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 Automatic
lubricators
The why and where of
single point automatic lubricators
by John Malone
When it comes to bearings,
grease is often the lubricant of choice. However, over- or
under-greasing can cause overheating, lubricant deterioration, and
eventual bearing wear or failure. To help ensure proper lubrication,
automated lubricant dispensing systems can be used to manage the amount
of grease applied to specific lubrication points.
Automatic lubricators
Single point automatic lubricators, which are used in a variety of
applications such as lubrication of bearings, fans, electric motors,
chains, slides and guide-ways, are among the types of automated grease
dispensing systems available in today’s MRO market place. They help
reduce operating costs and maximize equipment life by providing a
precise and controlled supply of lubricant to lubrication points.
Automatic lubricators reduce downtime caused by inadequate bearing
lubrication, thus contributing to the uninterrupted operation of plant
equipment and improved productivity and profitability.
As part of an overall
lubrication program, automatic lubricators play a key role because
without them, it is difficult to implement an easy and cost-effective
maintenance plan. Without a maintenance schedule in place at your plant,
problems can arise from:
• Personnel avoiding hard-to-reach or dangerous places
• Shutting down equipment to safely access bearings
• Mixing incompatible greases
• Adding too much or too little grease
The evolution of
lubrication technology
Prior to the introduction of automatic lubrication devices, it was
necessary to shut down some machinery in order to lubricate it.
Automatic lubrication devices reduce this downtime. Single point
automatic lubricators, now an important element of a lubrication
program, help improve grease-related maintenance practices by replacing
manual greasing and, in some cases, more costly central lubrication
systems. Because of this, automatic lubricators can be an inexpensive
way to maximize a plant’s maintenance resources.
Historically, there have
been four key lubrication methods used in a manufacturing environment:
1. Run to failure,
which is the operation of machines until breakdown. Equipment is
subsequently torn down, repaired, lubricated and then rebuilt. This
method is costly and inefficient. Not surprisingly, this operation cycle
was more common in the past then it is today.
2. Oil bath and splash,
which is either the submergence of all system gears and bearings in an
oil sump or the splashing of components with rotating gears. This
enclosed system is cost effective in the short term. However,
contaminants that may get trapped inside the system will decrease the
life of the oil and ultimately cause increased maintenance costs.
3. Central lubrication
systems, which store lubricant in a reservoir and then continuously pump
it to critical equipment components through a complicated system.
Although these systems are important for some particular manufacturing
purposes, they are not effective for most applications. Central
lubrication systems are also expensive to assemble and install.
4. Single point
automatic lubricators, which are designed to dispense lubricant
consistently for up to one year. They are a simple, accurate, and
cost-effective method for most applications.
Originally, automatic
lubricators simply enabled a facility to operate machinery and lubricate
bearings simultaneously. Today, single point automatic lubricators are
widely accepted in the modern manufacturing world and have an expanded
role to improve overall maintenance practices, reduce costs, increase
efficiency, and promote plant safety.
Resistance to change
Even though there is value in implementing automatic lubricators, there
is still some resistance in manufacturing circles due to the initial
investment required. Ultimately, lubrication related bearing wear and
equipment failure will be a much larger expense. Companies that invest
in automatic lubricators to improve preventative maintenance will
benefit financially in the long term.
Some companies prefer to
stick with “tried and true” lubrication methods and often times prefer
manual application of the lubricant. This method requires employees to
monitor the plant, interact with the machinery through the use of grease
guns and other manual lubricators and document the procedure in a
report. In these cases, companies may be uncomfortable relinquishing a
human’s responsibility to a mechanical device.
If a plant is concerned
about the reliability of automatic lubricators, we encourage them to
trial the lubricating device in less critical applications. Plants can
easily conduct a phase progression on equipment that is probably not
being lubricated regularly and has perhaps failed, such as fan bearings
on a roof, or pump bearings in a basement. This machinery may not be as
critical to the plant’s production line as other pieces of equipment.
Due to the difficulty in accessing these bearings, they may have gone an
extended period of time without proper lubrication. A plant will gain a
better understanding of an automatic lubricator’s reliability and role
in proper grease application through initial testing in less critical
areas.
As part of a lubrication
management program, automatic lubricators can help a plant ensure that
its machinery is receiving proper lubrication, in the right place, at
the right time, and in the correct amount. This helps plant efficiency
by minimizing the amount of grease being used and maximizing maintenance
resource time. Instead of assigning staff with the preventive
maintenance task of greasing bearings, the plant can benefit through
more active involvement with predictive maintenance work such as oil
analysis, vibration analysis, and thermography.
Summary
Single point automatic lubricators can be an important component to a
successful lubrication program. These devices are a cost effective way
to reduce bearing failure, minimize equipment downtime and contribute to
a plant’s continuous operational success.
John Malone is the Global
Industrial Segment Manager and Reliability Solutions Manager for Chevron
Products Company.
He is a member of SMRP as well as the Society of Tribologists and
Lubrication Engineers. If you have lubrication questions, contact Coach
Malone at: Phone: 713-432-2647;
E-mail: jvma@chevron.com.
This article appeared
in the December 2006/January 2007 issue of MRO Today
magazine. Copyright 2006.
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