Right Use of Lubricants 20140525

7/21/2019 Right Use of Lubricants 20140525

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Session Topic

Best Practices in Maintenance Management for

Process Industries

Speaker :Designation :Organization :

Right Use of Lubricants

Hasmukh Gohel

Consultant

27 May 2014 !eaker "ame 1

Introduction

227 May 2014

• #hat is bloo$ to human bo$y% lubricant is to machine&• Lubrication is !robably not gi'en re(uire$ attention at !lant

le'el&• #e $e!loy best skills for maintenance% but !ut unskille$

!erson on

Lubrication )ob&• *t is not the costliest lubricant bur the right lubricant +ill

meet the re(uirement&• ,'ery ru!ee s!ent on lubricant im!ro'ement +ill return 10

times&• Lubrication im!ro'ement is e-!ress +ay to reliability&

• .,M/s recommen$ations are not al+ays correct&• .,M recommen$ation changes +ith $e'elo!ment in lube

el$&• est recommen$ation are a'ailable in bearing catalogues&• "o+ a $ays +e use mineralR. +ater% +hat about mc&• 3 $octor relies on !athological test of bloo$& o +e use oil

analysis5•

Session Content

;!eaker "ame27 May 2014

•Lubrication case stu$ies•torage !ractice•Correct grease selection•Correct greasing !roce$ure•3ccessories to im!ro'e mc !erformance

Lube .il are generally selecte$ base$ on.,M/s recommen$ations& #hen the .,M is

*n$ian% selection is easy% as theirrecommen$ations are *n$ian make lubes&#hen the .,M is foreign base$ +e ha'e torefer lube e(ui'alent charts& ome timeslube recommen$e$ by such .,M is not

a'ailable locally an$ +e ha'e to makecom!romises& #hen re!eate$ failure ofe(ui!ment is face$ the faile$ com!onentsare stu$ie$& 3n$ if the root cause of thefailure is attribute$ to lubricant& U!gra$ing

the lubricant is re(uire$& Generally this is$one in consultation +ith .,M& ue to$e'elo!ment in the el$ of lubricants "e+o!!ortunities are a'ailable& .ur basicre(uirement is to enhance the reliability% sobetter lubricants are use$&

Common mistakes

•Lube oils / grease used intercangeabl!"

er'osystem% er'o!rime% er'omesh are use$interchangeably& er'ogem 2 < ; are use$interchangeably& Using er'ogem 2; in !lace of H=or ,:

•Mi#ing of lubes> ingle can% oil !um!% greaseguns use$ for $is!ensing of $i?erent ty!e of lubes&

•Contamination of lubes> Lube gettingcontaminate$ $ue to atmos!heric $ust% +ater%chemicals% rust etc&

•$rong recommendation> #rongrecommen$ation by .,M% +hile n$ing e(ui'alentlocal make&

•%ot replacing lubes in time> Re!lacementfre(uency not in line +ith .,M% or base$ on the

&ibre Plant : Drum Dr!ers

=+o nos $rum $ryers% each ha'ing 1@ $rums% each $rum tte$

+ith 22;179 ;nos bearings& .!erating tem!erature 100o

C.riginal grease recommen$e$ by .,M% Molykot C 44&omegrease +as !rocure$ $uring !ro)ect stage& *n$ian make:olymol 44 +as selecte$ for im!ort substitution& =his grease+as turning into rubber like substance in the bearing% an$ noof failures +ere notice$% resulting into !lant s$& Later on *.C

make er'ogem H= grease +as use$ for this a!!lication& =hisgrease +as also not suitable& *t +as becoming charcoal likesubstance in the bearings&

Aaile$ bearings +ere stu$ie$ for failure !attern an$ it +asobser'e$ that the failure of the bearings +as $ue tolubrication failure&

"o+ by this time Ms o+ Corning ha$ set u! manufacturingfacility in *n$ia Molykot 44 grease +as !rocure$ an$ use$ inthe $rum $ryer bearings&=his is !robably +orst case oflubrication failure& *t ha$ coste$ com!any huge amount% at thesame time unsafe +orking of mech technicians& amage to

allie$ !arts&

Spinning 'ear Pump dri(ing)nit

=his is a o!en gear $ri'e& aily in themorning% lube oil +as s!raye$ on the gears&Lube oil use$ Ser(os!stem *+," as !er

