Machinery Lubrication magazine published by Noria Corporation
Issue link: https://www.e-digitaleditions.com/i/108300
AUTOMATIC LUBRICATION edge to perform more analytical tasks, lubricant analysis and making improvements to the lubrication program? Benefits of Automated Lubrication There are many advantages in using automatic lubrication systems. These include reduced waste and risk of bearing failure, cleanliness, less labor, and improved environmental health and safety. An automatic lubricator can supply a continuous and accurate flow of fresh and clean lubricant. Reduced Waste and Risk of Bearing Failure Relubrication quantities are dictated by the physical space available in the bearing, while relubrication intervals are dictated by the working conditions that determine the degradation rate of the lubricant (speed, load, temperature, type of bearing, etc.). A single-point automatic lubrication system can deliver the right amount of grease at the right time to each lubrication point. This reduces both grease waste and the risk of bearing failure. For example, consider a bearing that needs to be relubricated with 2 grams of grease every week. With a standard grease gun, this would mean that the bearing should receive about 1.3 "strokes." However, manually delivering 0.3 strokes is difficult. In reality, two strokes would likely be given. In other words, the bearing would receive 3 grams instead of 2 grams of lubricant each time. If we assume the technician is satisfied with two strokes (if he doesn't see any grease coming out of the seals), then after a year the bearing will receive 156 grams (52 weeks times 3 grams per week) instead of 104 grams (52 weeks times 2 grams per week). This means that up to 52 grams (50 percent) of grease will be wasted. avoiding grease contamination can be a challenge. Processes must be clean to ensure no external contamination ingress to the grease, and each lubrication point should have a cap on its grease fitting. In addition, the utmost clean relubrication process for each point must be followed every time. In the previous example, the technician will relubricate the given point 52 times a year. As a result, the bearing will be exposed 52 times to external contamination as well as to over- and underlubrication. By comparison, a properly installed single-point automatic lubricator can supply a continuous and accurate flow of fresh and clean lubricant, keeping the application in proper condition while at the same time preventing contaminant ingress. Labor Savings The simple task of pushing a lever on a grease gun to provide manual lubrication can be easily replaced by a machine. However, the real issue is whether you are getting the maximum value from your skilled maintenance technicians. Such personnel can manage a lubrication program through: • Continuous improvement of the lubrication routes • Implementation of a lubricant analysis program • Implementation of a contamination control and oil reconditioning program This example shows the benefit of accurately delivering the right quantity of lubricant (the second "R"), but what about the frequency of lubrication (the third "R")? Extending relubrication intervals beyond the calculated limits will expose the lubricant to excessive degradation and the bearing to lubricant starvation conditions. On the contrary, shortened relubrication intervals with adjusted quantities would renew the lubricant's properties. To illustrate this point, consider that on average, a human being requires about 2,000 calories per day. Would you rather consume your weekly total of 14,000 calories once a week or in nearly equal amounts over seven days? Cleanliness Lubricant contamination will also affect bearing life and increase the risk of failure. In manual lubrication programs, 34 January - February 2013 | www.machinerylubrication.com • Implementation of a leakage control program Keep in mind that while deploying automatic lubrication systems can free personnel from time-consuming basic activities to provide extra value, it cannot replace staff who can deliver value at this level. Environmental Health and Safety Improper relubrication activities can have a significant impact on the environment. Consider again the grease waste calculations in the previous example. Now try to estimate the impact of this waste on the environment. Naturally, it depends on the disposal practices you implement at your facilities, but in basic environmental terms, the less waste the better. Next, consider points that are difficult or even hazardous to access and the potential impact to your personnel. This is another area where automatic lubrication systems offer real benefits.