COVER SERIES | Wastewater
Why Lubrication Still Matters
Understanding the role of lubrication in maintaining safe and efficient operations.
Jerrad Fisher | Motion
| IMAGE 1: This rendering of an oxidation ditch shows part of a remote automatic lubrication system for predictive maintenance. The white box (center) is the gateway that receives and sends routine data to a remote platform, helping to alert staff to changes in the equipment’s heat or vibration. (Images courtesy of Dodge Industrial, Inc.)
It started with a bearing that cost less than $100. By the time systems were restored to full capacity, that bearing had become one of the most expensive parts of a costly incident at a wastewater treatment facility. Operations were disrupted, emergency labor was called in, replacement components had to be sourced and valuable hours were lost. What began as a relatively inexpensive component failure ultimately cost thousands of dollars, and in some facilities, such situations can cost tens of thousands in downtime and lost productivity.
The post-failure investigation did not uncover a manufacturing defect. The bearing had not reached the end of its expected service life. The root cause was much simpler. The bearing was not lubricated correctly.
Stories like this play out every day across industrial facilities. Whether it is a pump, gearbox, electric motor, conveyor, blower, fan or mixer, rotating equipment depends on one simple principle that has remained unchanged for generations: controlling friction.
A Foundation of Industrial Reliability
Lubrication is key to rotating equipment longevity. Its purpose is to reduce friction and wear between surfaces by creating a protective barrier that prevents metal-to-metal contact. It is essential for maintaining equipment, prolonging the life of mechanical components and maximizing energy efficiency. Friction creates heat and wear. Lubrication reduces both.
Lubricants also create a protective film that helps prevent corrosion, rust and oxidation. Because lubricants are constantly circulating, they help carry away contaminants ranging from microscopic particles to larger wear metals, many of which are captured through filtration systems in high-pressure applications.
Within gearboxes, lubricants act as a cushion between meshing gear teeth, reducing vibration and absorbing sudden loads. Specialized greases and oils are even designed to seal around moving components, protecting them from dirt, dust, moisture and other contaminants.
The need for lubrication goes back centuries. Without it, the Industrial Revolution would never have happened. Facilities depended on the continuous operation of steam engines, textile mills and heavy iron machinery. Lubrication prevented the seizing of these machines from excessive friction and overheating.
Early industrial equipment relied on animal fats and vegetable oils, but as factories expanded, these products were no longer practical. The big breakthrough came with petroleum. The first commercial oil well was drilled in Pennsylvania in 1859. Within only a few years, refined mineral oils provided a chemically stable, economical and abundant lubricant capable of supporting the rapid expansion of industry.
Now, lubrication is everywhere. Beyond water treatment plants, think about automobiles, household appliances, manufacturing facilities, aviation, mining, food processing and power generation. Nearly everything that moves relies on lubrication, which has literally changed the way the world works.
| IMAGE 2: Lubrication systems installed with a belt conveyor provide lubrication to the mounted bearings and motor bearings.
Keeping the Flow
Proper lubrication is not about applying more lubricant. It is about applying the right lubricant, in the right amount, at the right place, at the right time.
Industry experts often point out that over-lubrication and contamination cause more bearing failures than simply running out of grease. Especially in continuously operating environments like water treatment facilities, water ingress is a major contamination culprit. When lubrication practices fall outside recommended guidelines, equipment can fail just as quickly as if no lubricant had been applied at all.
Doing the homework is well worth the effort and will help prevent lost time and money, as well as many headaches. Some common issues to avoid are:
- Over- and under-lubrication: Always carefully follow the manufacturer’s equipment/component instructions.
- Incorrect lubricant selection: Consider the lubricant’s purpose and environment. Base oil is determined by temperature, viscosity is determined by speed and the needed additives are determined by load. Additive deficiencies can lead to serious equipment damage from corrosion, wear, friction and other consequential issues.
