Maintenance Technology July 2017 - 36

LUBRICATION STRATEGIES

lubrication. Several "conditional" strategies can help your site gear up for this
move with little effort and expense.

Implementing conditional
strategies

shutdown to perform checks or fill up.
These systems can be inexpensively
redesigned with remote "quick-connect"
fill-lines piped to the machine perimeter
that will allow the reservoirs to be filled
to correct levels while the machine runs.
(For additional tips, see this article's
"Learn More" box, p.37.)

presence alarm levels. (For additional
tips, see the "Learn More" box, p. 37.)
Oil-temperature condition is important wherever ambient temperatures
fluctuate and an oil might become too
viscous to be pumped through a system.
This situation can create a bearing-starvation effect. In environments where this
could happen, a thermostat-controlled
automotive block heater or battery
blanket heater can be incorporated in the
system to ensure lubricant usability and
machine uptime.

Two basic elements underpin a condition-based lubrication program. The
first speaks to the integrated, proactiveStrategy 2: Oil condition
maintenance approach through involvement of operators as the primary "eyes
When the term "condition-based" is
and ears" in performing daily machine
used, oil analysis often comes to mind.
condition checks. The second element
The first stage in controlling the oil's
assures consistency and accuracy in
condition is to ensure the product is put
Strategy 3: Machine condition
the execution of value-based condition
in the reservoir at the correct servicechecks and lubrication actions.
level of cleanliness and that a contamThe ultimate lubrication-control is based
Some maintenance personnel might
ination-control program is in place.
on equipment running condition. Effecargue that the old PM job tasks stating
This will require a number of things: an
tively lubricated machinery will require
less power to operate and
"Fill reservoir as necessary"
bearing life will be extended
or "Lubricate as necessary"
by as much as three times
are perfect conditionthat of ineffectively lubribased instructions. Not so
An integrated, proactive-maintenance
cated machines. Correctly
fast: Those instructions,
approach maximizes machine
engineered and set up,
unfortunately, rely solely
automated, centralized
on maintainer experience.
availability and reliability.
lubrication-delivery systems
They will not deliver consisensure the right amount of
tency and accuracy without
lubricant is applied in the right place, at
controls that dictate how we assess a
effective oil-receiving and -distribution
the right time. If your plant's equipment
machine's condition and take appropriate strategy, operators and maintainers
is predominantly manually lubricated,
working together to keep the lubrication
actions built into the "necessary"
investigate converting to automated
system clean, use of desiccant-style
part of the work-task equation. That's
where implementation of the following
systems that require less maintenance
breathers, and remote, "quick connect"
conditional strategies pays off.
and return their investment in weeks
fill ports that can be hooked up to filter
or months. (For additional tips, see the
carts outside of a machine's operating
"Learn More" box, p. 37.)
envelope. (For additional tips, see the
Strategy 1: Reservoir-fill
Automated systems are highly adapt"Learn More" box, p. 37.)
condition
The second stage is to monitor the oil's able to new IIoT (Industrial Internet of
Things) protocols. The capability now
condition for contamination, oxidation,
If a lubrication system is to deliver
exists to install bearing-heat sensors (that
and additive depletion through the use
peak performance, it will require an
set temperature ranges of different bearof oil analysis. Extracting oil samples
engineered amount of lubricant. In
ings) for monitoring, amperage metering
for testing purposes is predominantly a
re-circulating and total-loss systems
(needed because friction demands an
manual process that can be conducted
alike, designated minimum and
increase in motive power that translates
outside of a machine's operating
maximum fill amounts aren't always
through amperage draw), and sensing of
envelope through a remote-piped "live"
clearly indicated on the reservoirs. In
oil levels and cleanliness.
re-circulating line or by using a remotesuch cases, the first step is to ensure that
Condition signals can be sent to an
a viewable sight gauge is in use, complete piped sight-level gauge with a built-in
automated system's lubricator to turn
extraction port.
with hi-lo markers for manual checks.
on and off for a timed or actuation
Based on a condition report, the
For critical equipment, an advanced
cycle, or to indicate an alarm state.
machine's oil can be cleaned by using a
approach can utilize a programmable
level control to electronically indicate the filter cart, with no downtime, or replaced These conditions can be monitored with
software tools and used for computerat a conveniently scheduled time. An
fill state to operators and maintenance
based automated decision making to
advanced alternative is to use an inline
personnel. Some equipment, of course,
reset a lubricator program based solely
sensor to monitor and electronically
is designed with reservoirs inside the
indicate pre-set oil cleanliness and water- (and precisely) on condition needs of a
operating envelope that require machine

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MAINTENANCE TECHNOLOGY

JULY 2017

Table of Contents for the Digital Edition of Maintenance Technology July 2017