Achieving Lubricant Health and Cleanliness Through Proper Storage
In the world of machinery lubrication, achieving and maintaining lubricant health is crucial for the longevity and efficiency of equipment.
Lubricant cleanliness is a critical aspect that ensures smooth operation, minimizes wear, and extends the service life of both the lubricant and the machine components.
However, despite the importance of the correct formulation and selection of lubricants, their effectiveness can be significantly compromised by improper storage and handling.
To maintain the efficacy of lubricants, the entire process—from receiving the product to its application—must be tightly controlled.
This article will delve into the various methods, practices, and considerations that are essential for achieving lubricant health and cleanliness through proper storage.
The Importance of Lubricant Cleanliness
Lubricants serve multiple roles in machinery, from reducing friction and heat to minimizing wear, preventing corrosion, and removing contaminants.
In modern machinery, where tolerances are tighter and performance expectations higher, even microscopic contaminants can wreak havoc on critical components.
Contaminants such as dust, water, and other particles can cause abrasive wear, corrosion, or chemical degradation, which accelerates equipment failure.
One of the most significant factors affecting lubricant cleanliness is the presence of particulate contamination. It’s also worth noting that approximately 70% of machine failures related to lubrication stem from particle contamination.
In addition to particulates, moisture is another detrimental contaminant that can degrade lubricants, especially for hydraulic fluids, gear oils, and engine oils.
Water, when emulsified or dissolved in lubricants, can promote oxidation, reduce load-carrying capacity, increase corrosion, and lead to pitting of metal surfaces.
Contamination, regardless of its form, compromises the health of the lubricant and its ability to perform its intended function.
Thus, maintaining lubricant cleanliness through proper storage becomes an essential component of a comprehensive lubrication management strategy.
The Storage Environment: Protecting Against Contamination
The first step in ensuring lubricant health is addressing the storage environment. Lubricants should be stored in an environment that protects them from contamination by external elements such as dust, moisture, and temperature fluctuations.
Ideally, the storage room should be located indoors and be climate-controlled to prevent temperature extremes that could accelerate oil degradation or increase moisture ingress.
Temperature Control
Temperature plays a pivotal role in maintaining lubricant integrity. Excessively high temperatures can accelerate the oxidation process, leading to the breakdown of oil additives and the formation of sludge and varnish.
Low temperatures, on the other hand, can cause the oil to become more viscous, making it difficult to pump and apply. It is important to store lubricants in a cool, dry area where temperature variations are minimal.
The recommended temperature range for most lubricants is between 10°C (50°F) and 30°C (86°F), though specific manufacturers may provide guidelines for the optimal temperature range for their products.
Humidity Control
Humidity is a major concern in the storage of lubricants, particularly for hydroscopic oils that readily absorb moisture from the surrounding environment.
Water contamination can occur through condensation, especially if drums or storage containers are exposed to fluctuating temperatures.
This can lead to corrosion of metal surfaces, additive depletion, and a reduction in the lubricant’s load-bearing properties.
To avoid moisture ingress, lubricants should be stored in a humidity-controlled environment, with an ideal humidity level kept below 60%.
In cases where humidity control is difficult to achieve, desiccant breathers or dehumidifiers can be utilized to prevent moisture ingress into storage drums and reservoirs.
Desiccant breathers, which absorb moisture from the air before it enters the storage container, are particularly effective for drums and large bulk storage systems.
Cleanliness of the Storage Area
The cleanliness of the storage room itself is equally critical. Dust, dirt, and airborne particles are common sources of contamination, and they can easily enter oil drums or storage containers if not adequately sealed.
It’s essential to keep the storage area free of dirt, debris, and potential contaminants by adopting rigorous housekeeping measures.
The floor should be swept regularly, and drums or tanks should be placed on pallets to avoid direct contact with the floor, which can introduce particulates or water into the lubricant.
Additionally, it is advisable to store lubricants away from chemicals, fuels, or other substances that could potentially contaminate the oil through vapor or accidental spills.
The Role of Proper Container Management
In addition to managing the storage environment, the containers used for storing lubricants must also be carefully selected and maintained.
The type of container, how it’s handled, and the sealing mechanisms all play a critical role in preventing contamination.
Sealing Containers Properly
Lubricant containers—whether they are drums, intermediate bulk containers (IBCs), or storage tanks—should always be properly sealed to prevent air, water, or particulate matter from entering. Improperly sealed containers are one of the leading causes of lubricant contamination.
Once a drum or container has been opened, its exposure to air can allow particulate matter and moisture to enter.
To minimize this risk, desiccant breathers or other types of filtering caps should be installed to prevent moisture ingress while allowing for the expansion and contraction of the fluid.
Storing Containers in an Upright Position
Oil drums should always be stored in an upright position, with bungs or openings sealed tightly. Horizontal storage, while common in some industries, increases the risk of contaminants entering the container through the bungs, especially when exposed to rain or dust.
If drums are stored outside, a drum cover or a waterproof tarp should be used to protect them from the elements, and they should be elevated on pallets to avoid direct contact with the ground, which can introduce water or other contaminants.
