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Too much grease

Too Much Grease Real Time Maintenance (RTM) - Instandhaltung in Echtzeit

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Too much grease

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When it comes to regreasing bearings, more is not always the better option and actually can be a costly mistake. Instead, greasing should be set on a frequency with proper calculations used to determine the amount of grease needed at each relubrication.

The determining factor for the amount required is based on the dimensions of the bearing or the bearing housing. Overgreasing can lead to high operating temperatures, collapsed seals and in the case of greased electric motors, energy loss and failures.

The best ways to avoid these problems are to establish a maintenance program, use calculations to determine the correct lubricant amount and frequency of relubrication, and utilize feedback instruments.

Too much grease volume overgreasing in a bearing cavity will cause the rotating bearing elements to begin churning the grease, pushing it out of the way, resulting in energy loss and rising temperatures.

This leads to rapid oxidation chemical degradation of the grease as well as an accelerated rate of oil bleed, which is a separation of the oil from the thickener.

The heat that has been generated over time along with the oil bleed eventually will cook the grease thickener into a hard, crusty build-up that can impair proper lubrication and even block new grease from reaching the core of the bearing.

This can result in accelerated wear of the rolling elements and then component failure. Seal damage is another negative side effect of overgreasing.

Grease guns can produce up to 15, psi, and when you overgrease a bearing housing, the lip seals can rupture, allowing contaminants such as water and dirt to gain access into the bearing housing.

Keep in mind that lip seals usually fail around psi. This excessive pressure can also damage single and double-shielded bearings, causing the shields facing the grease supply to collapse into the bearing race and leading to wear and eventually failure.

When too much pressure is generated from a grease gun due to overgreasing, it is easy for the hard, crusty grease formed from heat high operating temperatures to be broken apart and sent directly into the bearing track.

Overgreasing electric motor cavities has the same effect as with any bearing application except that grease can reach the motor windings.

When filled completely with grease, an electric motor bearing will generate excessive heat due to churning. This results in energy loss as well as an accelerated rate of oil bleed and hardening of the grease thickener.

Again, the high pressure applied from a grease gun can result in grease finding its way between the shaft and inner bearing cap and pressing into the inside of the motor.

The result over time is the coating of the electric motor windings with grease, which leads to both winding insulation and bearing failures.

Setting up a maintenance program is key to solving the problem of overgreasing. Each lube point, whether it be a bearing housing or electric motor, should be tracked as an asset, and records kept for scheduling planned maintenance or inspections of the asset.

While the initial setup of a maintenance system may take some time and hard work, the end results will have a major impact. Once you have planned the scheduling of the assets, you will need to determine the timing and amount of grease volume that should be applied at each point.

The volume can be calculated with a simple equation ref. SKF :. Next, calibrate all grease guns in use and train the technicians on the proper procedures of usage.

Calibrating a grease gun is very simple. All you need are the grease gun and a postal scale. Determining the weight in ounces per full stroke shot of the grease gun will allow you to identify the number of shots it takes to equal 1 ounce of grease.

This will help you establish the right volume needed to ensure you are delivering the precise amount at each use. How do we know when just the right amount of grease has been added?

By monitoring the friction level with ultrasound as new grease is applied — slowly, one shot at a time.

Listen to the bearing and measure the drop in friction as the grease flows in to the bearing. As the decibel level approaches a minimum value and stabilizes pay close attention.

Add single shots. Should the decibel level begin to increase slightly, stop! The job is done. Like any job there is a right way and a wrong way to do things.

Simply listening to a bearing with an ultrasound device that gives no measurement feedback is a recipe for disaster. The audible feedback alone is too subjective to draw any comparative conclusions.

No two people hear the same and there is no way to remember what the bearing sounded like a month ago. The third mistake is depending solely on subjective ultrasound noise when precise quantifiable data is available.

Therefore always use an ultrasound instrument with digital decibel metering. Better still, use a device that provides multiple condition indicators.

Maximum RMS and Peak dB measurements indicate alarm levels and greasing intervals while Ultrasonic Crest Factor provides insight about the bearing condition in relation to its lubricant.

Crest Factor helps us differentiate between bearings that need grease and bearings that need to be replaced. Ultrasound assisted lubrication of plant assets offers significant benefits that calendar-based lubrication cannot.

Lubrication serves a primary purpose, which is to create a thin layer of lubricant between rolling and sliding elements that reduces friction.

So it makes sense that the best way to determine the lubrication requirement of a machine is to monitor friction levels — not time in service.

Optimizing lubrication of plant machinery with ultrasound will result in a significant reduction in grease consumption.