.,M recommen$ations&High +ear of the gears +as obser'e$& Gearsan$ !inions +ere $e'elo!e$ locally an$ +erere!lace$&

=his +as a case of intermittent lubrication%calling for using lubricant ha'ing stickiness!ro!erty& ince s!ee$ +as also lo+% *.Cmake Ser(oline -., lube oil +as !rocure$

an$ use$& ri'e become silent an$ +earre$uce$ consi$erably&

$asing Macine Lo0er Be(el 'ear

*n 33 !lant t+o nos +ashing mc areinstalle$ for remo'ing nitric aci$ from s!unto+& ;2 nos lo+er be'el gearbo-es areinstalle$ in each mc& !ee$ of the be'el

gear !air is about 10 to 1B R:M& uite lo+&.,M ha$ suggeste$ to use *. 6G 1B0 lubeoil for this a!!lication& o$y of this G +aschange$ from C* to % $ue to se'erecorrosion $ue to nitric aci$ s!illage on theseG& *ngress of nitric aci$ +as seen in thelube oil through sight glasses& ame +asarreste$& ubse(uently lube oil +as change$to *.C make er'osystem ;20 the thickest

a'ailable +ith !lant&

C!clo Dri(es

.riginally Ms umitomo ha$ recommen$e$*. 6G 220 for cyclo $ri'e accor$ingly *.Cmake er'osystem 220 or H:CL make ,nklo220 +as use$& ome failure of eccentric

bearings +ere face$&Ms umitomo in their latest literature ha'erecommen$e$ er'omesh : 1B0 for in$oora!!lications an$ er'omesh : 220 forout$oor a!!lications& ince this lube oil has,: a$$iti'e eccentric bearing !erformanceshoul$ im!ro'e&

1213 pumps

Ms 33D ha$ originally recommen$3, 40 lube oil in their maintenancemanuals& 3ccor$ingly *.C make

er'osystem 1B0 or H:CL make ,"L.1B0 lube oil +as selecte$ an$ beinguse$ by all !lants& "o+ Ms 33D intheir recent manuals recommen$3,20 lube oil& *ts nearest e(ui'alentlube oil is er'osystem E@ lube oil&

=hicker oil +hen use$% results in higher

o!erating tem!erature of bearing

BPCL Pumps

uring lube a!!lication sur'ey of all!lants this +as notice$& "ormally lubeoil ha'ing ma-imum 1B0 Cst is use$

for centrifugal !um!s& .,M/s manual+as stu$ie$ an$ it +as obser'e$ that.,M has recommen$e$ *. 6G E@ for

this a!!lication& 3ccor$ingly *.C makeer'osystem E@ is no+ being use$ forthese !um!s&

Lube oil pumps 4urbine dri(en&

*.C make er'osystem E@ lube +asbeing use$ for this a!!lication&"ormally for turbines% turbine oils are

use$& Aor making turbine oils base oilis im!orte$ an$ it is grou!9**& etter(uality base oil% less o-i$ation% lessslu$ge formation etc& =urbine oil hasthe a$$iti'e +hich gi'es it +atersha$ing !ro!erty& #ater accumulate$$ue to steam ingress can be $raine$

easily& "o+ H: make =urbinol E@ is

5!drogen Compressors

uring sur'ey of lube oil use$ for allthe e(ui!ments% it +as notice$ that*.C make er'osystem 220 +as being

use$ for this a!!lication& .,M manualrecommen$e$ to use *. 6G 220 +ith,: a$$iti'e&

3ccor$ingly *. make er'omesh :220 lube oil +as recommen$e$&

Recycle Gas Com!ressor

H: make =urbinol E@ is use$ in the oilsum!& uring 200@ shut$o+n entiresum! +as em!tie$ an$ fresh oil +as

charge$& ut $ue to +ater ingress1000 ::M +ater +as obser'e$ in theoil& ,ntire turbine oil +as re!lace$ +ith

fresh oil& :ermissible limit of moisturein oil is 100 ::M

&luid Couplings 1.,+

!lant ha$ Fui$ cou!lings of t+o$i?erent makes& Ms 6oith% Germanyan$ Ms :emebril& Ms 6oith ha$

recommen$e$ *.6G ;2 lube oil% +hileMs :embril ha$ recommen$e$ *. 6G4E&:lant +as using er'osystem ;2 for

