Improving Rolling Mill Lube Oil Performance and Useful Life

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.

Using in-service oil analysis to improve machinery reliability has a long history. The first oil analysis was performed over half a century ago on a locomotive engine. Just as a human blood test provides important information about your health, the information provided by in-service oil analysis about machinery health, especially for a piece of complex machinery with many moving parts, such as a diesel engine, is unmatched by any other technologies on the market.

Rotating-element bearing manufacturers measure the reliability of their bearings using a Load-Life calculation rating, which is known as the L10 rating life. To achieve its design rating, the manufacturer assumes the bearing will be run in a clean operating environment. This takes into account providing an adequate lubricant film (adequate described as a film equal to, or greater than, the composite roughness of the two mating surfaces) of the correct viscosity for the designed maximum bearing speed and operating temperature ratings.

I routinely ask my consulting clients and seminar students if they have lube procedures, and they sheepishly admit that they don't. They often look embarrassed to have to admit it, but I believe these folks represent the cream of the crop. If they are attending classes on lubrication, or are having their program audited, they must have good intentions.

Using lubrication and oil analysis to enhance machine reliability is really too simple. Behind the appearances of complexity and vale of high science are the most basic of concepts. We can try to make it difficult, but why? With the right tools and a generous amount of training, a seemingly challenging task can be transformed into something almost mundane, but still powerful.

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.

Choosing a lubrication system to lubricate the chain can positively impact production as this process can be done while the chain is in motion. By implementing lubrication systems, additional savings can also be realized through improved worker safety and better housekeeping and or procedures.