The Building Blocks to Creating an Effective Lubrication Program

We change a lot of oil in our plants, mills, mines and factories. What are we doing to change our lubrication culture? In their book Learning to Fly, Collison and Parcell, employees of British Petroleum (BP), suggest a predictable pattern in achieving sustained culture change, which is a function of effort and time.

When we think of contamination in lubricated systems, we often focus on particle and water contamination. The fact of the matter is that there are many other contaminants we should consider and attempt to control. Most contaminants, which include any material not contained in the lubricant's formulation, can potentially damage the oil and the lubricated components. Although air is always present in lubricating oil, it is often justifiable to adopt measures to minimize its presence.

Improper bearing lubrication or re-lubrication accounts for up to 40 to 50 percent of machine failures. By eliminating lubrication from machinery, OEMs can minimize the costs and risks associated with maintenance for the end user. At the same time, costs related to the proper disposal of oil can be eliminated and the initial expenditure for ancillary components and processes (grease lines, zerks, manifolds, etc.) can be decreased.

The combination of high 'emulsified' water and high particulate levels create a perfect storm for bearing failure and reduced oil life! This article describes methods to improve lube oil performance.

Just like nutrition facts printed on the label of every item in a grocery store, the symbols on an oil can label tell consumers the service rating and certification for that product. In the United States, the American Petroleum Institute (API) administers the licensing and certification of engine oils through a system that meets the warranty, maintenance and lubrication requirements of original equipment manufacturers. OEMs, oil marketers, additive companies and testing laboratories work together to establish engine oil performance requirements, test methods and limits for the various classifications and testing processes.

Adding the correct amount of lubrication at each re-lubricating interval is essential to achieve maximum bearing life. An incorrect re-lubrication quantity, whether it's too much or too little, can actually decrease bearing life.

So what is going wrong with the lubricant and bearings in our pumps? We do not get a service life any where near those numbers. It turns out that most bearings fail prematurely for only two reasons: High heat that caused the lubricant to "varnish" and then form "coke" that will introduce solids into the lubricant, and contamination of the lubricant by water, moisture, and solids.