:embril make Fui$ cou!lings also& "o+*.C make er'osystem 4E isrecommen$e$ for this a!!lication&

Centrifuge Planetar! 'earBo#

:lant +as using ,nklo 220 lube oil forthis a!!lication& .nce ,nklo 220 lubeoil +as not a'ailable +ith stores& :lant

+ante$ to kno+ the e(ui'alent lubeoil& *ts e(ui'alent lube oil is *.C makeer'osystem 220& ut +hen .,M/s

manual +as stu$ie$& hell .mla& 220 <,sso !artan 220 +ere recommen$e$&*ts e(ui'alent nos are *.C er'omesh

: 220 < H:CL :arathan ,: 220

6#truder 'ear Bo# Motor

,-tru$er is a single line criticale(ui!ment& ,-tru$er gearbo- is $ri'enby H= motor ha'ing no +are houses!are& *.C make er'ogem; grease isuse$ for lubrication of this motor&ase$ on recommen$ation of one'en$or% elco grease +as trie$ for this

motor& *t resulte$ in tem!erature shootu! of the bearings& er'ogem ; grease+as re'erte$ an$ !roblem resol'e$&

%ikkiso Metering Pumps

*n "ikkiso metering !um!s er'omesh: 1B0 is to be use$ for !o+er en$lubrication an$ !in 12 is to be use$

for li(ui$ en$& :lant +as usinger'omesh : 1B0 for li(ui$ en$ also&"o+ for li(ui$ en$ *.C make s!in 12 is

Crane Section: 1mericanSk! orse

uring re'ie+ of Lube !ractice of!lants it +as obser'e$ that ,nklo 1B0lube oil +as use$ for gearbo-

a!!lication for this crane& "ormally forcranes automobile lubes arerecommen$e$& .,M has

recommen$e$ 3, 140& #e $on/t ha'ethis lube% so H:0 lube oil +asrecommen$e$&

6steri7cators

*n CC !lant ,stericators +ere o!erate$in batches& teaming follo+e$ by'acuum +as create$& =his 'acuum +as

breaking through the glan$ !ackings ofthe agitators& #hen the 'acuum +asgetting break% er'ogem2 grease +asuse$& =he o!erating tem!erature +as(uite high& *nitially er'ogem H= grease+as use$% results +ere encouraging&Ainally Molykot 44 grease +as use$ for

this a!!lication&

Solid 0aste Incinerator$orm 'ear Bo#

oli$ +aste incinerator +ascommissione$ in 17& #ithin Emonths the +orm +heel of the +orm

re$uction gearbo- use$ for rotation ofthe kiln faile$& .il +hen checke$ +ithngers a!!eare$ to be light& am!le+as teste$ in laboratory an$ it +as *.6G 100& *t +as conrme$ by thetechnician that he has use$ lighthy$raulic oil& H: make :arathan ,: ;20

lube oil +as arrange$ an$ the gearbo-

8ibrating Screen +,*

Are(uent failure of bearings of thise(ui!ment is chronic !roblem for !lant&:lant +as using er'ogem H= grease an$

s!herical roller bearing +ith metal cage forthis a!!lication& .,M literature +as not 'eryclear on this& .ne le from Ms "=" +as$o+nloa$e$ from internet an$ they ha'e

recommen$e$ s!herical bearing for 'ibratora!!lication% asymmetrical rollers an$ +ithbrass cage% an$ grease +ith ,: a$$iti'e&

1gitator 1-9,

Ms "e+ 3llanbarry make s!iral gearbo- isinstalle$ for this agitator& .,M hasrecommen$e$ er'o Cyclo C4E0 lube oil for

this gear bo-& =his is thick lubricant& !ecialgra$e so not easily a'ailable from *.C& =hisoil gets thicker like tar in the gearbo-$icult to $rain $uring short s$& *n

consultation +ith .,M as +ell as base$ onrecommen$ations for similar gearbo- ma$eby other .,M like Ms Ra$icon < Ms ,lecon%the lube oil is change$ to er'omesh :

