Importance of Proper Lubrication in Machinery

Lubrication of machinery is the best practice of introducing a lubricating agent into machine components and plays an important role in reducing energy losses by reducing friction between contacting surfaces in relative motion such as gears, bearings, dies, chains, spindles, cable, pumps, and rails, etc. Lubrication also helps in providing a heat transfer medium, works as a sealant agent on uneven surfaces and protects the equipment from oxidation. This blog discusses the lubricant characteristics, financial impacts of improper lubrication and lubrication methods. This blog also discusses how lubricant levels affect energy consumption. For Example, The ring spinning frame machine is an important phase in the yarn manufacturing process. Because of the resistance caused by the lubricant, the electricity consumption in the Ring frame increases with an increase in the lubricant level in the bolsters, so the lubricant level needs to be optimum, i.e. 75%, in order to save sufficient energy consumption in ring frames.

Characteristics of a Lubricant

1. The resistance of a fluid to a change in the motion or shape of adjacent parts is known as viscosity. Kinematic viscosity, the most popular unit of viscosity measurement, is typically quoted in data sheets at 40°C and 100°C measured in mm2/s. The change in viscosity with temperature is measured arbitrarily by the viscosity index (VI).
2. A normal lubricant has a viscosity index between 95°C to 100°C. The VI of a highly refined lubricant is up to 120.
3. The lowest temperature at which an oil will pour when cooled under specific circumstances is known as its pour point which should ideally be more than 10°C below the application’s lowest operating temperature to ensure proper fluidity at low temperatures.
4. The rate of oxidation in lubricants increased with time and increased the viscosity of a lubricant. Every 10°C increase in temperature causes the rate of oxidation to double.
5. The ability of a fluid to withstand degrading under heat stress is known as thermal stability A fluid with high thermal stability will age more slowly than a fluid with low thermal stability and will function for longer. Optimum performance, for both economy and power, is achieved at temperatures around 100-107°C. Up to 120°C is OK if a decent oil is used, but getting a little warm

Improper Lubrication

60% of lubrication professionals do not measure their lubrication program using metrics or any other key performance indicators (KPIs). When a proper lubrication schedule is not followed, this can cause the equipment to fail completely. To make the equipment smoother, an optimal level of lubrication must be followed. One of the major reasons for a bearing failure is inadequate lubrication. The majority of industries agree that improper lubrication is to blame for more than 35% of all industrial bearing failures. For Example, Over-lubrication can cause the bearing to jam, whereas under-lubrication causes the bearing to generate excessive sound and heat, leading to equipment failure.

Financial Impact of improper lubrication

According to a study conducted by the U.S. D.O.E., electric motors consume 23% of all electricity consumed, with 70% consumption in the manufacturing sector. Up to 95% of a motor’s costs can be attributed to the energy it consumes over its lifetime, with only about 5% attributed to the motor’s purchase, installation, and maintenance. Energy consumption’s financial impact is also frequently overlooked. An electric motor’s improper grease volume can account for 5-10% more energy consumption.

Proper Lubrication Procedures

Industrial bearings rarely function for more than 10% of their working lives without sustainable lubrication. Continuously needing maintenance on equipment increases production downtime and reduces overall commercial productivity. So in order to keep the equipment protected from wear and tear following methods needs to be adopted.

• Choose lube according to the desired specifications.
• List down the lubricants and lube points of every piece of equipment installed in the system.
• Install portable oil analyzers to check the temperature and vibration reading on time.
• Routine checking of lube sampling
• Record the lubricant losses. Record abnormalities if required.
• Use a filter to keep the contaminants out of the lubricant.