htm

 National Toxicology Program (NTP) http://ntp-server.niehs.nih.gov

 Centers for Disease Control & Prevention (CDC) www.cdc.gov

 Consumer Product Safety Commission (CPSC) www.cpsc.gov

 Department of Transportation (DOT) www.dot.gov

 Council of State Science Supervisors (CSSS) www.csss-science.org/safety.htm

 Laboratory Safety Institute (LSI) www.labsafety.org

Lubricant Health and Safety

Disposal & waste management

Safety training, policies and guidelines

Hazardous lubricants and toxicity

Microbial safety risks and control of transmission

Fluid pressure and fluid injection risks

Lubricant mists in the work environment

Confined space risks

Fire and combustion risks

Electrocution risks

Other mechanical risks

Lubricant
Disposal & Waste Management

Lubricant Disposal & Waste Management

Handling the waste oil so that it will value

Preventing the waste from polluting

Lubricant Disposal & Waste

Management

Proper collection and routing systems.

Most units of these types have their own pumping and discharge System

Waste oil is carted back to be put in holding tanks or drums for final disposal.

Lubricant Disposal & Waste Management

Waste Collection

Separate collection systems

Lubricating oils should be kept separate on the basis of degree of contamination

Reservoirs should be drained immediately after shutdown

Prevent contamination of process water, storm drains, and sewer

Open troughs or floor gratings and drains to catch leaks, spills, and drips or to route waste oil

Lubricant Disposal & Waste Management

FINAL DISPOSAL

Lubricants, including metalworking fluids, hydraulic fluids, and gear oils, eventually must be disposed of
as waste oil.

Reclaiming heat value by using as a fuel supplement

Re-refining and reconstitution of additives for reuse

Incineration

Coal or petroleum coke spray, or density control in specific processes where appropriate

Lubricant Disposal & Waste Management

Energy Generation

Considered Recycling

Feasible for Large, Medium, and Smaller users

Turn Waste Oil Into An Asset

Safety Training, Policies and Guidelines

Train Regularly, Cover Specific knowledge of Safety Data Sheet (SDS)

For First-hire Employees, Changing Positions / Responsibilities, Change or Implementation

Refresher Training Based on the Company or Group Need or by Regulation (at least annually)

Safety Training, Policies and Guidelines

Acute Toxicity

single exposure

LD50 (lethal dose) figure is given to characterize the substance

Acute LD50, value in grams or mg kg–1 body weight of the animal after which 50% of the animals die
after 1 dose.

In animal tests:

Orally (in the mouth)

Dermally (via the skin) o

Inhalation - lethal concentration in air, LC50 is given in mg L–1 air over a defined period of time

Sub-chronic and Chronic Toxicity

Health hazards after repeated exposure

Animal tests to determine these long-term effects

28 days (sub-acute)

90 days (sub-chronic)

Over a half-year (chronic)

Hazardous Lubricants and Toxicity

Hazardous Lubricants and Toxicity

Chemicals can be allocated to one of five toxicity categories based on acute toxicity by

Oral

Dermal

Inhalation route

Numeric Criteria Expressed as (approximates) LD50 (oral, dermal) or LC50 (inhalation) Values

Hazardous Lubricants and Toxicity

Inhalation cut-off values – 4-hr testing exposures; 1-hr exposures divided by

2 for gases and vapors

4 for dusts and mists

Recognized Saturated Vapor

Mixture:

Category 1 (100 ppm)

Category 2 (500 ppm)

Category 3 (2500 ppm)

Category 4 (5000 ppm)

Dust and Mist concentrations in respirable form

Criteria for Category 5 low acute toxicity hazard, danger to vulnerable populations.

Hazardous Lubricants and Toxicity

Oral or Dermal LD50 2000-5000 mg/kg or equivalent doses Category 5 toxic effects in humans indicate a
concern for human health or an acute nature.
The substance is classified in this Category, through Extrapolation, Estimation or Measurement of data,
if assignment to a more hazardous category is not warranted, and:

Reliable information is available indicating significant toxic effects in humans; or

Mortality tested up to Category 4 values by the oral, inhalation, or dermal routes; or

Expert judgement confirms significant clinical signs of toxicity, when tested up to Category 4

Expert judgement for significant acute effects from other Animal Studies

Hazardous Lubricants and Toxicity

Most products have an acute oral LD50 of > 10 g kg–1 and an acute dermal LD50 of > 2 g kg–1.

