The Dangers Of Dirty Lubricants

Lubrication contamination causes nearly 70% of all premature equipment failures. Because the cement industry operates in heavy-loaded and dusty environments, operators need to understand what contamination is, how it happens, and how to prevent irreversible machine damage.

When this understanding is achieved, no longer will the environment impact a machine’s performance, and as this competitive edge develops, reliability and productivity will thrive, resulting in a world-class facility.

What is contamination?

Contaminants are unwanted particles that invade assets and negatively impact their health and efficiency. Several types of contaminants exist, but solid particles are the most prevalent and destructive. Responsible for 82% of all wear-related failures, solid contaminants include dirt, dust, soot, and metal particles – substances not uncommon in heavy industries.

While it protects against contamination, lubrication can become overwhelmed and fail, allowing particles to flow freely and ravage machine surfaces if not properly maintained.

This can have disastrous effects, such as:

• Abrasions – Particles catch between two sliding surfaces and create gouges.
• Erosion – Quick-flowing particles scrape against and deteriorate machine surfaces.
• Fatigue – Particles catch in rolling elements, denting and weakening machine surfaces.

These particles also generate other contaminants; as they make contact, surface materials break off and travel throughout the system.

This replication process is why catching contamination quickly is crucial.

How does contamination happen?

There are two causes of lubrication contamination: external ingression and internal generation.

External ingression is the introduction of contaminants, such as process particles (dust, cement) and combustion debris (soot, ash), under normal operating conditions. This can occur due to:

• Poor seal design.
• Worn seal materials.
• Introduction of unclean lubricants.
• Maintenance repairs and routine inspections.
• Operational and environmental conditions.

With internal generation, machines produce their own contaminants. The lubricant will degrade and form a sludge if not properly maintained and replaced. This sludge contaminates the internal systems and fails to prevent friction.

Friction is the leading cause of:

• Corrosion
• Wear
• Abrasion
• Fatigue

All of which produce contaminants. The longer a failing lubricant is left in service, the more contaminants are created and the greater the likelihood of equipment damage and failure.

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Read the article online at: https://www.worldcement.com/special-reports/14062023/the-dangers-of-dirty-lubricants/