What are the best lubrication strategies for extending equipment lifespan in plant operations?

1 Lubrication basics

Lubrication is the process of applying a substance, such as oil, grease, or fluid, between two surfaces that are in contact and moving relative to each other. The purpose of lubrication is to create a thin film that separates the surfaces, reducing metal-to-metal contact and minimizing friction, heat, and wear. Lubrication also helps to prevent contamination, corrosion, and oxidation of the equipment components. There are three main types of lubrication: boundary, hydrodynamic, and elastohydrodynamic. Each type has different characteristics and applications, depending on the load, speed, temperature, and geometry of the contact surfaces.

3 Lubrication application

Applying the lubricant to the equipment is another important step in lubrication strategy. The lubricant should be delivered to the right place, at the right time, and in the right amount, to ensure adequate lubrication and avoid over-lubrication or under-lubrication. The lubricant should also be applied in a clean and safe manner, to prevent contamination and spillage. There are various methods and devices for lubrication application, such as manual greasing, automatic lubricators, centralized systems, and spray systems. Each method has its own advantages and disadvantages, depending on the type of equipment, the accessibility of the lubrication points, and the frequency and quantity of lubrication needed.

4 Lubrication monitoring

Monitoring the condition and performance of the lubricant and the equipment is essential for maintaining and improving lubrication effectiveness. Lubrication monitoring involves inspecting, testing, and analyzing the lubricant and the equipment components, to detect any signs of degradation, wear, or failure. Lubrication monitoring can help to identify and diagnose problems, optimize lubrication intervals and quantities, and prevent breakdowns and downtime. Some of the common tools and techniques for lubrication monitoring are: visual inspection, which involves checking the color, clarity, level, and leakage of the lubricant; sampling and analysis, which involves collecting and testing the lubricant for physical, chemical, and contamination properties; and condition monitoring, which involves measuring and recording the vibration, temperature, pressure, and noise of the equipment.

5 Lubrication improvement

Improving your lubrication strategy is an ongoing process that requires continuous learning and adaptation. You should always seek to update your knowledge and skills on lubrication best practices and innovations, and apply them to your plant operations. You should also evaluate your lubrication performance and results, and look for areas of improvement and optimization. Some of the ways to improve your lubrication strategy are: conducting lubrication audits, which involve assessing the current state and gaps of your lubrication program; implementing lubrication standards, which involve establishing and documenting the lubrication procedures and policies; and adopting lubrication technologies, which involve using advanced and smart devices and systems that enhance lubrication efficiency and effectiveness.

6 Lubrication benefits

Following the best lubrication strategies for your plant equipment can bring you many benefits, both in the short term and in the long term. Some of the benefits are: increased equipment reliability and availability, which means less downtime and more productivity; reduced equipment maintenance and repair costs, which means lower operating expenses and higher profitability; extended equipment lifespan, which means longer asset utilization and lower replacement costs; improved equipment performance and quality, which means better output and customer satisfaction; and enhanced environmental and safety compliance, which means lower risks and liabilities.

7 Here’s what else to consider

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