Most additives such as EP agents, polar additives and emulsifiers are also in this range. In a few cases,
additive values below 2 g kg–1 are found (some biocides).

Corrosive, Caustic Substances = Corrosive, 0.5 g or 0.5 mL

Explosion and Flammability – flashpoints between 21C and 55C.

Substances defined as being explosive, flammable - not used in metalworking fluids.

Hazardous Lubricants and Toxicity

Carcinogens

Corrosion inhibitors, NaNO2, amines (nitrosamines) and with polycyclic aromatic hydrocarbons.

Teratogens & Mutagens

Mutagens - Alter genetic structures

Hazardous Lubricants and Toxicity

Sulfate Reducing Bacteria (SRB)

This bacteria metabolizes sulfate and is anaerobic in nature.

Acid Producing Bacteria (APB)

This bacteria ferments sugars to acids (typically light organic acids), anaerobic

General Aerobic Bacteria (GAB)

This bacteria requires oxygen

Safety Training, Policies and Guidelines Review

Fluid Pressure & Fluid Injection Risks

Fluid Pressure & Fluid Injection Risks

High-Pressure Injection Hazards

High-pressure injection injuries - analogous to medical techniques used to administer immunization
shots without a needle.

Any person sustaining an injury of this sort should seek immediate medical attention, regardless of the
appearance of the wound or its size.

Common cases: pressurized grease guns, hydraulic systems.

Fluid Pressure & Fluid Injection Risks

Typically, grease guns operating at 621-1,034 kPa (90-150 psi) air pressure.

Most modern hydraulic systems operate in the range of 13,790 to 34,475 kPa (2,000 to 5,000 psi).

A stream of oil ejected from a nozzle or leak under pressure of this magnitude has a velocity comparable
to the muzzle velocity of a rifle bullet.

Fluid Pressure & Fluid Injection Risks

Fluid Pressure & Fluid Injection Risks

Hazards to Lungs – mists, dust, vapors, gases

Use approved respiratory devices

Always use the “two-man rule”

Fluid Pressure & Fluid Injection Risks Review

Confined Space Risks

Confined Space Risks

Environments such as vessels, tanks, containers, pits, chambers, or any other similar space that creates
conditions leading to an accident due to:

Flammable or explosive atmospheres

Harmful gases, fumes, or vapors

Free flowing solids or liquids

Excess oxygen

Excessively high temperature

…Developing the lack of oxygen

Confined Space Risks

Key Characteristics:

Substantially enclosed

Hazards present
Enclosed nature of the space

Potential injury results in a rescue team

Confined Space Risks

Hazards - Toxic Atmosphere

Previous Work

Deposits

Fire or flames

Seepage

Work processes

Confined Space Risks

Oxygen Deficiency

Displacement

Biological or chemical reactions

Absorption onto surfaces

Oxygen Enrichment

Confined Space Risks

Flammable or Explosive Atmospheres

Flowing Liquid or Free Flowing Solids

Excessive Heat

Confined Space Risks

Don’t do it if it can be avoided

Hazard Identification

Work is Pre-Planned

Appropriate Training Completed

Confined Space Risks

The emergency arrangements shall include:

Safety during rescue

Ability to raise alarm

Rescue equipment available

Training

Resuscitation procedures

Confined Space Risks – Assessment

Contents?

Oxygen Deficiency?

Previous Contents?

Oxygen Enrichment?

Residues?

Structure and Layout?

Contamination?

Confined Space Risks – Assessment

What will be created due to the work carried out in the space?

Sources of Ignition?

Flammable Substances?

What‘s outside the space that might pose a risk during the proposed work?

Inadequate Isolation?

Inadvertent Operation Of Plant?

Nearby Work Activities?

Confined Space Risks – Assessment

Competence, training, supervision and suitability

Permit-to-work procedure

Gas purging and ventilation

Dangerous residues

Testing and monitoring of the atmosphere

Mechanical, electrical and process isolation

Respiratory protective equipment

Other personal protective equipment

Safe use of work equipment

Communications
Access and egress

Flammable or explosive atmospheres

Combustible materials

Confined Space Risks – Permit-to-Work

Permit to work procedure - documentation known as a permit to work form.