First In, First Out (FIFO) Approach
To maintain lubricant health, it is essential to manage stock rotation efficiently, using a "First In, First Out" (FIFO) approach. Lubricants have a shelf life, which means that even under ideal storage conditions, the oil and its additives can degrade over time.
By adhering to the FIFO principle, you can ensure that older stock is used before it has a chance to degrade, which minimizes the risk of using an expired or degraded lubricant.
Labeling containers with the date of receipt and conducting regular inventory checks can help to manage this process effectively.
Bulk Storage and Dispensing Systems
For operations where lubricants are used in large volumes, bulk storage systems are often employed. However, bulk storage systems require particular attention to detail to maintain lubricant cleanliness and health.
Bulk Tank Design and Installation
Bulk tanks should be designed and installed with features that minimize contamination risks. Tanks should be made from materials compatible with the lubricant being stored, and the interior surfaces should be smooth and easy to clean.
Tanks with sloped bottoms are preferable, as they help to drain sediment and water that may accumulate over time. Additionally, tanks should be equipped with desiccant breathers to prevent moisture ingress.
Filtration and Monitoring Systems
It is common to use inline filters as part of the dispensing process from bulk tanks to remove any contaminants that may have entered the system.
Best practices dictate the use of high-efficiency filters (rated for the particle size of concern) and periodic monitoring of filter conditions.
A filtration system is a proactive measure to maintain the cleanliness of the lubricant, especially in high-precision applications like hydraulics and turbines.
The cleanliness level can be verified using oil analysis reports in compliance with standards such as ISO 4406, which provides guidelines on acceptable levels of particle contamination for lubricants.
Avoiding Cross-Contamination
Cross-contamination occurs when different lubricants mix, either during storage or dispensing. Different lubricants may have incompatible base oils, additives, or viscosities, which can reduce performance or cause component damage.
To avoid cross-contamination, it’s essential to use clearly labeled storage containers and dedicated dispensing equipment for each type of lubricant. Color-coded systems or specific labeling can help to prevent accidental mixing.
Dispensing hoses, pumps, and containers should also be cleaned or flushed when switching between different lubricants.
Handling Lubricants: Reducing Contamination Risk
Proper handling of lubricants is critical to maintaining their cleanliness throughout their lifecycle, from storage to application.
Handling errors, including the use of contaminated transfer equipment or poor hygiene during filling, are significant sources of lubricant contamination.
Using Clean and Dedicated Equipment
All equipment used for transferring lubricants—such as pumps, hoses, and containers—should be dedicated to a specific type of lubricant and thoroughly cleaned between uses.
Portable transfer containers, in particular, should have lids and filters to prevent contaminants from entering during the transfer process.
It’s essential to avoid using the same equipment for multiple lubricants without proper cleaning, as cross-contamination is a frequent issue when transferring oils.
Proper Drum Opening Techniques
When opening a drum or container for the first time, it is essential to use proper techniques to avoid contamination.
If a container is punctured or opened incorrectly, particles or debris can fall into the oil. Always clean the bung or cap area before opening, and use clean tools that have been stored in a contamination-free environment. After the container is opened, it should be resealed immediately if the lubricant is not used completely.
Oil Analysis as a Diagnostic Tool
While proper storage and handling practices are critical to maintaining lubricant cleanliness, it is equally important to verify that the lubricants in use remain clean and effective.
This is where oil analysis plays a vital role. Regular oil analysis provides a snapshot of the lubricant’s condition, identifying contamination, degradation, or additive depletion.
Monitoring Contaminant Levels
Oil analysis can detect particulate contamination (measured in microns) as well as water content, oxidation levels, and the presence of wear metals.
By establishing baseline cleanliness levels according to ISO 4406 or other relevant standards, it is possible to track trends over time and detect any contamination issues early.
For example, an increase in particulate contamination might suggest a problem with storage or dispensing practices, prompting an investigation and corrective action before serious equipment damage occurs.
Identifying Degradation
Oil analysis can also detect signs of lubricant degradation, such as changes in viscosity, acidity (TAN), or the presence of oxidation by-products.
By regularly testing the lubricant, maintenance teams can determine if storage conditions (such as temperature and humidity) are causing premature degradation and adjust accordingly.
Conclusion
Achieving lubricant health and cleanliness through proper storage is a multifaceted process that requires diligent attention to detail at every stage of the lubricant’s life cycle.
From controlling environmental factors such as temperature and humidity, to ensuring the cleanliness of storage containers, proper handling techniques, and utilizing filtration systems for bulk storage, the goal is to minimize the introduction of contaminants and maintain the integrity of the lubricant.
Regular oil analysis serves as a final check, verifying that storage practices are effective and allowing for early detection of potential issues.
In industries that rely heavily on machinery, the consequences of using contaminated or degraded lubricants can be severe, leading to increased downtime, costly repairs, and even complete equipment failure.
By implementing best practices for storage, handling, and monitoring, organizations can significantly extend the life of both their lubricants and their machinery, ultimately improving reliability and reducing operating costs.
Maintaining a proactive approach to lubrication cleanliness is not merely an option but a necessity for optimizing equipment performance and ensuring long-term operational success.