Spiral6le(ator

Aour nos s!herical roller bearingssuitable for 'ibrating screena!!lications are installe$& *nitially

1B0 lube oil +as use$ since this +asa rotating loa$ a!!lication% the lube oil+as not suitable& Castrol make =ribollube oil +as also trie$& Ultimately thebearings +ere change$ to greaselubrication& "o+ Mobil make MobilthHC 220 grease ha'ing synthetic oil is

use$ satisfactorily&

Aor aler er'o!rime 4E is being use$&er'o!rime 4E is a turbine oil& Aorhy$raulic systems er'osystem 4E or

er'osystem HL: 4E is to be use$& *thas anti9+ear a$$iti'es& :lant hasagree$ to change the lube oil $uring

ma)or !lant s$&

1213 pumps

Aor both the !lants% er'osystem 4Elube oil is use$ for ma)ority ofim!orte$ < !um!s as !er .,M/s

recommen$ations& :lant ha$stan$ar$i8e$ on er'osystem 4E for allCA !um!s inclu$ing 33D !um!s& Aor

33D !um!s er'osystem E@ isrecommen$e$ by .,M&

Pol! eactor 1gitator 'earBo#

=here are three !oly reactor agitatorsinstalle$ in ,, !lant& *.C makeer'osystem ;20 lube oil is being use$for this gear bo-es& #hen re'ie+e$& *t

+as obser'e$ that .,M ha$recommen$e$ hell make =urbo 220lube oil for this a!!lication& =urbostan$s for turbine oil& ince +e $on/tha'e turbine oil +ith *. 6G 220'iscosity& *t +as $eci$e$ to useer'osystem 220 or ,nklo 220 for this

a!!lication&

&& plant: Pumps

AA mech has stan$ar$i8e$ oner'omesh : ;20 for all its lubea!!lication& er'omesh : ;20 is

mainly use$ for gearbo- a!!lications&ut for all !um!s also , is usinger'omesh : ;20 lube oil&

Generally for centrifugal !um!ser'osystem E@ or 100 lube oil is use$&

211B !eaker "ame ;0

Geare$ Motor for 3erator1@ nos installe$&B to E al+ays out&Gearbo- oil going in tomotor

211B !eaker "ame ;1

211B !eaker "ame ;2

'as 4urbine: Load 'earBo#*.C make er'o!rime ;2 lube oil +asuse$ for this a!!lication& #ear of loa$gears is obser'e$ o'er a !erio$ of

Ms *.C has no+ $e'elo!e$ ne+!ro$uct% er'o!rime ;2=& *t has

a$$iti'e +hich re$uces +ear of thegears&

:lant has s+itche$ o'er to er'o!rime

Reformer Com!ressor

Reformer com!ressor is GHH makecre+ Com!ressor& *t has one helicalgear !air to maintain timing of both

the scre+s& .il s!ray is !ro'i$e$ onthe gear !air for lubrication of thisgear !air& .nce the lter in the lube oil

line +as !artially chocke$& =hisresulte$ in to ina$e(uate su!!ly oflube oil to the gear !air& =his $amage$

the gear !air an$ resulting in to !lant

5!draulic Oils for Po0erpacks

Aor our ol$ balers *.C make er'osystem 4E%E@% 100 lube oil is use$ as !er the oila'ailable at that time&

"o+ .il com!anies ha'e im!ro'e$ the lubeoil for hy$raulic systems& *t has bettera$$iti'es for +ear an$ o-i$ation& *t is kno+nas er'osystem HL: 4E% E@ < 100& *ts anti

o-i$ation !ro!erty is also better& "e+ baler!rocure$ for :R1 has er'osystem HL: 4Elube oil&

