Automatic Lubrication Systems & Their Maintenance V1

Automatic Lubrication Systems

& their Maintenance

By: Rodney Fitzpatrick

Introduction

Lubrication Engineers

Providing Lubrication maintenance solutions to Australian industries for 34 years

Represents leading brands in lubrication including:• Lubrication Engineers Inc• Fluid Defense• Bijur Delimon / Farval / IHI / Lubesite• LSC - Oil Mist Systems• Viper Wire Rope Lubricators

Automatic Lubrication Systems – Why use them?

Bearing lubrication requirements• Small amount • Frequently applied

• Machine operating conditions – 24/7• Cooling• Flushing contaminants• Reclaimer example

– Labyrinths‘ only lubricated


• Safety issues• Difficult to reach areas• Temperature - heat / cold• Lubrication points behind machine shrouds / guards


Bearings suspended over mixer 5m in the air

Automatic Lubrication Systems Types & Operation

Lubrication System Basic Outline• Controllers - Timer / PLC / Manual Operation• Pumps – Grease / Oil / Air / Electric / Manual • Metering Valves – Injector / Distributor / Divider / Piston• Accessories

– Fittings– Pipework– Spray valves– Brushes– Low / high level monitoring– Filters

– Pressure switches– Changeover valves

Automatic Lubrication System Types & Operation

Lubrication System Basic Outline• Controller / Timer / Manual Operation

• Controllers can range from basic to complexBasic - Controlling dwell time between operationsComplex - PLC control monitoring

– Dwell time (time between cycles)– Cycle time (time of operation)– Cycle count (how many cycles)– Lubricant high and low level– Blockage indicators (micro switches)

– Pressure measurement (high/low)– Flow monitoring– Temperature monitoring


Lubrication System Basic Outline• Pumps – Grease / Oil / Air / Electric / Manual

– Pumps can range from manual to electric or air operated – Delivery pressure can range from a few hundred psi to 3,500 psi– Volumes can range from 0.001cc per stroke to 4kg per minute


Lubrication System Basic Outline• Metering Valves – Injector / Distributor / Divider / Pistons

– Valves range from flow resistors to positive dividers to injectors– Delivery of oil or grease in continuous flow or minute quantities– Some valves can be monitored to measure lubricant flow– Some valves provide the ability to adjust lubricant quantity


Single Point Lubricators• Spring actuated SPL’s – Low pressure / refillable / adjustable• Gas powered units – 20 - 50psi / corrosion resistant /

temperature dependent• Battery actuated mechanical units – 850psi / adjustable

time / refillable


Single Line – Resistance System


Single Line – Resistance System• Comprises a manual or automatic pump• Delivers lubricant to resistance metering valves • Operates at low pressures around 200psi• Oil systems only

OperationThe pump is activated forcing a set volume of lubricant into the supply lines, the oil then takes the path of least resistance

and is dispensed through the metering valves. Metering valves with large orifices deliver larger volumes than smaller valves. Therefore

systems are designed with the metering valves matched to the lubricant requirement of each bearing. This is a total loss oil

system used on many small machine tools, presses etc. No system blockage or pressure indication is usually used although some systems may have a low level indicator on the reservoir.


Single Line - Positive Displacement Injector Systems


Single Line - Positive Displacement Injector Systems• Comprises a Grease or Oil pump with main line and injectors attached• Medium pressure typically up to 2500 psi• Injectors provide precise measured doses of lubricant• Injector lubricant quantities are often adjustable• Ideal for systems with lubrication points spread over large area

OperationThe pump is activated at a predetermined interval and builds pressure in the main line once the pressure overcomes the internal spring pressure of the injector it actuates. Grease is then pushed from the injector to the bearing. When the pump is stopped pressure from the main line is vented and the injector internal spring resets the piston and draws in the next shot of lubricant. Adjustment of the piston stroke will adjust the lubricant volume delivered.


Single Line Progressive Systems


Single Line Progressive Systems• Comprises a Grease or Oil pump with progressive distributors• Medium to High pressure typically up to 4,500 psi• Progressive distributors provide fixed doses of lubricant, slave /master• Typical used in systems of less than 100 points• Can be monitored via micro switch for blocked lines

OperationThe pump is activated at a predetermined interval and begins delivering lubricant to the progressive distributors. The lubricant is progressively divided through the use of drillings and pistons shuttling backwards and forwards. The lubricant delivery is absolutely positive as the system does not rely on valves, springs or seals. The systems typically have an indicator pin fitted to one of the pistons and micro switches can be fitted to this allowing for system monitoring.


