LUBRICANT CONTAMINATION THE PRIME CAUSE OF MECHANICAL MACHINERY FAILURE

It is a fact that some 80% of machinery failures are related to lubrication.

- By Charles Palmer

Of these, more than one-third result from the contaminated lubricant. These facts highlight the need to ensure all lubrication systems remain pure and contaminant-free.

This article clarifies misconceptions surrounding the subject, names the prime causes, and recommends suitable prevention methods. It further highlights modern laboratory analysis methodologies, which point directly to the contaminants found, and highlights the need for accurate sampling techniques. Finally, case studies of mechanical failures due to contaminated lubrication systems are presented, along with the paths taken to prevent these.

Misconceptions Regarding Lubricants

It is overlooked that most liquid lubricants arriving at an enterprise receiving bay are already contaminated. This is not due to the lubricant manufacturer but primarily because the drum or canister does not meet ISO codes of internal cleanliness. In some cases, the cleanliness level and particulate matter's presence exceed this standard five to ten times. A straight forward method of ensuring this lubricant does not cause problems is to provide a filter cart with appropriately selected beta-rated filters depending on the most stringent and critical application.

The second misconception is that lubricating grease is also pure, but once again, this is a fallacy. There are some methods of purification, the simplest being filtration.

The Causes of Lubrication Contamination

Industrial lubrication systems can encounter various contaminants that degrade their performance and reliability. Some common contaminants include:

Ingressed Contaminants:

• Dust, dirt, and airborne particulate from external sources

• Moisture and subsequent rust, corrosion, soot, microorganisms, and other contaminations result from water contamination

• Process contaminants