Lubrication Management

Competence Center Maintenance

Lubrication Management
Equipment availability

Lube Performance

=

KPIs

Handle and storage

Troubleshooting Application People Oil Analysis

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Agenda

Lubrication chart
Lubrication routines
Lubrication performance indicator

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Why is important the LUBRICATION CHART?

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Lubrication chart

The Lubrication Chart is one of the most important document

in the plant, talking about reliability.
All the information regarding machinery lubrication is
integrated in one document.
Lubrication points, type of lubricant and quantity and
frequency of its application
Lubrication activities and its frequency. (Revision, Cleaning,
Application, Sampling, Change and Filtering)
Is the main input to create the lubrication routines
It must be available for all maintenance and production
departments (Just in case)
It must be managed by the lubrication responsible

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Lets Save Money!!!

Youve heard the expression, why is there always

enough time to do it over, but never enough time
to do it right the first time? Restarted in a
maintenance context, Why is there always
enough time (and money) to fix a broken machine
but never enough time (or money) to prevent it
from failing?

Fuente: Jim Fitch, Noria Corporation

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Lubrication chart

Lubrication chart is the base of the lubrication program

To develop the lubrication, it is required an adequate knowledge of

Equipment to be lubricated
Lubricant properties
Selection and application
Lubrication and re-grease frequencies
Lubrication and re-lubrication methods

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Lubrication chart

The lubrication chart consists of a template where all

relevant information is gathered
Equipment identification including the specific lubrication
points,
Type, designation and amount of lubricant applied,
Identification of activity type and the corresponding
frequency,
together with all necessary information about:
Sampling, if required
Services
Inspections, frequency
Cleaning, frequency
Re-greasing or oil top-up, frequency and quantity
Grease or oil replacement, frequency

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Lubrication chart

Lubrication chart is an essential tool to structure and

build lubrication PMRs (Preventive Maintenance Routines)

From where to gather all necessary information?

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Flowsheet & plant equipment list

Make sure that you have

reliable information

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Identification of all equipment elements to be lubricated

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Identification of lubricant type and quantity installed

Operating
manuals

Source: SEW and Siemens Flender Operating manuals

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Inspections and cleaning

Operating manuals

Experience

Source: SEW and Siemens Flender Operating manuals

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Re-application quantities

Re-lubrication quantities suitable for each bearing are in

a direct correlation with:
the bearing size

and

the location of the lubrication point related to the

bearing

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Re-lubrication amounts - calculations

Re-lubrication from the side Re-lubrication from the center

Gp = 0,005 * D * B Gp = 0,002 * D * B

where
Gp = grease quantity to be added when replenishing, [g]
D = bearing outside diameter, [mm]
B = total bearing width (for thrust bearings use total height H), [mm]
Source: SKF
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Re-lubrication amounts - bearing dimensions

Source: SKF
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Re-lubrication amounts - bearing dimensions

Bearing dimensions to be considered for calculations

Gp = 0,005 * D * B
Source: SKF
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Re-application quantities and frequency

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Lubricant replacement time based (1)

Grease replacement intervals (SKF example)

L10h
Class of machine (operating hours)

Household machines, agricultural machines, instruments, technical apparatus for 300 ... 3000
medical use
Machines used for short periods or intermittently; Electric hand tools, lifting tackle in 3000 ... 8000
workshops, construction machines
Machines too work with high operational reliability during short periods of 8000 ... 12000
intermittently; Lifts (elevators), cranes for packaged goods or slings of drums, bales
etc.
Machines for use 8 hours per day but not always fully utilized; Gear drives for general 10000 ... 25000
purposes, electrical motors for industrial use, rotary crushers
Machines for use 8 hours per day and fully utilized; Machine tools, woodworking 20000 ... 30000
machines, machines for the engineering industry, cranes for bulk materials, ventilator
fans, conveyor belts, printing equipment, separators and centrifuges
Machines for continuous use 24 hours a day; Rolling mill gear units, medium sized 40000 ... 50000
electrical machinery, compressors, mine hoists, pumps, textile machinery
Water work machinery, rotary furnaces, cable stranding machines, propulsion 60000.. 100000
machinery for ocean-going vessels
Large electric machinery, power plant, mine pumps and mine ventilator fans, tunnel ~ 100000
shaft bearings for ocean-going vessels

Source SKF
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Lubricant replacement time based (1)

Equipment operating manuals

Source: SEW and Siemens Flender Operating manuals

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Lubricant replacement condition based

The first step in setting up an oil analysis program is to

select the systems to be monitored

Main criteria in selection of the system is the equipment

criticality and not oil volume itself!

