POWER October 2014 - 16

Proper Lubrication
Practices Improve Plant
Operations
Although industrial lubricants typically
account for only 1% of plant operational
costs (Figure 1), the lack of proper lubrication
products, techniques, or applications
can have a much more severe effect
on overall maintenance costs. One of the
smallest items in the budget directly influences
more than half of the total maintenance
cost.
Lubrication has proven to be the most
important factor regarding machinery
reliability and productivity. The three
major goals of operations and maintenance
(O&M) are to improve output
capabilities, reduce O&M costs, and increase
profitability.
Many plant managers are looking for
existing products or technologies combined
to produce a synergistic outcome
to create a significant advantage over
the sum of their parts. Lubrication is
one of the building blocks that can help
achieve this goal. The proper lubricant,
lubrication practices, training, and implementation
of a lubrication management
program (LMP) can reduce costs and
improve productivity.
Synthetics Versus Minerals
Choosing the wrong lubricant for a machine
component is more common than
you may think in power generation facilities
today. There is a big difference in per1.
The bottom line impact of lubrication.
This chart shows an average
breakdown of overall plant operating costs by
category. Source: Hydrotex
Lubricants, 1%
Synthetic
Depreciation, 15%
Overhead, 35%
Utilities, 19%
Mineral oil
formance between conventional mineral
oil lubricants and synthetic lubricants.
Mineral oils break down under extreme
heat and form deposits. While petroleum
oils are produced to a high standard of
purity, the fact remains that some unknown/unwanted
content is still present.
Because modern machines are built with
higher operating speeds than ever before
and produce more power, petroleum-based
oils have reached a plateau.
Synthetic lubricants and greases have
consistent properties and provide an array
of overall performance improvements.
Synthetics offer maximum protection for
engines, gearboxes, motors, machines,
and other moving parts because of their
more consistent properties:
■ Increased wear protection: Superior level
of fluid film protection; high shear
stability; and reduced scuffing, pitting,
and rolling contact fatigue.
■ Wide temperature range: Maintain fluid
film protection at higher temperatures;
lower pour points and greater fluidity
at low temperatures.
■ Longer oil life: Free of unstable molecules
that are prone to degradation;
extend oil drain intervals; higher resistance
to oxidation.
■ Improved bottom line: Optimize equipment
performance and reduce maintenance
costs.
The additive chemistry in synthetics
widens the operational temperature range,
extends drain intervals, and provides a
protective barrier on equipment against
outside contaminants and corrosion. Synthetics
typically have extended drain intervals
due to their oxidation resistance.
Increased oxidation resistance translates
into deposit control and longer oil and
grease life. Note the darker, thicker buildup
in the engine operated with mineral
oil on the right in Figure 2, compared to
the cleaner engine on the left, which used
synthetic oil.
Many people do not understand the difference
between initial price and overall
costs when comparing synthetic and mineral
oil-based lubricants and greases. Often,
the lubricant with the lowest initial
price is selected over another that will
provide sustainable long-term results and
overall cost-savings.
The leading benefits of synthetics and
specially designed lubricants are their
ability to reduce waste, increase equipment
life, and reduce energy consumption
while improving productivity, sustainability,
profitability, and carbon footprint.
Energy efficiency can be achieved with
synthetics by reducing friction, which lowers
power consumption. When evaluating
operating costs, especially with heavy machinery,
energy consumption is a critical
component. Proper lubrication with the
correct lubricant can reduce energy usage
by as much as 10%.
Fit for Purpose
There is no such thing as a one-size2.
Which do you prefer? This is an example of differences in oxidation resistance between
synthetic and mineral-based engine oils after a 500-hour, high-temperature bench test. The engine
on the right used mineral oil; the one on the left used synthetic oil. Courtesy: Hydrotex
Maintenance, 30%
16
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POWER | October 2014

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POWER October 2014

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