Lubrication efficiency
September 1st 2008

Within harsh operating environments manual lubrication regimes are seldom efficient. Multi-task operational requirements mean that timeconsuming, labour-intensive greasing schedules run an ongoing risk of neglect by either under or overlubrication.

Ray Mellor of RJ Mellor explains

Under-lubrication causes premature wear and downtime. Over-lubrication can have similar effects and in any event is wasteful. The Corus Maintenance team at the ore plant in Scunthorpe were aware of the potential costs of downtime caused by bearing failure (over £1000 per hour in this instance). They needed a failsafe system of control, monitoring and application of grease to achieve greater operationally efficiency, and peace of mind.

With only one 'stop' week per year for annual maintenance and overhaul, a system that could also reduce machinery overhaul requirements would be a bonus.

Industrial lubrication specialist RJ Mellor came up with the answer: LubeRight. The tailor-made system replaces normal grease points with 'smart' nipples which incorporate a sealed transponder which 'talks' to a grease meter fitted to the grease gun dispenser. Information from each grease point can then be downloaded as part of a planned maintenance schedule.

With the LubeRight system software on a normal PC, lubrication engineers can then design the optimum lubrication programme.

Recommended or preferred lubrication cycles and volume of product required for each bearing are entered in the PC – each nipple being individually identified. After a lubrication cycle, real time data is downloaded from the grease gun meter – any missed bearings will be highlighted and as the actual quantity of grease dispensed is recorded, any over or under lubrication will also be pinpointed. This real time managed system means that corrective actions are almost immediate and consequently, much more effective.

Andy Toyne maintenance technician stated, "Our system selection has been totally vindicated by the fact that we have had 10 trouble free months since installing the LubeRight System. Internal inspection of the problematic high speed fan bearings has demonstrated the benefits that using just the right amount of lubricant can bring in terms of extending bearing life. In addition, we have reduced our grease usage by over 60%.

"With operational maintenance demands peaking before and after weekends, the benefits of the system have made us move the lubrication schedule to mid week ensuring optimum recorded lubrication and risks from bearing failure caused by lubrication deficiency are minimised.

"Costs are now much more controlled, through maximising bearing efficiency and life. We are now reconsidering our replacement strategy for the 'stop' week based on our experience to date." Corus is now extending the LubeRight system throughout the Coal plant with a further 80 points. Andy feels they are now in control of plant lubrication such that any component failures are mechanical rather than lubricant related and LubeRight provides the data to prove it.

LubeRight is designed for use in harsh industrial environments. Each nipple transponder is sealed against attack from contaminants, and the rechargeable grease meter is illuminated in low light conditions.

Alan Heald of the Corus Planned Maintenance Team is moving from a twohanded lever action type grease gun to a cordless re-chargeable single finger operated grease gun with carrying harness. This enhancement ensures safer, easier access and controlled dispensing of grease to even the most inaccessible locations: replacing out of sight, out of mind with peace of mind.

With lubricant usage now under control, the maintenance team is now able to evaluate long life high performance complex greases which are self healing, regenerative and do not require periodic system purging, which should provide further savings in usage and time.

The LubeRight system has highlighted and solved problems that were not readily identified in the past. It has brought cost and efficiency benefits to the Scunthorpe Coal Plant, benefits that could well be mirrored within other departments in the Corus Group.

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