Sets out how the system defines:

Who may authorize particular jobs

Who is responsible

Inform

Identity

Location

Nature

Extent of the job

Hazards

Precautions

Ensuring the safe hand-back of the workplace

Confined Space Risks Review

Fire, Electrocution, & Mechanical Risks

Fire, Electrocution & Mechanical Risks

Fire Prevention

Plan work

Minimize materials

Observe housekeeping

Observe restrictions

Keep barriers in place

Fire, Electrocution, & Mechanical Risks

Wear proper PPE

Avoid working alone

Store solvents properly

Limit open flames

Do not keep or use solvents near heat sources

Remember the “RACE” rule in case of a fire.

R= Rescue/remove all occupants

A= Activate the alarm system

C= Confine the fire by closing doors

E= Evacuate/Extinguish

Fire, Electrocution, & Mechanical Risks

Fire and Combustion Risks

Know what to do.

Know where things are:

Be aware that emergencies are rarely “clean”

Train workers and exercise the emergency plan.

Fire, Electrocution, & Mechanical Risks

Fire and Combustion Risks

Fire Extinguishers

Pressurized Dry Chemical (Type BC or ABC) Carbon Dioxide

Specialized Class D Dry Powder

Water-filled extinguishers

PASS

P – Pull the pin

A – Aim nozzle at the base of the fire

S – Squeeze the trigger

S – Sweep the extinguisher from side to side

Fire, Electrocution, & Mechanical Risks

Electrocution Risks

Faulty equipment instrumentation

Damaged receptacles /connectors

Unsafe work practices.

Fire, Electrocution, & Mechanical Risks

Electrocution Risks – Lock Out Tag Out

Repair all damaged electrical equipment

Ensure that workers are trained

Select and use appropriate work practices

Follow requirements for Hazardous Classified Locations

Only “Qualified Persons,” are to work on electrical circuits/systems.

Fire, Electrocution, & Mechanical Risks

Mechanical Hazards

Handling Drums - 55-gallon drum of oil or grease 400lbs

Oil and Grease Spills

Grease and Oil Application to Machines

Fire, Electrocution, & Mechanical Risks

Mechanical Hazards

Machine Guards

Ladders and Work Lifts

Safe Clothing

Hand Tools

Hazards to the Skin

Fire, Electrocution, & Mechanical Risks Review

Laboratory Lubricant Analyst - Glassware

Selection of Glassware

Borosilicate glass has superior hydrolytic resistance

Very small coefficient of thermal expansion

Considered high quality glassware, selected for better dimensional conformation and mechanical
stability

Inspect all glassware for cracks, scratches or chips

Do not use damaged glassware for safety reasons

Cleaning Glassware

Glassware can be cleaned manually or automatically

Glassware must always be inspected for cleaning effectiveness

Selection of cleaners is application specific (U-tube capillaries must not be cleaned with alkaline
detergents)

Discard damaged glassware

Manual Cleaning

Advantages

Quicker when there are few items to be washed

Flexible in terms of duration of cleaning and selection of cleaning agents

Automatic Cleaning

Advantages

Reduced breakage risk; reduced risk of injury to staff

Saves staff resources

Quicker and more economical for large quantities of items to be washed

Drying Glassware

Physically drying with an absorbent material

Rinsing with a volatile solvent and allowing solvent to evaporate at room temperature

Driving off solvents at room temperature using an air stream (can introduce contaminants)

Driving off solvents at elevated temperatures

Allowing to drip-dry and ambient temperatures

In automatic washer, using heat drying cycle

Cautions for Drying Glassware

Hot oven or any other source of heat is not recommended as a means of driving off volatile organic
solvents

Heat should not be used to dry volumetric glassware- alternatively use an air stream in a well-ventilated
area

Dishwashers should not be used to clean calibrated glassware- alternatively use a particle- and
moisture-free air stream in a well-ventilated area

Glassware

Glassware

Glassware

Glassware

Glassware

Glassware

Glassware

Volumetric
Glassware

Volumetric Glassware

Required for High Accuracy and Precision

Required When Preparing or Using Standard Solutions

Volumetric Glassware

Accuracy and Precision

Standard Solutions

Buret

Buret

Buret
Buret

Buret

Buret

Buret

Buret

Meniscus Reader

Proper Reading

Bottom of Meniscus to Top of Graduation

Proper Storage

Volumetric Transfer Pipets

Volumetric Transfer Pipets

Fill By Vacuum

Fill By Vacuum

Exception

Properly Clean

Using Volumetric Pipets

1. Rinse with solution to be pipeted (Observe for even draining)

2. Fill to above graduation

3. Wipe off outside of pipet

4. Drain to graduation ( bottom of meniscus to top of graduation)

5. Touch tip to waste vessel

6. Transfer by gravity (vertical - don’t force)

7. Touch tip to inside of receiving flask

Volumetric
Flasks

To Prepare Solutions with Accurately Known Concentration

Invert Rapidly

Transfer To Reagent Bottle

 Laboratory Lubricant Analyst

 Laboratory Sample Handling & Preparation

 Analyte & Matrix

 Analyte & Matrix

 Matrix Enhancement & Suppression

Where:

 A Extract is the peak area of Analyte, when Diluted with Matrix extract.