Multi Line Systems


Multi Line Systems• Comprises a Grease or Oil pump with multiple outlets• Delivering lubricant to progressive or positive displacement injectors• Medium to high pressure typically up to 4,500 psi• Each outlet may be adjustable in outlet volume• Injectors provide precise measured doses of lubricant• Injector lubricant quantities are often adjustable• Ideal for systems with lubrication points in different locations

OperationThe pump is activated at a predetermined interval and

lubricant is delivered through each delivery piston to a separate delivery line. The grease is delivered to either progressive or positive displacement distributors, then pushed from the injector to the bearing. Adjusting the piston stroke of the delivery piston on the pump will adjust the lubricant volume delivered.


Dual Line Systems


Dual Line Systems• Comprises a Grease pump, changeover valve & two main delivery lines• Delivers lubricant to positive displacement injectors• Medium pressure up typically up to 2,500 psi• Injectors provide precise measured doses of lubricant• Injector lubricant quantities are often adjustable• Ideal for large lubrication systems with points from a few to hundreds• Can be used over very large distances


lubricant is delivered through the first main lines building up to pressure. Pressure in the line activates the injector delivering lubricant to the bearing. When the preset pressure is achieved either a hydraulic or electric changeover valve vents the first line to tank and begins pressurizing the second line. Once the second line achieves pressure the changeover valve vents grease to tank and the system resets.


Spray Systems


Spray Systems• Comprises a Grease or Oil pump• Can be any of the previous types of systems but with spray valves• Spray valves have air and lubricant applied • Medium pressure typically up to 2,500 psi• Injectors provide precise measured doses of lubricant• Injector lubricant quantities are often adjustable


lubricant is delivered to the spray valve from the distribution valve. Just prior to the lubricant being delivered to the spray valve air is applied to enable pre-cleaning of the nozzles. Air is continued to be applied after the lubrication cycle to flush lubricant through the nozzle.

Lubrication Systems – Inspection & Maintenance• Lubrication Systems involve electrical, mechanical, pressure,

hydraulic and chemical interactions.• Like all pieces of equipment they require regular maintenance• Critical factors influencing Lubrication Systems

– System design• Type of System / Pump / Pipe diameters / Duty Cycle / Material

selection– Lubricant type

• Mechanical Stability / Lubricant Base / Base oil viscosity– Lubricant Cleanliness– System Location

With correct design and regular maintenance systems can operate for many years

System Design

• A large proportion of lubrication system issues can be traced back to incorrect system design– Pump specification – volume / pressure / duty cycle– System type – Single line versus dual line– Material specification– Piping specifications– Lubricant specification

Fault Finding – Lubrication Systems

Visual Inspection is the number one tool for fault finding:– Broken, damaged or leaking lines

• PM job raised (KPC example)

– Dry bearings • System check (PM raised)

– Over greased bearings• System check (PM raised)

Lubricant Selection• Grease is made up of oil and thickener plus various

additives– Thickeners include soaps and clays

• NLGI grade selection– Typically an NLGI#2 is used – The higher the NLGI grade the more thickener used

• Lubrication systems whilst often designed to pump an NLGI#2 product do not necessarily work effectively

• Grease under pressure often separates leaving the base• Solid additives such as moly drop out on bends• Heavy viscosity oils create too much fluid friction

Fault Finding – Lubrication Systems Visual Inspection is the number one tool for fault

finding:– Grease levels in reservoirs

• How often does it require top up? / Interval of drum change-out documented

– Open reservoirs which allow ingress of contaminants• Immediate PM job raised / Design project to re-engineer

– System operating pressure • Have accessible operating gauges with system pressure listed

Fault Finding – Lubrication Systems

Visual Inspection is the number one tool for fault finding:– Distribution block inspection

• Dust caps• Pin operation• Mounted upside down• Monthly piston operation checks• Quantity output measurement

Visual Inspection

Corroded injectors with indicator pin stuck

Visual Inspection

Adequate grease visible

Visual Inspection

No grease visible

Manual Greasing

Grease nipple inside of safety guard no chance of greasing occurring

Automatic Lubrication Systems & Their Maintenance V1

Documents

Transcript of Automatic Lubrication Systems & Their Maintenance V1