A presentation given at the SIRF conference last year on Automatic lubrication systems.

1. Automatic Lubrication
Systems
&
their Maintenance
By: Rodney Fitzpatrick

2. Introduction
Lubrication Engineers
Providing Lubrication maintenance solutions to
Australian industries for 34 years
Represents leading brands in lubrication including:
• Lubrication Engineers Inc
• Fluid Defense
• Bijur Delimon / Farval / IHI / Lubesite
• LSC - Oil Mist Systems
• Viper Wire Rope Lubricators

3. Automatic Lubrication Systems – Why use them?
Bearing lubrication requirements
• Small amount
• Frequently applied

4. Automatic Lubrication Systems – Why use them?
• Machine operating conditions – 24/7
• Cooling
• Flushing contaminants
• Reclaimer example
– Labyrinths‘ only
lubricated

5. Automatic Lubrication Systems – Why use them?
• Safety issues
• Difficult to reach areas
• Temperature - heat / cold
• Lubrication points behind machine shrouds / guards
Bearings suspended over mixer 5m in the air

6. Automatic Lubrication Systems
Types & Operation
Lubrication System Basic Outline
• Controllers - Timer / PLC / Manual Operation
• Pumps – Grease / Oil / Air / Electric / Manual
• Metering Valves – Injector / Distributor / Divider / Piston
• Accessories
– Fittings – Filters
– Pipework – Pressure switches
– Spray valves – Changeover valves
– Brushes
– Low / high level monitoring

7. Automatic Lubrication System
Types & Operation
Lubrication System Basic Outline
• Controller / Timer / Manual Operation
• Controllers can range from basic to complex
 Basic - Controlling dwell time between operations
 Complex - PLC control monitoring
– Dwell time (time between cycles) – Blockage indicators (micro switches)
– Cycle time (time of operation) – Pressure measurement (high/low)
– Cycle count (how many cycles) – Flow monitoring
– Lubricant high and low level – Temperature monitoring

8. Automatic Lubrication System
Types & Operation
Lubrication System Basic Outline
• Pumps – Grease / Oil / Air / Electric / Manual
– Pumps can range from manual to electric or air operated
– Delivery pressure can range from a few hundred psi to 3,500 psi
– Volumes can range from 0.001cc per stroke to 4kg per minute

9. Automatic Lubrication System
Types & Operation
Lubrication System Basic Outline
• Metering Valves – Injector / Distributor / Divider / Pistons
– Valves range from flow resistors to positive dividers to injectors
– Delivery of oil or grease in continuous flow or minute quantities
– Some valves can be monitored to measure lubricant flow
– Some valves provide the ability to adjust lubricant quantity

10. Automatic Lubrication System
Types & Operation
Single Point Lubricators
• Spring actuated SPL’s – Low pressure / refillable / adjustable
• Gas powered units – 20 - 50psi / corrosion resistant /
temperature dependent
• Battery actuated mechanical units – 850psi / adjustable time
/ refillable

11. Automatic Lubrication System
Types & Operation
Single Line – Resistance System

12. Automatic Lubrication System
Types & Operation
Single Line – Resistance System
• Comprises a manual or automatic pump
• Delivers lubricant to resistance metering valves
• Operates at low pressures around 200psi
• Oil systems only
Operation
The pump is activated forcing a set volume of lubricant into
the supply lines, the oil then takes the path of least resistance and is
dispensed through the metering valves. Metering valves with large
orifices deliver larger volumes than smaller valves. Therefore
systems are designed with the metering valves matched to the
lubricant requirement of each bearing. This is a total loss oil system
used on many small machine tools, presses etc. No system blockage
or pressure indication is usually used although some systems may
have a low level indicator on the reservoir.

13. Automatic Lubrication System
Types & Operation
Single Line - Positive Displacement Injector Systems

14. Automatic Lubrication System
Types & Operation
Single Line - Positive Displacement Injector Systems
• Comprises a Grease or Oil pump with main line and injectors
attached
• Medium pressure typically up to 2500 psi
• Injectors provide precise measured doses of lubricant
• Injector lubricant quantities are often adjustable
• Ideal for systems with lubrication points spread over large area
Operation
The pump is activated at a predetermined interval and builds
pressure in the main line once the pressure overcomes the
internal spring pressure of the injector it actuates. Grease is then
pushed from the injector to the bearing. When the pump is
stopped pressure from the main line is vented and the injector
internal spring resets the piston and draws in the next shot of
lubricant. Adjustment of the piston stroke will adjust the
lubricant volume delivered.

15. Automatic Lubrication System
Types & Operation
Single Line Progressive Systems

16. Automatic Lubrication System
Types & Operation
Single Line Progressive Systems
• Comprises a Grease or Oil pump with progressive distributors
• Medium to High pressure typically up to 4,500 psi
• Progressive distributors provide fixed doses of lubricant, slave /master
• Typical used in systems of less than 100 points
• Can be monitored via micro switch for blocked lines
Operation
The pump is activated at a predetermined interval and begins
delivering lubricant to the progressive distributors. The lubricant is
progressively divided through the use of drillings and pistons shuttling
backwards and forwards. The lubricant delivery is absolutely positive as
the system does not rely on valves, springs or seals. The systems
typically have an indicator pin fitted to one of the pistons and micro
switches can be fitted to this allowing for system monitoring.

