Ensure machinery efficiency with our comprehensive guide on lubricant contamination control. Learn about key practices for preventing contamination, factors that deteriorate oil quality, and advanced solutions to achieve optimal lubricant cleanliness. Protect your equipment and boost ROI today!

Contamination control in lubrication is a critical aspect of maintaining the longevity and efficiency of machinery. Ensuring that lubricants are clean and free from contaminants from the moment they enter your facility can significantly reduce equipment downtime, maintenance costs, and extend the lifespan of your machinery. According to Machinery Lubrication, we will delve into the importance of quality checks at the doorstep, highlighting when contamination control must actually begin.

Understanding Contamination Control

Contamination control refers to the practices and procedures put in place to prevent foreign substances from entering lubricants, hydraulic fluids, and other critical machine fluids. These impurities may include water, dirt, metal shavings, and other debris that could impair the equipment's functionality.

Preventing these contaminants from interfering with the lubrication process is the main objective of contamination control, as this could result in excessive wear, corrosion, and equipment failure. Strict quality control must be put in place as soon as the lubricants are received in order to accomplish this. You can refer to our previous blog to discover tactics to control oil contamination.

Lubrication accounts for 1-3% of the total maintenance budget and is the reason for 70%–80% of machine failures in industries such as tribology and machine reliability. Lubrication has a 1:4 investment rate. It means that for every $1000 invested in it, $4000 can be saved, for a 300% return on investment. It has been essential to pay regular attention to these minor aspects in daily life in order to preserve machine reliability and avoid machine malfunctions.

Lubricant quality has a significant impact on the lifespan, productivity, and efficiency of machines. The idea that fresh oil is clean is common, nevertheless. When oil barrels are kept in warehouses or other covered areas, many elements such as sunshine, high temperatures, dust, dirt, moisture, and weather can all contaminate them. This contamination may start before to actual use. The contamination may start prior to operational usage. When receiving barrels, it is important to take into account the circumstances leading up to their arrival and the factors compromising the oil's quality. The durability and safety of equipment depend on appropriate maintenance and inspection procedures. To understand more about lubricant quality, check out our previous blog “Understanding Lubricant Lifecycle”.

Stage 1: Production of Lubricants

Additives and base oil are combined to create lubricants; thickeners are added to grease as well. In order to meet the needs of the intended usage, these ingredients are carefully combined in precise proportions. This mixing process includes a variety of approaches, such as using air to stir or large-scale mixing apparatus intended for careful blending in a regulated atmosphere.

Potential worries at this point:

• Sanitation and cleanliness of the blending container
• The quality of the air utilized for agitation, ensuring it is devoid of moisture
• Verification of whether the components involved in the blending process undergo filtration
• The absence of a breather mechanism on the blending container

Stage 2: Intermediate Storage of Lubricants

Since lubricants are manufactured in large quantities, they are first stored in large reservoirs before being distributed to the specified area. Based on volume requirements, new intermediate containers are built or old ones are repurposed.

Possible concerns during this stage:

• Presence of welding or grinding residue within new containers
• Insufficient cleansing of previously used containers
• Improperly installed breathers, leading to the infiltration of particles and moisture into the tanks
• Lack of options for filtration during the transfer of lubricants

Stage 3: Transportation of Lubricants

Lubricants are delivered in large quantities or batches to your location. Diesel fuel or steam are used to clean oil tankers during bulk transit. The final oil product may become contaminated due to the use of hoses, pipelines, and connecting parts in this process. In the same way, batch deliveries made in drums or totes run the risk of becoming contaminated.

Possible concerns during this stage:

• Lack of containers dedicated to specific types of oil and the materials used for these containers
• Risks of cross-contamination between different types of oils
• Insufficient handling practices lead to the introduction of contaminants when bungs, pipe connectors, and couplers are left open
• Inadequate flushing of used tanks or drums before subsequent use

Factors such as servo valves and gearboxes can compromise oil cleanliness, affecting the system negatively. Acceptable standards vary based on application, and even newly received oil may have ISO codes of 21/19/16 or above NAS 10, indicating compromised cleanliness levels.

How and When to Perform Quality Checks for Lubricant Contamination

Inspect the lubricant container condition: Inspect for damage or incorrect printing on the oil drum or container before you arrive at a site. Make a checklist to keep track of the label's state, date of manufacture and expiration, batch number, supplier quality certificate information, inspection time and date, and quality inspector signature. This strategy teaches teams the value of reliability-centered maintenance and helps with lubricant quality control. This well-researched strategy encourages proactive maintenance in addition to helping with lubricant quality control.

Ask for the test certificate: Customers have the option to obtain test certificates for lubricants supplied by the site or in lots. These certifications have to include comprehensive details regarding quality assurance, including oil analysis, test findings, and conducted analysis. This is essential to have on hand, particularly for critical or supercritical machinery.

Perform basic oil analysis: Examine samples at random from each batch to ascertain the viscosity, moisture content, and ISO cleanliness level. For precise analysis, the plant can choose a neutral lab or build up an on-site lab. Quick sample turnaround times, quality assurance, lubricant optimization, lubrication analysis expertise, report interpretation, test limits, cost savings, and time savings are all advantages of setting up internal labs. Selecting a neutral lab will enable it to deliver precise analysis details in the allotted period.

Adopt oil filtration practices: An oil analysis or test certificate is required to guarantee oil cleanliness. To get rid of moisture and solid particles, the lubrication room needs a mechanical filtration system installed. A complete cleansing process requires the use of a specialized machine for switching between various oil grades.

Standard lubricant storage: The purpose of lubricant storage is to protect them from impurities, moisture, and particles. It reduces outdoor storage and requires inside warehousing. The storage area should feature concrete walls, a roof, a non-slip floor, ventilation, sealed climate control, clearly marked workstation boundaries, educational displays, specialized equipment, safety gear, and efficient maintenance procedures to maintain a dust- and dirt-free atmosphere.

Educating your team: Despite its substantial impact on plant efficiency and performance, lubrication is frequently disregarded. Developing consciousness and attention to detail requires education. This can be done within the plant by doing things like evaluating case studies, showing trend charts, adding lubrication-related topics to Toolbox lectures, providing specialist training, and putting different plans into action. Plant dependability is largely dependent on proper training and meticulous attention to detail.

Conclusion

Contamination control must begin at the doorstep to protect your machinery and ensure efficient operations. By implementing strict quality checks and utilizing advanced storage and handling solutions, you can significantly reduce the risk of equipment failure and maintenance costs.

At Le Price International, we understand the critical importance of contamination control in lubrication. We offer a range of solutions designed to help you maintain the highest level of lubricant cleanliness and protect your valuable equipment.

Our Oil Safe Satellite Lube Room provides a dedicated, clean environment for storing and dispensing lubricants. This system ensures that lubricants are protected from contaminants and can be efficiently managed to maintain optimal cleanliness levels.

Our Lubrication Work Center Bulk Storage System is designed to store large quantities of lubricants in a clean and organized manner. This system includes advanced filtration and dispensing features to ensure that lubricants remain contaminant-free from storage to application.

We provide the solutions you need to maintain the highest standards of lubricant cleanliness. Contact us today to learn more about our products and how we can help you achieve your contamination control goals.

Remember, when it comes to lubrication and contamination control, starting at the doorstep can make all the difference.