Introduction
Grease is considered one of the most important factors of industrial machinery as it plays a massive role in determining the lifespan and performance of the equipment. Proper lubrication of the machinery is vital to keep it running smoothly. However, many times, businesses make some common mistakes during the lubrication process that can result in equipment failure and costly downtime. One of the most common mistakes that causes premature machinery failure is using the wrong grease for the application. However, the machine shows warning signs before its complete breakdown which can help one to figure out what went wrong.
10 Warning Signs Shown by the Machinery
Below stated are 10 key signs which indicate the failure of lubrication process due to application of incorrect grease:
- Unusual Sound Coming from the Equipment: Squeaking or grounding sounds are signals of increased friction due to inadequate lubrication. If this issue is addressed early, it can prevent significant damages while knocking or humming over-lubrication or other lubrication-related issues. If a machine that used to run quietly suddenly starts making noise, then it is the earliest and clearest sign of improper lubrication.
- Increased Operating Temperature: If the machinery is hotter than its usual temperature, it means that the lubrication is insufficient. In such cases, it is important to check the lubricant levels and types. A smell of burning oil is also a clear sign of overheating and lubricant breakdown. Thus, heat is considered one of the biggest enemies of both grease and machinery. Over-lubrication is also a leading reason for premature bearing failure as too much grease or oil increases the friction and heat which leads to seal damage and bearing failure.
- Grease Leakage Around Seals: It is easy to spot over-lubrication when there is a grease leakage along with increased temperature during operation and unusual noises. Over-lubrication tends to break the seals and leads to leakage. Thus, it is important to check for excess lubricant around seal areas. If the grease is noticeably pooling or oozing out from around the bearings or seals, it can be a strong indication of either excessive application of grease or the grease being the wrong choice for the component.
- Excessive or Uneven Wear Patterns: Excessive wear or scoring is an indication of parts running without adequate lubrication which leads to metal-to-metal contact. Uneven wear can be a signal that the lubricant is not reaching all the necessary areas or the wrong type of grease is used. Thus, when the machine is dismantled for routine maintenance, it is important to check how components have worn out. Uneven wear is not random usually; it almost points back to a lubrication issue.
- Unusual Vibration During Operation: Under-lubrication is equally bad in comparison to over-lubrication as insufficient amount of grease or oil leads to metal-to-metal contact and result in wear and overheating. The signs of under-lubrication are high operating temperature, unusual vibration and premature wear. Thus, vibration analysis is considered one of the major and reliable diagnostic tools. The increase in vibration levels is also considered one of the primary measurable signs that indicate something is wrong with the lubrication regimen.
- Grease Break Down or Changes Color Quickly: Checking the color of grease is another useful indicator of the lubrication needs. If the grease that was supposed to last for months is turning dark, thinning out or hardening much sooner than expected, then it is the sign that grease’s base oil or thickener is not compatible with the operating temperature or load conditions of the machine.
- Dirty or Contaminated Grease: Contaminated grease can attract foreign particles that can damage the machinery due to which regular inspection and replacement are necessary. While the contamination can come from external sources, the wrong type of grease can also be one of the reasons for it to break down and become contaminated with its own degraded particles. This accelerates the wear from both inside and outside.
- Clogged Lubrication Paths and Lines: Using the wrong lubrication or mixing incompatible thickeners or base oils leads to uncertainty that the grease will be able to handle the speeds, loads and temperatures of normal operations. If the lubricating system is clogging repeatedly and requires more frequent flushing, then the grease’s consistency or thickener type may not be according to the requirements of the pumping systems.
- More Frequent Bearing or Component Failures: When the wrong grease is used continuously, the cumulative effect shortens the lifespans of the components across the board. Bearings, joints, and gears that should last for years may begin to fail within months. If one notice the pattern of repeated failures in the same type of component, then it is necessary to review the grease specification rather than assuming it as a mechanical issue.
- Lubrications that Do Not Match OEM Specifications: It is really important to check OEM’s specifications for grease type, quantity, lubrication intervals, etc. that are based on bearing size, speed, operating temperature, load and environmental conditions. If the grease being applied does not match those OEM specifications, then it is a clear sign of wrong lubrication. Also, if the manual advice of application is not specific enough, then it is advisable to refer to calculations of grease volumes from various leading bearing companies.
Take Away
This is the brief explanation about 10 signs that indicate the lubrication failure. We hope this information will be effective for you. Please let us know through your valuable feedback and the suggestion in the drop box.