What Everyone Should Know About Automatic Grease Lubricators
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1 What Everyone Should Know About Automatic Grease Lubricators [Type the company address] White Paper Sponsored by: [Type the phone number] [Pick the date] PLI, LLC 1509 Rapids Dr Racine, WI Phone: Phone: Fax:
2 What everyone should know about Automatic Grease Lubricators: There are a number of important reasons why everyone should consider using automatic lubricators in their plant: 1.) Improve the quality of lubrication 2.) Improve the level of control over the lubrication process and 3.) Reduce the man-hours required, and thus cost, for grease application. Like most other lubrication methods, the successful use of single-point automatic grease applicators requires some knowledge of lubrication fundamentals; many common mistakes can thus be avoided. In order to get positive results from such devices, you must select the device best suited for your applications, install the device correctly, use the proper lubricants and set the device to dispense the lubricant at the rate appropriate for the application involved. Types of Automatic Lubricators Today, basically two types of self-contained automatic lubricator are available on the market. One of these is the single use, throw-way, gas generator type lubricator and is a technology that is over 40 years old. The second type is the newer technology electro-mechanical reusable machine that uses replaceable lubricant cartridges and a computer chip to control its operation. Once you have purchased the machine you need to only buy the low cost replaceable lubricant cartridges and battery pack. A variety of power source options are generally available, including models that permit the lubrication process to be turned on when the machine is operating and off when it is not or controlled by a PLC, either free standing or associated with the machine being lubricated. Using a PLC controller you may control the lubrication process based upon hours of operation, a count of machine cycles or any other desired criteria. The distinctions between these two technologies, electro-mechanical and electro-chemical devices is a subject covered in other articles. The subject of our concern in this White Paper is the newer technology, electro-mechanical devices. While there are some application considerations that may favor the older technology in some situations, the newer electro-mechanical type devices are those that, for reasons of operational flexibility, improved control, reliability and cost advantage, will dominate the market in the future. Therefore, the subject of interest in this article is the comparison of manual lubrication to electro-mechanical lubrication Comparing Methods There are certainly many advantages in automating an application when comparing to the alternative manual practices. Most obvious of these is that it is preferable to apply small amounts of grease at short intervals rather than large amounts of grease at extended intervals. When using manual lubrication methods there is a natural tendency to over lubricate a bearing with the supposed good intention of reducing the frequency of manual lubrication cycles required. With
3 manual applications, the trick is to apply as much grease as possible without causing harm to a bearing due to over-lubrication. Over lubrication can damage a bearing by creating excessive internal heat due to excessive friction. Also, with the tremendous force of ejection possible with a hand grease gun (over 10,000 psi in some cases) it is possible to rupture bearing seals, particularly when over lubricating. Ruptured seals open a bearing to the likelihood of contamination and thus a shortened life for the bearing. There are many applications that can benefit from more frequent lubrication or could be harmed by larger lubricant volumes. Of course, you could choose to simply lubricate all components frequently, but the associated labor cost would likely make the option of automatic lubricators even more attractive. As an aid to determining which lubricated components would be good candidates for automatic applicators; you should consider the factors that cause a need for frequent re-lubrication, or the need for a more controlled volume of lubricant injected on a given lubrication cycle such as, heavy loads, excessive temperature, high speeds, contamination or water wash out. Figure 1 Lubricant output volume is sensitive to variations in ambient temperatures and tends to be irregular and not well controlled as to volume being injected.
