10 ways to improve your Lubrication Reliability program
Key factor of a World Class Maintenance Organization is the Lubricant Management. While Lubrication has for long time been seen as “another-job-to-do”, today a modern Lubrication Reliability Program is the only answer. Here are 10 ways to start or improve your Lubrication Reliability Program.
Lubrication is the bloodstream of your machinery.
It has been said many times before: while the bearing is the heart of your (rotating) machine, the lubricant is considered as the blood. The health of your blood is as “life threatening” as the quality of the lubricant – whether oils or greases – are. Bad lubricant quality is extremely harmful for the reliability of machine components. Quality does not only relate to type or brand, but to many more intrinsic aspects we will discuss later. Of course it all starts with the correct machine – lubricant combination in the design stage, but this we will not address in this article. Lubricant quality in the Lubrication Reliability Program is a matter of managing the selected lubricants in the best possible way baring in mind the 6 “lubrication rights”:
It has been proven many times by independent organizations that bad lubrication is responsible for over 60% of bearing / machine failures: here asset maintainers have sinned against one or more of the 6 Lubrication Rights. Turning the bad practices into a Lubrication Reliability attitude will have a direct impact on fundamental machine health. Aside from bearings, “best lube practices” should be applied to gear technology, hydraulics or basically all lubrication related technologies.
Time for a maintenance culture change with an important Return-On-Investment.
Silent Phase in bearing life time – time to start Lubrication Reliability.
In a bearing service life we have 3 phases: the Silent phase, Prediction phase and Breakdown phase.
The initial silent phase is that part of the life time where wear and eventual damage can occur due to inadequate lubrication or contaminated lubricants ( 6R’s ). Or adversely, when lubrication is managed in the proper way, internal wear can be reduced significantly and bearing life maximized. It is during this phase that prevention is most effective. We call it “silent phase” because in the component life time no predictive techniques are able to capture any potential failures yet.
At a certain moment in time – point of no return – initial wear or damage is detectable by predictive methods ( vibration, temperature, oil analysis, visual inspections, ultrasonic ) . It is now too late to maximize the bearing life and the life time is now set beyond return. During the prediction phase it is only possible to monitor wear and damage by measuring anomalies via – commonly called – Condition Monitoring. One can understand that CM is changing the quality of lubrication but only measures its level.
Eventually the CM techniques will detect that a failure will occur. If in time, repair or replacement can be planned and implemented.
Conclusion: is imperative that Lubrication Reliability should be implemented at the start of the silent phase.
10 Ways to implement Lubrication reliability.
Lubrication Reliability is a combination of managing best practices, tools and strategies. In order to understand and implement it in an efficient way, we will explode LR in 10 separate components. Eventually, in excellent
1. Assess before all
To start a new LR strategy (or just implement one or more of its components ) it is crucial to assess the actual lubrication management situation. Evaluation and benchmarking will disclose actual flaws in the organization and stress out the weak points in the fields of: strategies, CMMS, cleanliness & contamination control, lube supply, expertise, etc. Actual status is categorized from Basic Level evolving to Best in Class.
2. Plan, manage & organize
No maintenance organization today should manage its activities without modern software tools like CMMS, or ERP. Unfortunately no general management software is able to address lubrication in its full right. Lubrication is a very specialized field of maintenance and thus dedicated Lubrication Management Software is best suited. Key is that the tool needs to address the specific needs of a lubricator and its management: component database, routing, lubricant data, etc. Ideal LMS integrates lubrication activities with inspection data, condition monitoring data like vibration analysis and oil sample data. Future?
3. Identification & inspection
Lubrication points without proper identification are perfect source for errors with dramatic consequences: wrong oil or grease in a machine can cause sudden breakdown. Sometimes even small quantity cross contamination can result in catastrophic failure inducing. It does not take huge investments to well identify or color code lubricants, dispensing equipment and lube points on machinery to avoid malicious cross contamination.
While identification is imperative, lubricant inspection should be a continuously worry. It happens every day that machine components like gear boxes run dry of oil/grease. Oil Levels are overseen or to dirty to inspect or not even included in the technicians inspection route. Or worse, no oil level indicator is installed on the machine making inspection impossible without opening the machine or draining it. What is needed is an inspection culture: installation of oil levels on all machinery inducing regular monitoring.