- Incorrect lubrication intervals: Check the manufacturer’s equipment manual for a baseline and then consider—in addition to temperature, speed and load—how much contamination and abrasion may occur from dust, moisture and other environmental factors. Heavy vibration can also affect the timeline. An autolube system can be a huge timesaver once the optimal intervals are determined.
- Incompatible lubricants: If oils or greases that are incompatible mix, the chemical reaction dilutes or even destroys their individual abilities to protect equipment, ultimately leading to failure.
Color coding and standardized identification systems reduce the chances of cross-contamination while improving technician efficiency. Dedicate lubricant dispensers to specific lubricants. Always purge reservoirs—which should also be labeled or coded—completely during changeouts before adding the new grease or oil.
Standardization is a good template to follow to address not only cross-contamination but also the issues identified above. Implementing a lubrication program will create opportunities to improve overall maintenance efficiency. By surveying facility assets and standardizing lubrication practices, organizations can reduce lubricant inventory, consolidate products, minimize expired materials, improve storage practices, reduce contamination and simplify maintenance procedures.
Applying lean manufacturing and Six Sigma principles to lubrication management helps improve organization, reduce waste and ensure the correct lubricant reaches the correct asset every time. Following these strategies can extend equipment life while decreasing maintenance costs and downtime.
The Human Element
Even the best lubrication products and systems cannot do their jobs without human oversight. Workers are still critical in maintaining equipment reliability. Missed preventative maintenance intervals, labor shortages, retirement of experienced technicians, inconsistent grease delivery methods and variations in lubrication practices all contribute to equipment failures.
Lubrication is often referred to as “liquid engineering,” because even small inconsistencies can have big consequences. A simple maintenance oversight can eventually lead to major equipment failures, production losses and expensive downtime. Dedicated training and a solid maintenance program are necessary to overcome these challenges and ensure optimal operations.
Smarter Lubrication
Modern lubrication technology continues to remove many of the variables associated with manual lubrication. Automatic lubricators, remote lubrication systems, vibration analysis, temperature monitoring, predictive analytics, wireless communication and condition-based maintenance allow workers to automate routine tasks and monitor equipment health with greater consistency and accuracy (Images 1 and 2).
These technologies reduce human error, extend equipment life, improve maintenance planning and help facilities maximize uptime and productivity. However, proper training on the technologies built upon the workers’ knowledge of lubrication basics and best practices is essential to realize the best return on investment.
Most importantly, lubrication is not only about protecting equipment. It is about protecting people.
Routine lubrication often requires technicians to enter confined spaces, work at elevated locations, remove equipment guards, work around rotating machinery, perform lockout/tagout procedures and complete repetitive maintenance tasks. Automatic lubrication systems reduce many of these exposures by delivering the proper lubricant at the proper interval without requiring frequent manual intervention (Image 3).
Plants directly improve their safety metrics by standardizing lubrication practices to prevent equipment failures and leaks. Ultimately, the result is improved equipment reliability and a safer working environment.
| IMAGE 3: These two covered lubricators are equipped with wireless connectivity for real-time remote condition monitoring and other maintenance efficiencies. The placement also enhances site safety.
Looking Ahead
The future of lubrication is rapidly evolving. Artificial intelligence, smart sensors, continuous monitoring, digital twins, automated reporting, predictive analytics and reliability-centered maintenance programs are transforming how facilities manage rotating equipment. These technologies provide maintenance teams with better information, earlier warning signs and improved decision-making before failures occur.
Successfully implementing these technologies requires knowledgeable in-house or third-party partners capable of evaluating existing equipment, recommending practical solutions and supporting long-term reliability initiatives. A practical first step would be the site survey mentioned earlier.
Investing in lubrication is investing in equipment reliability, employee safety, energy efficiency and operational uptime.
Jerrad Fisher is a water treatment industry segment specialist at Motion with more than 20 years of fluid handling experience. For more information, visit motion.com.
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