Reliability's Dirty Little Secret

This was one of those defining moments. It was some surprising insight on where maintenance and reliability professionals are in the journey to lubrication excellence.

I received a phone call from a stranger who introduced himself as a maintenance manager of a large steel mill. He told me he was preparing to teach a group of lube techs about how and when to perform an oil change on mill machinery. However, he first wanted my advice.

I agreed, expecting one of the usual questions, such as whether they should switch to a synthetic or if a flush was needed. Instead, I was startled by a question I’d never heard before … and never expected to hear.

He asked:

“What should the oil feel like between your fingers when it’s too dirty and in need of a change?”

He said he wanted his lube techs to change the oil based on feel. At first I thought it was a prank call; you know, from a friend looking for a good laugh.

I listened intently but stayed quiet, studying the caller’s voice. He kept talking. Soon, however, I realized this guy was for real.

My reply to him was measured and regrettably a little rude.

I told him that perhaps before he taught anything to anybody about lubrication, he should get into a class himself. I explained to him the microscopic size of clearance-sized particles and how they compare in dimension to the ridges in your fingerprint. I mentioned that by the time you can see or feel dirt in the oil, much damage to your machine has already been done.

Then I offered him a generous discount to attend one of Noria’s seminars. The call ended and I haven’t heard from him since. For the next couple of days, I kept thinking about the larger message behind his question. What had I learned from talking to him?

Was it possible that there was such general misconception in the maintenance community about the No. 1 cause of machine wear (invisible small particles)? Did his question reflect an unspoken general belief about particles in oil being harmless if they can’t be seen or felt?

As I said, this was no small revelation for me. It reminded me of the philosophical question: if a tree falls in the woods, does it make a sound if nobody is there to hear it? If you cannot see or feel particles, are they there? Do they impart harm?

Despite the fact that most people who work around machinery have never seen the likeness of a virus or bacteria, many share the belief that similarly small particles in oils and greases are generally benign - out of sight and out of mind.

Today’s reality check is that small particles indeed pack a wallop in terms of machine reliability and life expectancy.

The widely held belief that small particles in lubricants are not harmful sadly remains reliability’s dirty little secret.

Clean Oil Starts with Storage and Handling

Effective storage and handling protocols for lubricants are essential for minimizing contamination and maintaining lubricant quality and performance. The storage area should be clean and free from dirt, dust, and other contaminants. Bulk storage systems for industrial lubricants are commonly used in industries where large quantities of lubricants are required, such as manufacturing plants, refineries, or transportation companies.

OilSafe Bulk System

A proper tank or vessel is necessary to avoid contamination and to prolong the life of the lubricant in storage. These tanks are available in various sizes and materials, such as steel, stainless steel, or high-density polyethylene (HDPE), based on the specific requirements of the lubricants being stored. The tanks should be compatible with the lubricant to prevent chemical reactions or contamination. Good practice involves using modifications including breathers, sight gauges, filtration and conditioning equipment, and overfill protection devices.

The care and treatment of new lubricants must be carefully considered for two reasons. The first is that new lubricants are typically not clean, which is why we emphasize the use of filtration equipment. The second is that the lubricant will undoubtedly become contaminated in the machine, and the cleaner we can keep the lubricant before it enters the machine, the longer the lifecycle. Though a lube storage room with all the bells and whistles may require a heavy investment in time and resources, it is undoubtedly a worthwhile investment when you consider the resulting benefits and cost savings achieved when you ensure clean, cool, and dry lubricants.