While we’ve been using calendars and calculators to determine grease replenishment requirements in bearings for a long time, this science is wrong. Most bearings never reach their L10 engineered life, and poor lubrication practices are attributed as the primary failure cause.
Bearings fail when they are over-greased. We lubricate them too often, and we use too much grease.
Change Your Thinking.
We lubricate bearings to manage friction, but over time, grease gets old and needs replenishment. The first sign is when friction levels increase. Ultrasound performs well at sensing and measuring changing in friction levels. It’s the perfect technology to guide lube technicians during the lubrication-replenishment task.
We want to grease bearings correctly. That means using the right grease, at the right location, following the right procedures and intervals, injecting the right amount, and receiving the right feedback when the task is done. New technologies from SDT are engineered to do just that.
The days of relying on calendars and calculators are over. Use our 5-Step Acoustic Lubrication Procedure and start greasing bearings the right way!
Download our Ultrasound Lube Technician Handbook to learn more!
by Yolanda Lopez
Question: When is it OK to over-lubricate your bearing?
Answer: NEVER!!!!, (almost) the exception is when high vibration exists.
If you attended the SDT/LUDECA Acoustic Lubrication Workshops then you now understand grease as a lubricating mechanism. You understand that the Churning Phase of the lubrication task is inevitable, and long-term, detrimental to the health of the grease. Therefore, we want to move as quickly as possible from the Churning Phase to the Bleeding Phase. This is the natural progression of precision lubrication.
Grease is not a robust grease mechanism. It is actually quite fragile compared to an oil only system. But we need grease as a lubricating mechanism in bearings because the properties of grease help to keep the lubrication in and around the warzone while sealing out contaminants.
Vibration is inherent in every machine system. Excessive vibration however, negatively impacts the ability of grease to lubricate. Some machine systems are intentionally vibrated as part of their function and process. Other equipment vibrated excessively because of a defect such as imbalance, misalignment, poor installation, or poor workmanship. For these machines, it might be best practices to over-grease their bearings.
I know that sounds counter to what we teach and know, but consider this. It is better to have thickener and oil in the warzone of the bearing, than it is to set up a bleeding mechanism and have the reservoir destroyed because of high vibration. If we let this happen we may never get any oil where it’s needed.
High vibration? Slightly over grease your bearing and allow a little thickener to exist in the warzone. It is the best compromise.
Download our 5-Step Acoustic Lubrication Procedure.
by Yolanda Lopez
1. A Change in the Quantity of Grease Consumed
Maintenance departments track their grease consumption to monitor and control costs. A change in consumption is a sure sign that your lubrication program is on the right track.
Most organizations are guilty of over-lubricating. Expect lower grease consumption as your program matures. Bad procedures lead to bearings routinely receiving more grease than they’re designed to handle. The excess ends up being pushed into the motor casing or purged onto the floor.
Over lubrication happens when re-greasing intervals are scheduled based on time instead of condition. Control lubrication tasks with ultrasound to monitor condition and maintain optimal friction. The time between greasing intervals increases, resulting in less grease used per bearing.
2. Fewer Lube-Related Failures
Do you track failures and perform root cause analysis?
Organizations with optimized greasing programs experience fewer lube-related failures. Less fixing and fire-fighting translates to more creative time for maintenance. Use that time to bring more machines into the greasing program.
Additionally, with ultrasound you find many non-trendable defects. For example, broken or blocked grease pipes and incorrectly fitted grease paths prevent grease from reaching the bearing.
3. Optimized MRO Spares Management
Your new and improved lubrication program is delivering wins; better control of grease consumption, fewer failures, and more productivity for maintenance. Use this time to study trends and better manage your storeroom.
A decrease in bearing related failures improves spares optimization. Share your ultrasonic lubrication data with your MRO Stores manager to create a plan to reduce the number of emergency parts on hand.
Since you’re taking stock, why not shift some burden to your suppliers? Ask them to confirm your emergency parts against their own stock. If it can be supplied on the same day then it doesn’t need to be on the balance sheet.
4. Increased Number of Machines Monitored
One benefit of an effective lubrication program is time.
• Time allotted to monitoring machines instead of fixing them.
• Time allotted to correctly assessing the real needs for lubrication.
• Time to look at the big picture.
Take for instance, criticality assessment. Many lubrication programs begin with small steps. All the “A” critical machines receive priority, rightly so. But what about the rest? With more time to plan, organize, and schedule, the number of machines acoustically monitored for optimal lubrication increases.
5. Save Time. Combine Acoustic Lubrication and Condition Monitoring
You worked hard for these results. It’s time to use your data for more than just lubrication.
Acoustic lubrication is the proven method to ensure precise bearing lubrication. New technology from SDT, LUBExpert, combines the power of on-board lubrication guidance with Four Condition Indicators for bearing condition assessment.
The time savings from assessing bearing condition during the lubrication process is beyond valuable and another sign your acoustic lubrication program is on the right track.
6. Inspector Confidence at an All-Time High
Reliable machines are the product of an effective lubrication program. You have:
• Managed grease consumption
• Fewer grease related bearing failures
• Optimized MRO spares
• More machines under watch
• Increased data collection intervals
The power of adding ultrasound to your greasing program delivers win after win for reliability. Reliability breeds confidence. More confident inspectors making the right calls and infecting a positive culture throughout the organization.
by Allan Rienstra - SDT Ultrasound Solutions
Rotating equipment produces a sound (ultrasonic) signature during operation. This signature can be measured and trended over time. As the machine components begin to fail a change in the ultrasonic signature will occur. The change in sound level can be used to alarm that could be related to lubrication or bearing damage. A key factor to using an ultrasound tool successfully to determine machine health is collecting the measurements at the same location every time. The first step is to identify a measurement test point for each bearing to be monitored. One method for data collection is to use a magnet that should be attached to a metal pad epoxied to the measurement location. The use of a magnet and mounting pad will allow for repeatable and consistent data for accurate trending and alarming. If access to measurement locations is restricted, then a sensor can be permanently installed so that measurements can be taken remotely. Ultrasound is an extremely valuable tool which can be used to detect bearing problems with slow speed applications.
Ultrasound is an important part of any reliability based condition monitoring program and can provide early warning of mechanical failure. This early warning can lead to reduced downtime and increased plant reliability.
by Dave Leach CRL CMRT CMRP
Friction is all around us. Without it we would have difficulty to walk, run, or even stand. We need friction to drive our cars and fly our airplanes; and we need friction for our motors to drive pumps and our pumps to push product. So when it comes to our plant assets, friction is both friend and foe.
Lubrication of rolling element bearings is one of the most misunderstood tasks in industry. Can it be true that 40% of bearings never live to their engineered life cycle and bad lubrication practices are a leading cause?
To achieve optimal lubrication we must know:
- When a bearing needs new grease
- What quantity of new grease is required
- And how much is TOO MUCH!
Acoustic Lubrication with ultrasound testing is the technology of choice for Lube-Techs who want to avoid these three common mistakes:
Three Mistakes to Avoid When Lubricating Bearings:
- Lubricating based on TIME instead of CONDITION
- Over or under lubricating the bearing
- Using low quality “Listen-only” ultrasound instruments
To Hear More about implementing a world-class ultrasound greasing program, download Ultrasound Lube Technician Handbook.
by Allan Rienstra - SDT Ultrasound Solutions