4. Lubricant storage by cleanliness control
Did you know that 10 ppm of water in a bearing lubricant will half the bearings lifetime. This is the relative amount of two drops of water in a glass of great Belgian beer? Seriously!
Did you know that contamination is the cause of more than 30 % of lubrication related bearing failures?
Did you know that new oils have commonly a higher contamination level than recommended by the machine supplier?
Cleanliness control of new and stored lubricants is a focus in the program. As it is a basic issue, with small investments but huge return. It’s all about improving the quality of new lubricants and protecting these lubes from environmental contamination like moisture, dirt, chemicals etc. Today many innovative solutions are available to properly store & condition lubes: the best have dedicated tanks with pumps and filters for on line filtering, proper identification and have protections like desiccant breathers. Systems that do not work in this way are just bad practice.
In cleanliness control it is recommended to keep track of your efforts: with regular oil analysis for contamination levels by ISO4406 (standard test by which contamination particles are counted and codified into or a 2 or 3 digit code). This KPI will guide you from initial cleanliness level to a desired one. Filter rating is selected in function of targets and applications. Eg. hydraulic fluids can have a desired IS04406 level of 14/12 while a gearbox lubricant might be ISO4406 20/17. With a Cleanliness Improvement program that decreases the ISO level of “new” oil from 22/19 to a super clean oil with ISO 13/10, the lifetime of hydraulics or diesel engines will be extended by a factor of 10 or more ( ref Noria ).
5. Oil dispensing is an art
No, it is a question of using the right tools for the job. Oil cans need to have these basic requirements: fully sealed, translucent for inspection, color coded and identified and adapted to the application and fluids, preferably made from plastic to avoid rusting.
Forbidden are open steel cans or bottles, funnels or similar that attract contamination instead of keeping dirt and moisture out! Unfortunately we see these bad practices and dirt collectors every day in use.
6. Grease lubrication
Greases are difficult to clean up once contaminated. Therefor it’s recommended to use techniques that avoid uncleanliness during storage and application: the lesser transfer of bulk grease the better. Use of cartridges or automatic lubrication systems are preferred.
In case bulk is used from drum, apply the right follower plate, cover and pump.
Lubrication Reliability is also about using best practice techniques to apply grease: digital volume meters or ultrasonic grease pumps are suitable to control applied volume. Too much grease is as catastrophic as not enough grease.
7. Control Contamination
Now once lubricants are applied to the machine the same strategy should be implemented: avoid further contamination and if possible decrease existing contaminant levels.
In first instance we recommend protection systems like desiccant breathers on key machinery and machinery that operate in a dirty industrial environment (dust, humidity). These systems are designed to collect as much dust (with filters of 0.5 to 2 µ) and moisture as possible.
Secondly filtration of lubricant on the machine might be needed in case of high contamination levels.
Some on-line filtration units can be installed permanently, other are only suitable for water removal.
8. Measure quality by Oil Analysis
Lubricant condition can be detected by means of oil analysis. In a LR program we recommend to set up a full Oil Analysis program. A “once-and-again” philosophy has no sense as trending of results more crucial than the unique result.
An oil analysis program is an indispensable part of the Lubrication Reliability strategy as it’s the best way to continuously monitor lubricant quality and thus machine condition.
9. Environmental Control
It is nearly impossible to keep lubricants clean if the lube room is messy or machines dirty.
We recommend a “cleanroom regime” for all lubricant environments. All “dirt creating” products ( sand, sawdust, etc. ) used to clean oil spills should be banned.
10. Feed the brain & train.
No Lubrication Reliability program should start with a group of people not having the right skills and training. No need for PHD’s in tribology, but technicians, reliability engineers, foremen and managers will have to be educated at their level. Plenty of good training programs are available out there.
A very good way to motivate and appraise Lubrication Reliability co-workers is to certify them ( e.g. ICML Lube council ).
Mission Impossible? No!
Implementing the 10 key factors of Lubrication Reliability in one go is an impossible mission. Gradually taken step by step and well planned in time: it is well feasible.
Remember, Lubrication Reliability is not a project, it’s a continuously evolving program or should we say culture in which cleanliness control should be a continuous strive for excellence. Automatically machine & component reliability follows.
Many industries have proven it in the past, the door is now open for your plant.