211B !eaker "ame ;7

Sperical oller 'reasing

!herical roller bearings +ith a lubricationgroo'e an$ three lubrication holes in theouter ring shoul$ be oriente$ correctly +henmounting insi$e the machine& =his is toensure that there is a$e(uate amount oflubricant in the outer ring race+ay of thebearing& Make sure the lubrication hole isnot locate$ at the si- oIclock !osition

other+ise the lubricant +ill $rain out fromthe bearing an$ re$uce the le'el of lubricantinsi$e the bearing& =his ti! is 'ery im!ortantfor bearing lubrication +ith grease% oil s!ray

or oil $ro! lubrication&

elubrication 8olume

.ne of the more im!ortant an$ fre(uently botche$ com!onents of

the greasing strategy is relubrication 'olume& #hen aske$ ho+in$i'i$uals $etermine the amount of grease to a!!ly to a !articularcom!onent% a common res!onse is Jho+e'er much it takes&K =his

is ob'iously not a !recise metho$& =here are many acce!tablemetho$s for estimating the a!!ro!riate relubrication 'olume& 3

common metho$ is recommen$e$ by A% +here grease

re!lenishment 'olume is $ene$ by the follo+ing e(uation>'p ; ,",,+ < D < B

+hereG! grease re!lenishment amount gmN

bearing outsi$e $iameter mmN

total bearing +i$th mmN

'reasing Procedure

Use grease gun +ith correct grease

Remo'e grease !lug&

*f e(ui!ment is sto!!e$ remo'e har$ene$

grease from the !lug& #i!e aroun$ greaseni!!le& :um! out an$ $iscar$ one stroke ofgrease& :ut the no88le on the grease ttingan$ slo+ly in)ect !ro!er amount of grease

strokes& to! if clean grease comes out& #ithe(ui!ment running allo+ grease to !urgeout of o!en !lug for 1B minutes& Re!lace!lug& #i!e out !lug an$ grease tting&Re!ort any abnormal noise&

'rease Compatibilit!

Grease +ith $i?erent soa!s may be

incom!atible&9Chemical interaction bet+een thickenersa$$iti'es

9Mi-tures break$o+n usually softensN inser'ice&

9More se'ere at high tem!erature an$ shearrates

#hen changing grease

9:urge the ol$ grease to the $egree !ossible

9ecrease re9lubrication inter'al to com!lete

ub)ect>9 Lube oil leakage from CA !um!s

Leakagefrom

Leak agePath

Probable reason Remedial actions

Whilecharging

Spillage

Oversized dispensing can Use funnel or can withsuitable nozzle

Drain plug

hreads

Damaged threads !ot full" tightenedP#$ tape not used%ake shift arrangement

Use magnetic drain plugof correct size with P#$ tape

Oilcup

hreads

Damaged threads !ot full" tightenedP#$ tape not used

Use P#$ tape& and replace oil cup having damaged threads

Oilcup

'od" Oil level more in brg housing during initial oil top up Lube oil top up& b" seeing level in the elbow of the cup

Oilcup

#romdome

Damage to the dome%anufacturing defect

Replace it

'R(covers

(ask ets

Damaged gaskets Use new gaskets with R) compound

Oilseals

*D Damaged oil seal*ncorrect oil seal size +his happens when %% sizeoil seal is used in place of inch size, )ent plug holechocked

Use Parker& )ako or Pioneer make oil seals-lean vent plug,

OilSeals

*D Shaft step worn out Use new or reconditioned shaft b" hard chrome plating or useSpeedi sleeve supplied b" S.# or /% -lipper make

OilSeals

OD *ncorrect oil seal size Use correct size, Pl check %% or inch

'earing housing remaining hot due to incorrect lube

oil& inade0uate cooling water flow in the brg hosing

Use correct lube oil and ensure cooling water flow& clean water

passages

L)B6 OIL =)1LI43

• )S6 O& 5I'5 P6&OM1%C6

L)B6 OILS

• )S6 O& CO6C4 6COMM6%D6D

POP6/CO6C4 M1I%46%1%C6

P1C4IC6

• 16S4 L6121'6S>O%6 DOP P6MI%)46 COS4S +,, L4S P6 1%%)M?