Having an ultrasound programme in place will help create a better culture involving cleaner storage practices, sampling, and avoiding mixing greases.

Machines that are properly lubricated require less energy to run. Imagine that reducing the amount of money spent on grease will actually lead to lower energy bills.

Machines that consume less electricity run cooler and machines that run cooler have longer life cycles.

Ok, the real reason to optimize bearing lubrication is to extend the life of bearings by making sure they have the right amount of grease, but not too much.

When everything is running according to plan, lube-technicians will spend less time greasing bearings that do not need it. A practice that does not use this combination is not a real solution when lubricating bearings.

Who knew so much good could come from such a simple shift from calendar to condition based maintenance? Now you know. Emerson has introduced two new compressed air dryers designed to significantly extend maintenance intervals, minimize downtime and reduce energy costs in rail applications, including brakes and door control.

Typically, air dryers have an average service interval of fewer than two years. SKF has gained hazardous area approval for its QuickCollect sensor, which collects vibration and temperature data.

Finland's state-owned research institute VTT's new piloting platform for process chemistry in VTT Bioruukki Pilot Centre has been designed to accelerate corporate bio- and circular economy projects.

The modernisation and digitalisation of processes offer improved tools for developing, for example, chemical plastics recycling. A virtual opening of the piloting platform for process chemistry at VTT Bioruukki was be held on 23rd September Compressed air is a power source that drives equipment, machinery, and processes, which have a profound impact on the amount of energy an industrial process or plant consumes.

Improving energy efficiency with industry-leading measurement tools yields significant cost savings.

It requires sound knowledge of the machines, taking into account of early signs and economic realism. Vattenfall and Modvion have entered into collaboration on using wooden towers for onshore wind turbines, a venture expected to reduce carbon dioxide emissions in manufacturing by at least 25 percent.

Vattenfall will be assessing Modvion's wooden tower for potential use in future wind farms. Two Nasa astronauts took the first all-female spacewalk.

It was not just for fun, Christina Koch and Jessica Meir were responsible for replacing defective equipment from the International Space Station ISS , and in that way also formed the first female maintenance team in the space.

Euromaintenance will take place in Athens at the end of May. It is the ideal moment to reflect on maintenance in a European context.

The conference, with the support of the EFNMS, is the only commercially independent conference covering the topics we deal with in the maintenance world.

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This should be done before re-installing the purge port or bottom grease relief valve and cleaning the area of any excess grease. Always make sure exhaust ports are cleaned out from any debris or old, hard crust that could be blocking the passageway.

Consider installing grease guns with pressure gauges, shut-off grease fittings or relief-type vent plugs.

Slowly pump grease into bearings every few seconds. Using a quick-lever action could cause seal damage and not allow the grease to distribute throughout the bearing correctly.

Improving Electric Motor Lubrication Policies. Advice for Greasing Electric Motor Bearings. Toggle navigation Toggle search. Magazine Subscribe Today!

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Buyer's Guide. Grease Guns. Cleaners and Degreasers. Write to Jamie Ducharme at jamie. By Jamie Ducharme. It makes you run to the bathroom The most common symptom of digestive strain is an unpleasant one.

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By signing up you are agreeing to our Terms of Use and Privacy Policy. In fact, if you apply dielectric grease to the extent where it becomes thick and goopy, your vehicle will most likely not start.

The objective of the grease is to provide a seal and prevent high-voltage electricity from being leaking out. Therefore, just a thin film of it is enough on every spark plug.

Applying a thick film of dielectric grease will make it impossible for you to push the sockets all the way in. And because the grease does not conduct electricity, the lack of contact will most likely prevent your car from starting.

If your car will not start after greasing your spark plugs, you should clean them out using cotton swabs and then set everything correctly before starting your car again.

A dielectric grease product is one of those products you will buy and stay with for a very long time. It can stay for years. Some people tend to think that dielectric grease products automatically go bad two or three years after they have been opened.

However, this is not correct. If you have a dielectric product that is still thick and pasty, you should not shy away from using it.

It may smell funny but that is how they all smell. As long as the grease still looks and feels like grease, you can use it as long as you want.

There may be ingredients in a specific product that make it ineffective after several years. Permatex makes some of the most sought after grease products in the automotive industry.

This because the company has a reputation for making extremely high-quality tune-up products. This right here is one of their top dielectric grease products.

It is one that provides maximum protection against both moisture and corrosion. It is a great lubricator for spark plug boots and gaskets.

And you can use it to tune up your motor vehicle, boat, or even motorbike. The best thing about this product is that despite being a high-quality product, it is quite affordable.

This is a versatile dielectric grease formula that includes a thinner.

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