Category Archives: Heavy Equipment Lubes

Effective greasing of heavy equipment can elongate its life

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We take a good deal of effort to ensure that our heavy equipment are in order and it does not break down when we need them the most. For instance, when we have an important project in hand and need the machine to work all throughout the day, we will just not want it to stop working for any stupid reason. But in case if it breaks down due to its parts being not sufficiently lubricated, it only shows how much we care for our equipment. It is therefore of utter importance that we apply appropriate greasing on the equipment at regular intervals. This will not only ensure that our machines are in order but also will save you from incurring any financial losses.

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In order for the heavy equipment to work in proper condition, appropriate greasing is very essential. Over greasing can also become a big problem which can prove very costly to you. It can lead to several complications in the machines like collapsed seals, high operating temperatures etc. So, people who are of the thought that applying lot of grease can strengthen the life of the machine can fall completely flat on their faces when they will begin to experience these issues in their machines.

Before you apply grease on your machine, it is also important to understand that if the grease is the right one for your machine. Not all kind of grease on earth will suit your equipment and in order to know what will go better with your equipment, you need to check the user manual of the product. In case, you are unable to understand that, you can also go through few internet articles that speaks about the kind of greasing you need to do for your machine. Lastly, you may also get in touch with an expert mechanic who will guide you with the lubricant you can apply on the machine.

Grease is ideally a combination of 3 components; i.e. oil, thickener and additives. By mixing these 3 components, lubricants of different types are produced. The oil that is used in lubricants is ideally mineral oil and it has been seen that such greases have shown significant performances in keeping the machine well lubricated. However, in case of extreme temperatures, synthetic based oil is most effective. The oil is then mixed with a thickener which can be a metallic soap. This will turn the soap into a semi fluid structure. Concurrently, companies are also using complex thickener type greases as it can provide outstanding capability to pull huge loads.

The complex greases are made by merging the metallic soap with an organic acid that has a very low molecular weight. Just in case if the machine is working in high temperatures, then usage of grease without any soap thickeners can bring optimum results.

For users who do not know what kind of grease they need to apply on their machines, it is recommended that they take some help of experts who knows about the different types and quality of greases and then work it on their machine.

Best practice of lubrication procedure

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As industries are growing at a rapid rate, plant managers need to develop their lubrication procedures. Best practices of lubrication procedure can boost up equipment reliability, reduce energy consumption and carbon-dioxide emissions and optimize maintenance. In order to increase productivity, top-notch lubrication methods, perfect staff training and high quality lubricants are essential.

Three stages of lubrication strategy

  • Boundary lubrication: – In boundary lubrication, an equipment faces the friction most as it was in its “start –up” phase. During start up, speed is relatively low and the load is high. The lubricant cushion is here only a thin film.
  • Mixed lubrication: – When the speed increases, the lubricant cushion builds and draw more lubricants in between the metals. Though the friction is reduced in mixed lubrication, but it can’t stop metal–to-metal friction at full.
  • Hydrodynamic lubrication: – Continuously increasing speed bring lubrication to its final stage known as “Hydrodynamic Lubrication”. Here friction is reduced to the minimum and the surfaces are properly coated with lubricant to avoid metal-to metal friction.

Tips to accomplish lubrication goals

  • Choosing the right tool for lubrication process is an important part. Pump and system maintenance experts gain an insight into the condition of the lubricant of the machinery with the help of ultrasound technology. Thus the team able to put right amount of lubricant at the correct time at correct place.
  • Identification is another step in which a labelling system is involved. It is used because in large plants various lubricants are applied. The labelling helps to avoid errors of mixing lubes (as lubricants are composed of chemical compositions and hence incompatible) especially in food industry.
  • One of the main reasons of equipment’s early failure is the oil contamination. So, in order to carry out the lubricant safely and clean, one should use fully sealed container and contamination – free containers which means containers that will not generate contaminants.
  • Dispensing equipment should be efficient and user friendly. The containers should be well identified to avoid any kind of mistakes.
  • It is advisable to colour code the grease guns to make sure right lube is used for right application.
  • Controlling the oil contamination in the equipment also plays a vital role. Online and offline filtering system help to clean the oil.
  • Before applying oil in the lubrication strategy, one should undergo a chemical analysis of the oil.
  • As lubricant has the power to pollute the environment, most maintenance strategies work hard to prevent such accidents.
  • The basic training of lubrication personnel should be encouraged to carry on an effective lubrication procedure.

The customers should make their lubrication strategy not under any pressure and their decision to buy lubricant should not falsely guide by the purchasing department. Most of the customers don’t realize that their equipment stop working not due to any mechanical failure, but due to lack of or improper lubrication procedure. There are OEMs which acts as a guideline to choose the right lubricant. Many customers report leakage as a problem. This leakage increases the consumption of lubricant by upto 25% which is not negligible. Some companies specially designed dyes to find out where such leakage is taking place which is really an effective tool to optimize lubrication strategy.