4 Maintaining consistency in the frequency of application and volume applied is difficult to achieve in manual lubrication. Figure 1. In a Simple Comparison between Manual and Automated Lubrication, temperature is a perfect example. In high-temperature applications, some bearings may need to be lubricated every day or even every few hours. While this is an extreme example, it's easy to see that it would require a great deal of technicians time to perform manual re-lubrication on hundreds of bearings every day, thus making automatic application the preferred method. Some high-speed applications not only require frequent application, but they also may be damaged by the addition of large volumes of grease, causing overheating or skidding of bearing elements. In many cases, the largest contributing factor to grease re-application is contamination. Any application can require very frequent re-lubrication when contamination is severe, regardless of other factors. These are just some of the primary factors in the consideration of automatic lubricators; there certainly are others, such as bearing inaccessibility, highly dangerous bearing locations or
5 bearings located on operating equipment and limited manpower for lubrication activities. Advantages of Single-Point over Central Systems For situations with many lubrication points centralized automatic systems are often ideal. But for many others, including situations with just a few lube points or with long distances separating the lube points, single-point lubricators offer many of the same benefits as a central system but at a small fraction of the cost. Consider a long coal conveyor in a power plant with bearings that require frequent lubrication due to contamination ingression. In such an application, a centralized system would require extensive plumbing to lubricate only a few points, making single-point applicators a great fit. Grease-lubricated pump bearings, fan bearings and grease-lubricated packing seals are all good examples where such devices would likely provide significant value as such equipment is generally spread over a wide area of the plant, requiring a great deal of costly time just to reach all of the lube points involved. Typical Issues with Single-Point There are several issues to keep in mind when using single-point lubricators that may lead to an improper application. These issues include: 1.) Insufficient pressure of the device being considered to deliver the grease. 2.) Using improper dispensing rate settings. 3.) Failure in the discipline of changing the cartridges at appropriate intervals and 4.) A failure to properly inspect the devices for proper operation as a part of the regular maintenance activity. The issue of insufficient pressure isn't a problem with the applicator, but rather a problem with selection. Depending on the delivery method, some of these devices only generate approximately 50 to 75 psi, while others have output pressures exceeding 300 psi. It is important to ensure that the output pressure of the device will be sufficient for a given application and installation method. Where a question of adequate pressure exists, this can be determined by first manually applying grease to the component using a grease gun fitted with a pressure gauge. This issue should also be considered when first installing the units. Steps can be taken to minimize the amount of back pressure on the device by, a.) using as few fittings as possible, b.) keeping the length of any tubing or piping to specified maximums and c.) using as large an inside diameter as possible when selecting flexible tubing or pipe required for the installation. Whatever the requirements are, you should be able to select a device that provides ample pressure for your application. While there are factors that can affect dispensation rates, such as temperature and grease consistency, a most common problem is simply selecting the wrong lubricant ejection rate setting. Before installing the unit, determine the appropriate application rate by using valid lubrication engineering methods or using the equipment manufacturer s lubrication specification.
6 Satisfactory historic manual practice may also be your guide. That is, relating the grease volume that had been used in manual lubrication to the programming of the automatic lubricator. Many problems can arise from over-or under-lubricating a component, including overheating, excessive wear or simply wasting grease and making an unnecessary mess that must be cleaned up. Of course, as mentioned, a big pitfall is a failure to routinely inspect single-point lubricators for proper function. Installing an automatic lubricator doesn't ensure that you will have a properly lubricated component. They must be inspected just like any other piece of machinery. In fact, a proper inspection process should identify and allow for correction of the previously mentioned issues. Determine the frequency of inspection based on the unit's application rate and the component's sensitivity to over- or under-lubrication. One idea for such inspections is to record the installation date on the unit and make marks at each inspection noting the date and reservoir level. Based on the desired application rate and reservoir size, you should be able to determine if the unit is operating normally. Inspect the lubricated component as well, checking for an indication that the grease application rate is optimum. You may want to include condition monitoring such as acoustic energy measurements or high-frequency vibration to monitor the condition of lubrication. Education, Before Selection Most industrial facilities have at least some applications that will benefit from automatic grease application; and for many of those, single-point lubricators may be the best option. Those considering the addition of single-point lubricators to their lubrication program should educate themselves on the different types of systems available, the pros and cons of each, including operating costs. Things not to be overlooked are how you may employ the increased capability available in these mechanical devices to save even more time and money, such as mounting the lubricator remote from the bearing to make it more accessible to service, or using a single lubricator to lubricate more than one bearing. The increased output pressure offered by these units makes it possible to use them as low cost, miniature, central lube systems lubricating from two to twelve lube points with a single lubricator. Increased control is another important feature. The mechanical lubricator operation can be directly tied into the operation of the machine being lubricated either through the several power source options available or by using a PLC to control their operation. Last but not least Cost and Savings The financial impact of using self-contained automatic lubricators is an important part of any decision to proceed with the conversion of your method of lubrication from a manual system to automatic lubricators. To facilitate your analysis we have prepared a financial model that can be quickly run on your computer using MS Excel. This no cost financial model can be accessed at Memolub.com/Sound Money Decisions. By entering a few variables that best describe your situation in terms of the cost of labor and volume of lubricant used in your plant or department, the comparative cost of manual versus
7 automatic lubrication is calculated. Rerunning the financial model using cost factors representing different automatic lubricator products will assist in making a factual comparison of the cost advantages of one product over another. If there are questions that arise as to data input requirements or if we can be of assistance in your use of the analysis model please telephone our office and we will be pleased to assist you White Paper Sponsored by: About PLI, LLC PLI, LLC is a company with over 40 years of experience in the self-contained automatic lubrication business. As one of the early manufacturer / distributors to introduce these products to the United States market, we have been working in manufacturing plants of all types and know intimately the equipment and problems our customers encounter. PLI, LLC has been helping manufacturers and municipalities reduce maintenance costs and increase machine life for years with reliable lubrication systems and outstanding customer service. Contact: David D. Crouther, PLI, LLC 1509 Rapids Drive, Racine, WI Phone: / Fax:
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