Insufficient attention to every day industrial lubrication tasks can compromise safety and lead to costly breakdowns. I have witnessed, firsthand, the consequences of inadequate attention to lubrication in industrial settings, which include injuries, premature equipment wear, costly breakdowns, and lost productivity.
The efficient and safe operation of industrial machinery is only made possible with proper lubrication. Regular lubrication, especially when part of a comprehensive lubrication program, helps proactively prevent breakdowns and premature wear and tear.
Selecting the right lubricants is a major stage in a good lubrication program. Different machinery will require specific types of lubricants based on operating conditions, load, and temperature. And with so many different types of lubricants used in a wide range of industrial applications, the choices can sometimes be daunting. Furthermore, we can also recognize the importance of an optimized, consolidated list of lubricants to use throughout a plant to a selection of lubricants that helps avoid cross-contamination and among other benefits.
Choosing the right lubricants for the operations in your plant is typically guided by manufacturer recommendations and tested lubricant performance. Historically, many lubricants met a certain standard of industry use, and similar to most industries, these standards have changed over time.
For example, many lubricants on the market today are biodegradable and made from renewable resources. They're popular for industries that prioritize sustainability and reducing environmental impact.
While lubrication in a factory or plant requires more than just choosing the right lubricant, the connection between proper lubrication and machine reliability and plant safety cannot be overstated. Here are a few reasons why industrial lubrication is crucial for a truly safe and efficient working environment.
The Fundamental Role of Industrial Lubrication in Workplace Safety
Industrial lubrication refers to the process of applying a lubricant to reduce friction between moving parts in machinery. The primary purpose is to minimize wear and tear, enhance performance, and promote longevity. Friction and heat are two major factors that cause accidents in the workplace.
When moving parts rub against each other without proper lubrication, the friction can cause excessive heat buildup which can result in machinery suddenly seizing, breaking apart, exploding, or catching fire. Correctly applying lubricants reduces friction and heat generation, preventing accidents and ensuring the machinery can be operated safely.
Another safety consideration is workplace noise, which at high levels has been shown to damage hearing, increase the risk of cardiovascular health risks, and adversely affect concentration — potentially leading to user errors and an increased risk of accidents. Using proper lubrication can significantly reduce noise generated by machinery, contributing to a quieter and safer work environment. Continuous monitoring of noise reduction ratings and lubricant conditions plays a crucial role in ensuring that the levels of noise exposure remain within safe limits.
Implementing Safe and Effective Lubrication Maintenance Schedules
While proper lubrication of equipment ensures the components function properly with minimal friction to reduce the risk of breakdowns or accidents, prevent premature failure, and avoid costly repairs, the implementation of an effective lubrication schedule is crucial for the long-term safety and efficient operation of machinery.
Implementing proper maintenance schedules also reduces costs by extending the lifespan of equipment, which improves efficiency and performance. Key components of an effective lubrication maintenance plan include choosing the right lubricant and equipment, determining specific lubrication requirements, considering operating conditions, following manufacturer recommendations, and regular equipment inspection and training to avoid mistakes such as under- or over-lubrication or using the incorrect lubricants.
- When choosing a lubricant, it is good to first consult the manufacturer's guidelines for the specification of lubricants to be used and the recommended lubrication intervals. Furthermore, calculations for the lubricant and lubrication intervals may need to be performed to best fir your unique operating and environmental circumstances.
- Consider the equipment usage; continuous or high-load usage may require shorter lubrication intervals.
- Monitor environmental factors such as temperature, humidity, and dust levels. These can all affect the appropriate lubrication schedule, so adjust accordingly. For example, check out the regrease interval and volume calculator to observe how these factors can influence the relubrication needs.
- Regularly inspect sight glasses for proper oil level and oil conditions, as well as overall equipment conditions for any signs of wear or leaks.
- Carry out a lubricant analysis at regular intervals for early detection of potential problems before they lead to expensive wear or equipment failure.
- Train employees in correct lubrication techniques and follow best practice procedures.
- Keep detailed records of all lubrication maintenance carried out and any problems identified.
Health and Safety: The Impact of Lubrication on Machinery
Lubrication can have a significant impact on machinery health and worker safety. Proper lubrication will promote worker safety by reducing resistance, minimizing noise and vibrations, and preventing accidents. Inadequate lubrication can lead to worker safety hazards caused by machinery overheating, ultimately resulting in catastrophic failure and potentially serious or fatal injury to operators.
By implementing consistent, effective lubrication techniques, including selecting the appropriate lubricants, regular lubrication inspections, and implementing the proper maintenance schedules, worker and overall plant safety can be easily promoted and applied in any given industrial settings.
Common Mistakes in Industrial Lubrication
Lubrication mistakes with industrial machinery can be costly and dangerous.
- Probably the most common mistakes are insufficient contamination control, degraded lubricant, wrong lubricant or mixing of lubricants, which can lead to total equipment failure. It's important to ensure contamination is taken seriously with headspace management and good filtration as well as ensure the correct lubricant is used based on the manufacturer's recommendations, the environmental conditions and the operating conditions.
- In expensive machinery with safety implications, simply using the correct oil is not enough. Regular monitoring of the lubricant condition is crucial, as this can identify issues with wear and heat buildup before they become too serious or dangerous.
- Another common mistake is the failure to establish or stick to a regular lubrication schedule, or Lube PM’s. Using the right Lubrication PM software is usually recommended.
Avoiding these common mistakes helps to ensure smooth operations and maximum efficiency with minimum costs.
Industrial Lubrication Regulatory Standards and Compliance
Complying with regulatory standards helps to create a safer working environment and protects against legal penalties. Having regulated industry standards means all businesses operate on a level playing field, particularly with environmental regulations such as the Clean Air Act and the Clean Water Act, which have provisions to reduce pollution caused by lubricants. Companies today need to regularly review their lubrication procedures to ensure compliance, which will help avoid penalties and lead to better plant safety and improved operational efficiency.
Upon considering the factors discussed here, along with the history and large-scale implications of industrial machinery, the commitment to proper and consistent machine lubrication and contamination control stands as a linchpin for workplace safety and operational efficiency. Proper lubrication not only mitigates friction-related accidents but also extends equipment lifespan and reduces maintenance costs.
Implementation of effective lubrication maintenance schedules, including adherence to manufacturer guidelines, regular inspections, and employee training, is vital to most industrial settings. By prioritizing compliance with regulatory standards and avoiding common lubrication mistakes, businesses can ensure a safer, more efficient working environment while minimizing environmental impact and legal liabilities.