17. Automatic Lubrication System
Types & Operation
Multi Line Systems

18. Automatic Lubrication System
Types & Operation
Multi Line Systems
• Comprises a Grease or Oil pump with multiple outlets
• Delivering lubricant to progressive or positive displacement injectors
• Medium to high pressure typically up to 4,500 psi
• Each outlet may be adjustable in outlet volume
• Injectors provide precise measured doses of lubricant
• Injector lubricant quantities are often adjustable
• Ideal for systems with lubrication points in different locations
Operation
The pump is activated at a predetermined interval and
lubricant is delivered through each delivery piston to a
separate delivery line. The grease is delivered to either
progressive or positive displacement distributors, then pushed
from the injector to the bearing. Adjusting the piston stroke of
the delivery piston on the pump will adjust the lubricant
volume delivered.

19. Automatic Lubrication System
Types & Operation
Dual Line Systems

20. Automatic Lubrication System
Types & Operation
Dual Line Systems
• Comprises a Grease pump, changeover valve & two main delivery lines
• Delivers lubricant to positive displacement injectors
• Medium pressure up typically up to 2,500 psi
• Injectors provide precise measured doses of lubricant
• Injector lubricant quantities are often adjustable
• Ideal for large lubrication systems with points from a few to hundreds
• Can be used over very large distances
Operation
The pump is activated at a predetermined interval and
lubricant is delivered through the first main lines building up to
pressure. Pressure in the line activates the injector delivering
lubricant to the bearing. When the preset pressure is achieved
either a hydraulic or electric changeover valve vents the first line
to tank and begins pressurizing the second line. Once the
second line achieves pressure the changeover valve vents
grease to tank and the system resets.

21. Automatic Lubrication System
Types & Operation
Spray Systems

22. Automatic Lubrication System
Types & Operation
Spray Systems
• Comprises a Grease or Oil pump
• Can be any of the previous types of systems but with spray valves
• Spray valves have air and lubricant applied
• Medium pressure typically up to 2,500 psi
• Injectors provide precise measured doses of lubricant
• Injector lubricant quantities are often adjustable
Operation
The pump is activated at a predetermined interval and
lubricant is delivered to the spray valve from the
distribution valve. Just prior to the lubricant being delivered
to the spray valve air is applied to enable pre-cleaning of
the nozzles. Air is continued to be applied after the
lubrication cycle to flush lubricant through the nozzle.

23. Lubrication Systems – Inspection & Maintenance
• Lubrication Systems involve electrical, mechanical, pressure,
hydraulic and chemical interactions.
• Like all pieces of equipment they require regular maintenance
• Critical factors influencing Lubrication Systems
– System design
• Type of System / Pump / Pipe diameters / Duty Cycle / Material
selection
– Lubricant type
• Mechanical Stability / Lubricant Base / Base oil viscosity
– Lubricant Cleanliness
– System Location
With correct design and regular maintenance
systems can operate for many years

24. System Design
• A large proportion of lubrication system issues can be
traced back to incorrect system design
– Pump specification – volume / pressure / duty cycle
– System type – Single line versus dual line
– Material specification
– Piping specifications
– Lubricant specification

25. Fault Finding – Lubrication Systems
Visual Inspection is the number one tool for
fault finding:
– Broken, damaged or leaking lines
• PM job raised (KPC example)
– Dry bearings
• System check (PM raised)
– Over greased bearings
• System check (PM raised)

26. Lubricant Selection
• Grease is made up of oil and thickener plus various
additives
– Thickeners include soaps and clays
• NLGI grade selection
– Typically an NLGI#2 is used
– The higher the NLGI grade the more thickener used
• Lubrication systems whilst often designed to pump an
NLGI#2 product do not necessarily work effectively
• Grease under pressure often separates leaving the base
• Solid additives such as moly drop out on bends
• Heavy viscosity oils create too much fluid friction

27. Fault Finding – Lubrication Systems
Visual Inspection is the number one tool for fault
finding:
– Grease levels in reservoirs
• How often does it require top up? / Interval of drum change-out
documented
– Open reservoirs which allow ingress of contaminants
• Immediate PM job raised / Design project to re-engineer
– System operating pressure
• Have accessible operating gauges with system pressure listed

28. Fault Finding – Lubrication Systems
Visual Inspection is the number one tool for fault
finding:
– Distribution block inspection
• Dust caps
• Pin operation
• Mounted upside down
• Monthly piston operation checks
• Quantity output measurement

29. Visual Inspection
Corroded injectors with indicator pin stuck

30. Visual Inspection
Adequate grease visible

31. Visual Inspection
No grease visible

32. Manual Greasing
Grease nipple inside of safety guard
no chance of greasing occurring