Lubrication Surveys: Increasing Machine Reliability

By Kristopher Sonne – Trico Corp.

Auditing your facility’s lubrication program is a time consuming, tedious job but in the long run it will increase your machine reliability, save time and save money.  Many companies rely on their lubricant supplier to compile a list of equipment with lubricant and replenishment frequency.  Although lubricant manufacturers and suppliers are a great resource for lubricant information the result of the lubrication survey is generally no more than a cross-over chart from what you were using before.  The outcome from a lubrication survey should be a clear concise list that includes: machine IDs, manufacturers, models, OEM recommended lubricants and frequencies, chosen lubricant, replenishment frequency, and the technical reasons for using the chosen lubricant.

The first step in the process is information gathering and field verification.  The basic equipment list with equipment name, number, manufacturer and model can be easily attained from the facility’s CMMS system.  This information is a good start, but many things can change since the information was entered.  This list is to be taken out in the plant and verified that the information is indeed correct.  While walking down the list the ambient temperature, component temperature are to be taken, as well as, the environment conditions the machine is subjected to (such as outside environment, humid/moist, frequent wash-downs, etc.) and speed.

Once all the equipment information has been gathered and conditions recorded, the next step is more information gathering.  It is now time to hit the facility’s engineering and maintenance office to gather the OEM recommendations from the manufacturer’s operation, installation and maintenance manuals.  Generally the manuals will contain generic or specific lubricants to use and the oil change or re-greasing frequency based on different run times or operating temperatures.  If this information cannot be found, knowing the manufacturer and model number will allow you to download the manual from the manufacturer’s website.  If all else fails, speaking to the manufacturers’ Application Engineer can get you the information you require.  If the lubricant brand and type is what you receive (such as Brand X 100 EP Gear Oil) the product data sheet should be obtained to find out exactly what the lubricant is.  Recording the base oil, type and viscosity (example: ISO 100 EP Mineral Gear Oil) will simplify the process of choosing the lubricant to be used and if any consolidation can be performed.  Other important information to note is the viscosity at 40°C, viscosity at 100°C or the viscosity index (VI).  Understanding how the OEM specified lubricant’s viscosity changes due to temperature is important because with this information the viscosity the machine requires at various operating temperatures can be calculated. 

Most facilities have a favored lubricant supplier, having a secondary supplier is suggested.  Today’s lubricant manufacturers all have good products if applied correctly, but it is rare that one manufacturer will have all the appropriate lubricants for all of your applications.  There may even be specialized lubricants that will require having a tertiary supplier as well.  With the use of viscosity-temperature charts the OEM specified lubricant and the proposed lubricant can be plotted against each other to determine how well they compare.  At this time the information previously collected such as the environmental conditions and even how accessible the equipment is will help in determining if there would be an advantage of using a synthetic over a mineral based lubricant.

In an ideal world the lubricant being used on a machine would be exactly what lubricant the OEM recommends down to the brand.  Lubrication type and frequency is designed in to the equipment.  Equipment designers select the lubricants factoring in speeds and loads.  Straying too far away from their selection, will impact the reliability of the machine by either creating an inadequate lubrication condition thereby increasing the likelihood of metal-to-metal contact between frictional surfaces or by generating excessive heat (and the consequences that excessive heat entail).  If consolidation of stored lubricant products is to be performed at this time, there are many considerations to take in to account.  Criticality of the machinery and its affect on the process is the largest consideration; the more critical the component the less likely you should be to stray away from the OEM specified lubricant type.  If there is any type of drastic change in the lubrication regime of any important piece of equipment extra research and periodic testing of the lubricant while in use is highly recommended.  Even if the base fluids are compatible, there could be compatibility issues between the additives and thickeners (in grease).  Besides compatibility issues between the previous used and new lubricant, compatibility between the new lubricant and the seals should be determined.  Another issue may be the proposed lubricant’s affects on ‘yellow metals’ such as brass gears and bushings.

When it comes to the ‘life blood’ of machines great care has to be taken in all steps of the process.  Basing decisions without the knowledge necessary is a dangerous affair and can lead to severe consequences.  Your equipment OEMs and lubricant manufacturers each know their own products better than anyone else but they don’t know or understand each other’s.  As maintenance professionals these are our machines and it is up to us to insure all the homework has been taken care of.

Comments

[Clark Dodge]

Interesting article and it is right on the mark. Most of the oil company representatives do as you said, they look at the chart and cross it from what was used before, then see where they can cut cost and deliver a product that will or may work. This is very poor way to sell products for many reasons. Many of today’s equipment manufactures make changes to machinery components and the lube requirements need to change. It is up to the Chief Engineer and maintenance team to evaluate the choice of products to be sure operating changes or needs are met. An on site or internal inspection of equipment is mandatory. A good example is governor controls where a random choice of oil, just because that is what was used before, is looking for failure. Stop, look, smell and revise thinking, open the specs of the product and the machinery. Many changes are made on both sides and some lubrication products are very different between manufactures, so don't always believe one person. I was a senior Staff Chief Engineer, so I always studied the manufacture specs and the lube supplier product data. Don't be afraid to change products if you are not getting the life of equipment, it could be your fault for not upgrading a product.

[Rhett Ouzts]

Have you designed a survey form that includes the information that was discussed in your article.
I am a lubricates salesman for a company in Chattanooga, TN. This would be most helpful in calling on new customers and providing solutions for existing customers.

[Bob Rebar]

This is a very good article and it is simple enough to do. Auditing the lubrication programs will improve reliability, keep your company organized(who is caring for the asset), and update the type of lubricants being used.