• M1I%41I% POP6 S61LI%'

• 266P &IL46S CL61%• C56C2 1%D M1I%41I% OIL L686L

• 18OID 1LL LOSS S3S46M O&

L)BIC14IO%• 18OID O86 1%D )%D6L)BIC14IO%

'OOD S4O1'6 1%D 51%DLI%'P1C4IC6

• ')11%466S POD)C4 =)1LI43 • 6LIMI%146S CO%41MI%14IO%

• 6LIMI%146S I%CO6C4 )S1'6O& POD)C4• D1M1'6 4O M1C5I%63 I& )S6D

I%CO6C4/D646IO146D

L)BIC1%4S• 6D)C6S LOSS6S $1S41'6

1%D 5I'56 M1I%46%1%C6COS4S

• 18OID LOSS O& POD)C4IO%

S4O1'6 P1C4IC6

• P6&61BL6 I% DOOS>1$13 &OM 1%3POSSIBL6 CO%41MI%14IO%?

• D)MS S4O6D O% 456I SID6S $I45

B)%'S I% 4I'54 POSI4IO%• OIL D)MS 16 1L$13S S4O6D I%

5OI@O%41L POSI4IO% $I45 B)%'S I% -1%D A O CLOC2 POSI4IO%

• '61S6 D)MS 16 1L$13S S4O6D I% )P

I'54 POSI4IO%• )S6 $OOD6% B1446%S &O M)L4I

S4O1'6

• 18OID DOPPI%' O& D)MS

51%DLI%' 1%D DISP6%SI%'P1C4IC6

• &IS4 I% &IS4 O)4 S3S46M

• ISS)6 D)MS 4O S6C4IO%S I% C1S6 O&L1'6 CO%S)MP4IO%

• )S6 B16L P)MPS O B1SS 41PS &O ISS)6S

• )S6 413S 4O COLL6C4 SPILL1'6

• )S6 M641LLIC P1DDL6S &O '61S6

DISP6%SI%'

• %686 )S6 '1L81%IS6D CO%41I%6S &O41%S&6 O& POD)C4

211B !eaker "ame B0

211B !eaker "ame B1

211B !eaker "ame B2

Lub oil facility9MGCC

211B !eaker "ame E1

am!le calculations for common !um! bearings

'earing !o

OD *D %ean

RP%2345

Suggested

Lube oil

RP%6755

Suggested

Lube oil

8958 :6 95 42 :9745 )( 255 23:755 )( 8;

895: ;5 94 4; ;3255 )( 255 1 28;655 )( 8; 1

8957 255 34 :9 254;45

)( 255 1 622:55 )( 8; 1

t higher 6G lube oil is selecte$ for sim!licity% an$ as recommen$e$ by

211B !eaker "ame E;

33D < Goul$s

Alo+ser'e

irloskar

3s an o'erall checklist to hel! gui$e users

3s an o'erall checklist to hel! gui$e users%thefollo+ing factors are among the most

signicant in selecting the lubricant forbearing>

•machine ty!e•bearing ty!e an$ si8e•o!erating tem!erature•o!erational loa$ con$itions•s!ee$ range•cooling con$itions•sealing eciency•e-ternal en'ironment

Lubrication &ailure Mapping $orkseet :

Area of Investigation Lubricant / Lubrication System Examples (Not Exhaustive)

Equipment / aterialproblem

Defective or failed part Filter, seal, pump, slinger ring, spray, nozzle, vacuumdehydrator etc.

Defective or failed material Lubricant, filter media etc.

Defective weld, braze of soldered joint Piping hoses, valves, filter housing etc.

anufacturer shipping error !mproper lubricant labeling, lubricant cross"contamination etc.

#lectrical or instrument noise Pressure gauge, flow meter, online oil analysis instrument etc.

contamination Particles, moisture, air, heat, glycol, fuel, process chemicals,radiation etc.

!roce"ure !roblems $

Defective or inade%uate procedure &elubrication, oil change, filter change, inspection, sampling,oil analysis etc.

Lac' of procedure &elubrication, oil change, filter change, inspection, sampling,oil analysis etc.