 A Standard is the peak area of Analyte in the Absence of Matrix.

The concentration of analyte in both standards should be the same.

 ME effect close to 100 indicate Absence of matrix influence.

 ME value of less than 100 indicates Suppression.

 ME larger than 100 is a sign of matrix Enhancement.

 Matrix Enhancement & Suppression

The advantages of this definition are that:

 Negative values indicates suppression

 Positive values are a sign of matrix enhancement

 Blank Determination

 Contamination from an unknown Analyte

 To minimize, subtract a blank from sample / standard measurement

 Standards

Standards are used to calibrate instruments and equipment

Primary standards

Secondary standards

Reference standards

Transfer standards
Working standards

Traceability is the documentation to work backwards through that chain to the Primary Standard

 Primary Standard

 Primary reference standards are maintained by organizations (such as NST) to provide a

common basis for comparison

 Used to develop Secondary reference standards for distribution to organizations

 Multiple primary standards may be referenced to document the calibration of an instrument

 Secondary Standard

 Items that are calibrated by the Primary Standard using high precision comparator and adjusting
for non-ideal measurement conditions

 Secondary reference standards for mass are stainless steel kilograms

• Calibrated by comparing with a primary standard on a high precision balance and

correcting for the buoyancy of air

• These weights become the reference standards for assigning values to test weights

• The test weights would be in the hands of the laboratory and would be traceable to the
Primary Standard by certificate documentation. These would be used to create
calibration curves.

 Transfer standards are used to ensure agreement between organizations holding secondary
standards

 Traceability

 The ability to go back to one standard is called traceability

 Ensures the validity of results and gives a standard that all labs and instruments can work from

 Example-

• NIST calibrates a platinum resistance thermometer (PRT) for a manufacturer

• Manufacturer calibrates a PRT from NIST calibrated PRT

• A digital thermometer and probe from NIST calibrated against the second PRT

• The digital thermometer is used in a lab and checked against an ice point

 Certified Reference Material

 Material property is certified by technically valid procedure

 Accompanied by a “certificate”

 Traceable to a “certificate”
 Issued by a certifying body

1. Identification of the Calibration Lab - A calibration certificate must identify where the
calibration was performed.

2. Title - Ensure the document is a 'Certificate of Calibration' or 'Calibration Certificate'.

3. Unique Identifier - Each Certificate of Calibration is unique and should have a unique identifier
such as a serial or certificate number.

4. Identification of the calibrated instrument - The calibration certificate should clearly identify
the instrument, including a serial number and any model information.

5. Environmental conditions in the laboratory environment - At minimum, the temperature and

relative humidity that the calibration was performed at should be specified.

6. Date of Calibration

7. Identification of the calibration method used - Any calibration should be performed in

accordance with an established and approved procedure. Some equipment manufacturers
publish their calibration procedures.

8. Traceability evidence - Traceability is a main purpose of a calibration certificate, and evidence of

traceability must be documented.

9. Calibration results - A calibration certificate must document the actual instrument readings
against the reference values and indicate whether the instrument readings were within
tolerance of the reference standards.

10. Name, title, and signature of the person performing the calibration

11. Accuracy Statement - The certificate must specify the uncertainty that the instrument has been
calibrated. This is often identical to the manufacturer's specifications but may be limited by the
capabilities of the calibration lab.

Accreditation body logo/information (unless the certificate is issued by the equipment manufacturer) -
For certificates not issued by the equipment manufacturer, a logo or identifying information from the
body who accredited the lab should be present

 Record Keeping

 When recording calibrations-

• Follow a standard format

• Maintain Consistency

 Record all specifics-

• Calibration technician

• Date of calibration
• Procedure or method followed

• Technical background needed

• Materials used

• If corrective action is necessary and actions taken

 Audits

 Audits are scheduled checks to verify calibrations and calibration program

• May be performed quarterly, annually.

• If non-conformance exists, frequency may increase

 Audits allow for improvement or changes to the process