A PIT & QUARRY SPONSOR UPDATE  |   JULY 2017   |  
Pit and Quarry Direct
 
Reduce risk failure with a well-designed lubrication program

By GREG PALUSKA and MICHAEL LONGBOTTOM

When mining companies look at their maintenance expenses, big-ticket items such as labor, components and other materials often overshadow lubricants. That's not surprising. After all, lubricants account for just 1 percent to 3 percent of most maintenance budgets.

The comparatively small up-front costs, however, belie the much greater cost that lubrication failures can have on equipment life, reliability and operating efficiency. Lubrication issues can contribute to as much as 80 percent of all equipment failures, and they can result in shortened component life. These issues can also add to labor costs. When equipment fails without warning, it must be repaired or replaced rather than having issues resolved during a routine maintenance program.

"Whether it's a very large component or a very small one, we try to put our focus on helping to ensure that the lubricants are doing what they were designed to do."

Lubrication issues can contribute to as much as 80 percent of all equipment failures.

"It's a negative feedback loop in which your maintenance budget is getting larger and larger, and the root cause could be something as simple as your lubricants," says Greg Paluska, who leads Shell's North America Technical Team in the eastern U.S.

By improving their lubrication program, however, mining companies can help reduce equipment ownership costs, reduce downtime and increase reliability.

Common causes of lubricant failure

An effective lubrication program is designed to avoid the most common causes of lubrication failure, including contamination, unsuitability and improper application. About 45 percent of all lubrication problems are the result of lubricants that have been compromised — either the lubricant is old or it has been infiltrated by solid or liquid contaminants.

"Whether it's a very large component or a very small one, we try to put our focus on helping to ensure that the lubricants are doing what they were designed to do," says Michael Longbottom, Shell Global LubeExperts' services manager. "The right lubricant at the right time in the right volume is critical to keep machines in operation."

"Whether it's a very large component or a very small one, we try to put our focus on helping to ensure that the lubricants are doing what they were designed to do."

Enter Shell LubeExpert

Once a lubrication program has been designed, Shell's LubeExpert executes the plan by conducting both operational audits and shutdown inspections.

A well-designed lubrication system will also identify over-lubrication. For example, a Shell LubeExpert found that a large ball mill was operating with three times the necessary number of injectors. The LubeExpert recommended a new system setup, lowering the timers and reducing injector numbers to deliver one-third the volume of grease per injection. As a result, this company was able to save $63,000 a year in excess grease costs.

By adopting a well-designed lubrication program that is tailored to their specific needs, mining companies can help reduce the high percentage of machinery failures such as these, which are linked to lubrication. In summary, identifying and resolving these sorts of lubrication faults can help reduce your TCO and potentially realize substantial savings. A number of Shell customers have reported savings totaling hundreds of thousands of dollars.


Greg Paluska, North America Technical Manager for Eastern US, has over nine years of experience in Shell Lubricants including experience with lubricant application and lubrication systems support for heavy machinery.

Michael Longbottom, Global Shell LubeExpert Manager, has 30+ years of experience with mining companies providing the Shell LubeExpert unique service that is consistent, delivers real value, reduces customers total cost of ownership (TCO), improves availability and reliability of customers critical assets.

Visit lube-education.com/mining for the latest industry insights from Shell. Please direct all inquiries about Shell Lubricants to Cassie Hackstedt at Cassie.Hackstedt@shell.com.

Pit & Quarry Direct provides professionals in the aggregate mining industry with insights on timely innovations in equipment and technology. This newsletter was produced by North Coast Media's content marketing staff in collaboration with Shell Lubricants.

View details.

VIEW MORE FROM PIT & QUARRY   LEARN MORE ABOUT SHELL LUBRICANTS