Introduction

Lubrication failure is one of the most critical issues in machinery and engines. It occurs due to the faltering of the lubrication supply system that is responsible for the reduction of wear and friction. Thus, it is important to understand the causes and analysis methods for the lubrication failure. Lubrication failure occurs due to various factors like oxidation, high temperatures, pollutants, insufficient lubricant levels and viscosity issues. Oxidation causes chemical changes in the oil affecting its performance. High temperatures lead to thinning of oil and reduce its effectiveness. Pollutants and sediments compromise the quality of lubrication gradually and insufficient lubricant levels and viscosity issues double the problems.

Top 5 Equipment Failures Due to Poor Lubrication

Below stated are top 5 equipment that fail due to lubrication failures:

• Bearing Failures: Bearings are an important part of machinery as they are found everywhere from conveyor belts to motors. If they are not lubricated properly; they face increased friction and result in overheating and premature wear. Eventually, they would seize up and bring one’s operations to a screeching halt. To prevent bearing failures, one should choose the right type and sufficient amount of lubrication for the bearings. Those bearings should be lubricated regularly and should be kept away from contaminants such as dirt, moisture, etc.
• Gear Wear and Breakage: Gears tend to work hard. If they are not lubricated properly, they would grind against each other instead of meshing smoothly. This results into excessive wear, pitting and ultimately failure. To prevent this, one should choose the correct lubricant based on gear speed, load and operating conditions. The condition of lubricant should be monitored continuously and it should be replaced when needed. Also, all the gears should be kept clean as dirt or metal shavings can increase the damage.
• Hydraulic System Malfunctioning: Hydraulic systems rely on clean and properly lubricated components to maintain pressure and function efficiently. If they are not lubricated properly, it can cause overheating, reduced performance and total system failure. To prevent this, one should use high-quality hydraulic fluids recommended by the manufacturer. They should be checked regularly to detect leaks or contamination. One should also follow proper fluid change intervals to avoid sludge buildup.
• Chain and Sprocket Wear: Chains and sprockets of conveyor belts, bikes and heavy equipment should be lubricated to reduce friction and prevent excessive stretching or snapping. To prevent chain and sprocket wear, the lubricant should be applied evenly and consistently to all the parts. The lubricant should be chosen according to the operating environment and the chains should be cleaned regularly and kept away from dirt, grime speed, wear and tear.
• Engine Seizures: Engines rely on oils to keep the components function smoothly. If they are not lubricated properly, the metal parts would rub against each other and generate extreme heat which can also lead to catastrophic failure. To prevent this, the oil levels should be checked regularly and manufacturer’s guidelines should be followed for oil changes and filter replacements. It is also essential to use right oil viscosity for the engine and operating conditions.

Analyses and Investigation of Lubrication Failure

Below stated are some of the ways to analyze and investigate lubrication failure:

• The Power of Visual Inspection: Visual inspection is considered one of the most powerful defenses against lubrication failures. By visually inspecting the quality of lubrication, one can easily spot problems before they escalate which saves both time and money. This process also involves identification of visible contaminants and issues that might be invisible to machinery senses. One can inspect factors like color and clarity, texture, contaminants, odor and fluid level through this method.
• Oil Analysis Testing: Oil testing is considered one of the most valuable tools for diagnosing lubrication issues. It can see things which can’t be seen through naked eyes. Some of the common types of oil testing methods are Wear Particle Analysis- used to identify wear pattern and sources, Spectroscopy- used to determine chemical composition and wear, Viscosity Measurement- used to check for changes in lubricant viscosity, Water Content Analysis- used to detect water contamination in the oil and Acid Number Analysis- used to indicate oil degradation due to acidity.
• Wear Particle Analysis: Wear particle analysis is a special technique that helps in pinpointing the source of wear in machinery. It tends to provide essential insights about the condition of components and allows proactive measures. Some of the common types of wear particles are metal particles- that can indicate wear on metal components, non-metallic particle- that can identify issues like dirt and chemicals, particle size- that can help in gauging the severity of wear, particle shape- that can at the type of wear occurring and concentration levels that can indicate the magnitude of the problem.

Tips to Prevent Lubrication Failure

Below stated are some of the key tips to prevent lubrication failure:

• The lubrication levels should be monitored regularly and maintained.
• Periodic oil analysis should be performed to detect early contamination.
• Worn-out seals, gaskets and filters should be replaced properly.
• Manufacturer guide should be followed for lubrication schedules and types.
• The operators should be trained on proper lubrication techniques and system monitoring.

Take Away

This is a brief explanation about lubrication failure, top equipment that fails due to improper lubrication, ways to analyze it and tips to prevent those failures. We hope this information will be effective for you. Please let us know through your valuable feedback and the suggestion in the drop box.