×

 

Published by 
Noria Corporation

Contamination Control: The Key to Maximizing Equipment Reliability

Noria Media

Contamination Control: The Key to Maximizing Equipment Reliability

In the world of maintenance, reliability, and machinery lubrication, contamination control is not just a best practice — it's a necessity. As industrial equipment becomes more sophisticated and expectations for uptime increase, the role of contamination control in ensuring long-term reliability cannot be overstated.
 
Whether you manage a fleet of heavy machinery or oversee the lubrication systems in a manufacturing plant, understanding and implementing effective contamination control strategies can mean the difference between peak performance and costly downtime.
 

Understanding Contamination in Lubrication Systems

Contamination in lubrication systems can stem from various sources, including dirt, dust, water, and even airborne particles. Once these contaminants enter the system, they can lead to issues such as accelerated wear, corrosion, and reduced lubricant effectiveness. Over time, the presence of contaminants can degrade a machine's performance, leading to unplanned maintenance and, in the worst cases, catastrophic failure.
 
The most common types of contaminants include:
  • Particulate Contaminants: These are solid particles such as dirt, metal shavings, or dust that can enter the lubrication system through various pathways, including seals, breathers, and improper handling.
  • Water Contamination: Water can enter lubrication systems through condensation, leaks, or a byproduct of specific processes. Once inside, it can cause rust, reduce the lubricant's film strength, and lead to the formation of emulsions.
  • Chemical Contamination: This includes unwanted chemicals that can mix with the lubricant, altering its properties and reducing its effectiveness. Common sources include incompatible lubricants, cleaning agents, and process chemicals.
     

The Impact of Contamination on Machine Reliability

Contamination in lubrication systems is a leading cause of premature equipment failure. Studies have shown that over 80% of machinery failures are directly related to contaminated lubricants. This statistic underscores the importance of implementing robust contamination control practices.
 
When contaminants are present in a lubrication system, they interfere with the lubricant's ability to form a protective film between moving parts. This leads to increased friction, heat generation, and accelerated wear and tear. Over time, even minor contamination can cause significant damage, leading to increased maintenance costs, unscheduled downtime, and reduced equipment lifespan.
 
For instance, particulate contaminants can cause abrasive wear, leading to the scratching and pitting of metal surfaces. On the other hand, water contamination can lead to cavitation, corrosion, and the formation of sludge, all of which compromise the efficiency of the lubrication system.
 

Strategies for Effective Contamination Control

Implementing a proactive contamination control strategy is essential for maintaining machine reliability. Here are some critical steps that can help achieve this goal:
 
  1. Filtration: High-quality filtration systems are the first line of defense against contaminants. Filters should be selected based on the type of lubricant and the operating environment. Regularly replacing and maintaining filters is crucial to ensure they remain effective.
  2. Breathers and Seals: Contaminants often enter lubrication systems through breathers and seals. Using desiccant breathers can help prevent moisture and airborne particles from entering the system. Ensuring that seals are in good condition and properly installed can also minimize the risk of contamination.
  3. Regular Oil Analysis: Conducting regular oil analysis is vital for detecting contamination early. By monitoring the condition of the lubricant, you can identify potential contamination issues before they lead to significant problems. This allows for timely corrective actions like oil changes or system flushes.
  4. Proper Handling and Storage: Contaminants can be introduced while handling and storing lubricants. It's important to use clean containers, avoid open environmental exposure, and ensure that lubricants are stored in a controlled environment. Educating personnel on proper handling techniques can further reduce the risk of contamination.
  5. Maintenance Best Practices: Implementing maintenance best practices, such as routine inspections, timely repairs, and proper equipment operation, can help minimize contamination risks. Regular maintenance checks should include inspecting seals, breathers, and filters for signs of wear or damage.


The Role of Training and Awareness

While equipment and technology play a significant role in contamination control, human factors are equally important. Ensuring that maintenance and reliability personnel are trained in contamination control best practices is essential for the success of any program. This includes understanding the sources of contamination, the impact on equipment reliability, and the steps needed to prevent it.
 
Promoting a culture of cleanliness and attention to detail can significantly reduce contamination risks. This includes enforcing cleanliness standards in areas where lubricants are handled, stored, or applied and emphasizing the importance of following established procedures.
 

Conclusion: The Payoff of Proactive Contamination Control

Investing in contamination control is an investment in your equipment's long-term reliability and performance. By implementing effective contamination control strategies, you can significantly reduce the risk of equipment failures, lower maintenance costs, and extend the life of your machinery. In an industry where uptime is critical and margins are tight, proactive contamination control is not just an option — it's a necessity.
 
Contamination control is a continuous process that requires vigilance, the right tools, and a commitment to best practices. By prioritizing contamination control, maintenance and reliability professionals can ensure that their equipment operates at peak performance, day in and day out.

Supplier Spotlight

Pulsarlube USA 1480 Howard St., Elk Grove Village, IL 60007 847-593-5300 | Pulsarlube.com

Pulsarlube provides the most innovative and reliable Automatic single-point lubricator on the market. Backed by years of research and development, Pulsarlube offers a wide range of superior products to meet the needs of our customers. Pulsarlube provides high-quality products and services worldwide through its well-established distribution network.

Esco Products 2501 Central Pkwy, Suite A-5, Houston, TX 77092 800-966-5514 | EscoPro.com

Esco provides solutions for maintenance and lubrication problems in any industry that uses reciprocating and rotating equipment with oil reservoirs. In addition to our revolutionary Visual Oil Inspection product line of sight glasses, Esco is one of Dow & Dupont’s largest distributors of Dowsil sealants and Molykote high-performance lubricants. As a DesCase partner, we offer their full line of breathers and fluid handling equipment. Contact us today to learn more!

Fluid Metrics 4514 Chamblee Dunwoody Rd. #252, Dunwoody, GA 30338 p: 770-393-8636, f: 770-393-8631 | FluidMetrics.com

Founded in 2003 by a compressor industry veteran, Fluid Metrics utilizes the latest lubrication technologies to maximize compressor performance and reliability. When combined with a proactive, condition-based maintenance plan, our advanced compressor oils, purifiers, and conditioners are proven to dramatically increase compressor reliability, slash your oil and parts consumption, and save you time and money. Give us a call today to learn how much easier and better compressor oil maintenance can be.

ITW Pro Brands 4647 Hugh Howell Road, Tucker, GA 30084 800-241-8334 | www.itwprobrands.com

ITW Pro Brands’ innovative product offering includes LPS, SCRUBS, DYKEM, Accu-Lube, Rustlick, and Spray Nine. These premium maintenance/repair/operations chemicals deliver improved performance, inventory simplification, waste reduction, and overall cost reduction. ITW Pro Brands’ extensive product portfolio can be used throughout your facility — from front office to production to warehouse.

Royal Purple One Royal Purple Lane, Porter, TX 77365 281-354-8600 | RoyalPurple.com/industrial/

Formulated for demanding industrial operation needs, Royal Purple® high-performance synthetic lubricants improve reliability, extend drain intervals, reduce lubricant consumption, lower operating temperatures, decrease downtime, and reduce maintenance and energy costs- transforming your Total Cost of Ownership into an investment in excellence.

Subscribe to Machinery Lubrication

About the Author
Since our inception in 1997, we've been on a mission to revolutionize machine reliability. Our focus? Harnessing the power of top-tier lubrication and oil analysis practices. For more than two decades...