Oil analysis program steps

Establish the sampling frequency (considering machine
and oil age both are moving targets, readjustments
required)
Determine the cleanliness target of oil sample
Ensure proper sampling methods and techniques
Ensure a proper evaluation and documentation of
sampling results (history and graphical trend analysis are
essential parts of the evaluation process)
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Lubricant replacement

Condition based and time based lubricant replacement

information are part of lubrication chart

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Agenda

Lubrication chart
Lubrication routines
Lubrication performance indicator

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Lubrication routines

Revision Date Nov 10

Lubrication chart
Lubrication Chart
Lubricant
Quantity
Inspection Clean
ACTIVITY TYPE

Condition Reapplication Change Lube Date Of

Hac Equipment Name Element To Lubricate Installed Sample Of Application Method
Points Modification
Equipment
Type Designation Value Unit Freq Unit Freq Unit Freq Unit Quant. Unit Freq Unit
241-AD1 Auxiliary Drive Gearbox Auxiliary drive motor bearings Grease Lithol-24 0.2 kg 1 w 1 w stopped 6 m 0.20 kg 6 m 2 Manual
241-AD2
241-SP1
241-SP2
241-SP3
Auxiliary Drive Gearbox
Pump Y-800/ 400
Pump Y-800/ 400
Pump Y-800/ 400
Auxiliary drive motor bearings
Motor bearings
Motor bearings
Motor bearings
Grease
Grease
Grease
Grease
Lithol-24
Lithol-24
Lithol-24
Lithol-24
0.2
0.7
0.7
0.7
kg
kg
kg
kg
1
1
1
1
w
w
w
w
1
1
1
1
w
w
w
w
6
6
6
6
m
m
m
m
0.20
0.70
0.70
0.70
kg
kg
kg
kg
6
6
6
6
m
m
m
m
2
2
2
2
Manual
Manual
Manual
Manual
Lubrication routines
241-SP4 Pump Y-800/ 400 Motor bearings Grease Lithol-24 0.7 kg 1 w 1 w 6 m 0.70 kg 6 m 2 Manual
241-VA1 Slurry valve Motor bearings Grease Lithol-24 0.15 kg 1 w 1 w 6 m 0.15 kg 6 m 2 Manual
241-VA3 Slurry valve Motor bearings Grease Lithol-24 0.15 kg 1 w 1 w 6 m 0.15 kg 6 m 2 Manual
241-VA7.M1 Valve motor Bearings of electric motor 5kW Grease Lithol-24 0.2 kg 1 w 1 w 6 m 0.20 kg 6 m 4 Manual packed lubr.
301-1 Electric bridge crane l/ c 12,5t Bearings of electric motor 2,2kW Grease Lithol-24 0.1 kg 1 w 1 w 6 m 0.10 kg 6 m 2 Manual packed lubr.
302-1 Electric bridge crane l/ c 25t Motor bearings Grease Lithol-24 0.2 kg 1 w 1 w 6 m 0.10 kg 6 m 2 Manual packed lubr.
361-AD1.M1 Auxiliary Drive Electric motor Auxiliary drive motor bearings Grease Lithol-24 0.3 kg 1 w 1 w 6 m 0.30 kg 6 m 2 Manual
361-MD2.M1 Main Drive Electric motor Auxiliary drive motor bearings Grease Lithol-24 0.3 kg 1 w 1 w 6 m 0.30 kg 6 m 2 Manual
361-MD4.M1 Main Drive Electric motor Auxiliary drive motor bearings Grease Lithol-24 0.3 kg 1 w 1 w running 6 m 0.30 kg 6 m 2 Manual

Process flow

Equipment physical location

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Lubrication routines

Lubrication routines are check list developed to help

lubrication technicians to apply in systematic way the
required activities

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Walk-by inspection

Walk-by inspections use our human senses to Touch

monitor the condition of our equipment

Visual

Audio

Smell

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Walk by inspection lubrication related topics

Lubrication related topics must be included in the walk

by check lists:
Housekeeping
Inspections
Oil level,
Blocked oil breathers
Damaged seals
Oil and grease leakages
Open gear boxes
Open lubrication tanks
Oil flow in lubrication system
Pressure drop per oil filters
Oil temperature
Bearings temperature
Oil smell
Oil color
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Walk by inspection topics selection

Operating manuals

Source: SEW and Siemens Flender Operating manuals

Experience

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Agenda

Lubrication chart
Lubrication routines
Lubrication performance indicator

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Lubrication performance indicator

Oil Consumption Ratio (OCR)

KPI measuring and evaluating the overall lubrication
situation / performance of a plant, tracked on yearly
base

=

only volume of oil installed over 5 liters shall be taken into

consideration.
mobile equipment as e.g. trucks used in the quarry shall
not be considered for the calculation

Good practice value 0.45 to 0.85

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Lubrication points inventory

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Centralized Lubrication Systems

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Lubrication Activities

Revision
Simple activities such as oil and grease levels
Proactive tasks for hidden failures (centralized systems)
Simple activities to test the function of automated systems
Measure of wear in bearings roller elements (during the
grease change)
Inspection of lubrication systems which are only accessible
in a stopped state of the machinery (e.g., pipes for bearing
lubrication in separators)
Cleaning
Activities related with housekeeping to keep machinery
neat and with appropriate cleanliness
Cleaning activities must be scheduled to be performed
without putting at risk the personnel safety

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Lubrication Activities

Application
Grease relubrication in motors and bearing houses
Sampling
To perform oil change in base on condition
Activities to draw an oil sample in order to perform field test
as well as routinely laboratory oil analysis
Change
Oil changes by frequency.
Small equipment with low probability of failure and impact
(screw conveyors, hydraulic couplings, etc.)
Filtering
Filter critical equipment ( main speed reducers) in a regular
basis or according with the oil analysis results

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Questions?

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