!ersonnel !roblems

!ersonnel !roblems #

!nade%uate wor' environment Poorly e%uipped lubrication room

!nattention to detail (ffects all lubrication tas's and activities

)iolation of re%uirement or procedure (ffects all lubrication procedures and re%uirement

)erbal communication problem (ffects all aspects of lubrication, particularly interface withother organizational groups

*ther human error

$esign !roblems #

!nade%uate man"matching interface +ant access grease zer's, no place to draw representativesample, lube maintenance and-or sampling re%uires etc.

!nade%uate or defective design Lubricant delivery system, filtration system, coolers etc.

#%uipment material selection error /rong lubricant specified, incompatible materials etc.

Drawing specification or date errors Lube flow system, filtration system etc.

%raining $eficiency !roblems #

0o training provided achinery lubrication, contamination control, oil analysis

!nsufficient practice of hands"one1perience

achinery lubrication, contamination control, oil analysis

!nade%uate content achinery lubrication, contamination control, oil analysis

!nsufficient refresher training achinery lubrication, contamination control, oil analysis

!nade%uate presentation of materials achinery lubrication, contamination control, oil analysis

anagement !roblems #

!nade%uate administrative control 0o lubrication program metrics, such as overall lubricationeffectiveness 2*L#3, consumption ratio etc.

/or' organization planning deficiency Planning and scheduling system not capable of supportingproper lubrication and oil analysis.

!nade%uate supervision Lac' of basic awareness training renders managementincapable of supervision.

!mproper resource allocation !nsufficient lube tech staffing, training, tools, supplies etc.and-or lube techs called away to perform other duties.

Policy not ade%uately defined,disseminated or enforced

Failure to ma'e proper lubrication a priority.

External !henomena #

/eather of (mbient +ondition Failure to select lubricant or lubrication system that can dealwith the adverse conditions.

Power Failure or 4ransient

#1ternal Fire or #1plosion

4heft, 4empering, 5abotage,)andalism

$! Oil goes bad

=here are three !rimary causes that

necessitate an oil change> $egra$ation ofthe base oil% $e!letion of a$$iti'es an$contamination& ome of these con$itions canbe reme$iate$% yet others cannot&

=he most common ty!e of base oil failure islikely o-i$ation& #hen oil o-i$i8es% the!rimary by9!ro$ucts are aci$ an$ insolublematerials% +hich can lea$ to serious surface

$e!osits an$ corrosi'e +ear& =o a$$ress this!roblem% most lubricants are formulate$+ith antio-i$ants% but they $onIt last fore'er&

Like many lubricant a$$iti'es o-i$ation

Like many lubricant a$$iti'es% o-i$ationinhibitors are use$ u! as they !erform theirinten$e$ function& .nce these a$$iti'es are

consume$% the base oil begins to o-i$i8eContaminants also cause signicant changesto the rate of o-i$ation% acting as catalystsfor the reaction or% in the case of air%!ro'i$ing one of the reagents&

3$$iti'e e!letion> 3lthough many a$$iti'essuch as antio-i$ants enhance the !ro!ertiesof the base oil% other a$$iti'es !erformfunctions the base oil cannot& 3nti9+ear%e-treme !ressure% $etergents an$$is!ersants are e-am!les of such a$$iti'es&,'en if a lubricantIs base oil is in goo$con$ition% the lubricant can no longer!erform all of its $uties +hen certain

a$$iti'es are $e!lete$ an$% therefore% must

Contamination> Many ty!es of contaminants

Contamination> Many ty!es of contaminantscontribute to the $egra$ation of lubricating oils% butthatIs not the +orst of it& .f course% +e all kno+

that contaminants such as !articles are res!onsiblefor the ma)ority of mechanical +ear in manymachine com!onents& ecause of this% +e oftenchange oil before it fails% sim!ly to remo'e thecontamination&

Aor systems +ith no means of contaminationremo'al% such as mechanical lters% this is the only+ay to control contaminants an$ ensure !ro!erlubricating con$itions& Ho+e'er% changing oil toremo'e contamination +ill be only !artially

e?ecti'e% at best& #hen the oil is change$ in mostmachines% a signicant !ortion of the ol$contaminate$ oil is left behin$&

ust remember to keep te oil clean cool anddr!

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Right Use of Lubricants 20140525

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