Proactive Lubrication Protects Valuable Aggregate Equipment

Aggregate producers working with multi-million dollar pieces of equipment understand the need to stay ahead of equipment failures by performing regularly-scheduled routine maintenance. One of the most vital cogs in an aggregate facility which requires particular attention are rock crushers, but unfortunately many times crushers are neglected until they seize and lock up. At that point, the only remedy is replacement, which is an extremely expensive solution.

An aggregate plant faced with this situation implemented a preventive lubrication maintenance program in order to protect their investment in a newly-installed rock crusher. Rather than reaching the point when the crusher can’t operate any longer, a scheduled repair protocol was developed using Prolong Super Lubricants AFMT (Anti-Friction Metal Treatment) Multi-Purpose Lubricant Concentrate.

The timing of the maintenance process is focused on when the power supply to the rotating system is cut off, as the system begins to lose momentum gained during sustained operation and finally comes to rest. The exact time period, from when the power is cut off until the rotor comes to rest, is called Coast-Down Time (CDT). At the end of a shift, a vital part of any maintenance checklist for crusher operation is to note and log the crusher motor amp draw (running empty) and the coast-down time.

Noting an increase in amp draw or shortened coast-down time indicates increased friction and is an indicator of a developing problem. CDT can be used as an effective diagnostic parameter and can provide pertinent information regarding the degradation and effectiveness of lubrication. In the current example, within 12 hours of Prolong AFMT being installed, the coast-down time (CDT) was logged at 38.74 seconds. By contrast, prior to seizing, this crusher had logged a CDT of 29 to 31 seconds. AFMT is formulated to chemically bond to metal surfaces and create a protective layer to prevent metal-on-metal grinding, the cause of friction and increased heat.

Periodically checking and logging the temperature of each bearing is another monitoring procedure that should be consistently done at the end of the shift. Any increase in temperature would be an indicator of a developing problem. According to this aggregate producer, the use of Prolong AFMT virtually always includes reduction in equipment temperature. Also, within the first 12 hours of using this product there was an amp drop of about eight percent and lower temperatures than ever previously recorded.

Over the past three years, plant operations management has seen how the use of Prolong AFMT creates unique, superior resistance to extreme pressure friction and heat – major enemies of equipment life and efficient performance. Reducing the cost of operations and improving the functioning of the entire plant has been achieved through applying advanced technology and consistent attention to equipment maintenance.

EP-2 is formulated for effective lubrication over a wide and extreme temperature range, making it particularly well-suited for Canadian production environments. “Our EP Grease is designed to provide superior protection against wear and corrosion in harsh environments,” said Jeff Victer, Prolong Super Lubricants, director of sales - global. “That’s a huge benefit for companies who require constant productivity. Many of our customers have experienced significant cost savings through productivity improvements or reduced maintenance requirements simply by upgrading lubricants.” 

Jeff Victer is director of sales - global, Prolong Super Lubricants.