Lead Particles Predict Bearing Failure

History:

• R.J. Reynolds Tobacco Company had been performing lubricant condition monitoring on its equipment for 20 years.

• A few years ago, the Predictive Maintenance Group in the Utilities Division implemented a routine oil analysis program to not only monitor the condition of the lubricant, but also to monitor the condition of its machinery.

• This program was implemented to detect possible impending problems before a failure occurred. The goals were to increase reliability, minimize unexpected failures and decrease downtime.

Laboratory Lubricant Analysis:

• A routine oil sample was collected from a reciprocating air compressor and sent to
  a lab for analysis.

• Spectrometric analysis found an unusually high lead content.

• The Predictive Maintenance department was immediately notified of the findings and quickly shutdown the system for visual inspection.

Evaluation:

• The lead contamination found in the oil sample was a direct result of the old and damaged rod bearing breaking apart due to age.

Solution:

• Replace three bearings.

• The success of this catch reinforced their belief in regular routine oil analysis.

Impact:

• Downtime and costs associated with repair were minimal.

• This catch saved R.J. Reynolds Tobacco Company’s Utilities Division an estimated $50,000 to $75,000 on plant machinery had the corrective action not taken place when it did.

Submitted by Lana Robin, PdMA