Debunking 12 common lubrication myths with best-practice realities

In industrial lubrication engineering, several common fallacies can lead to improper practices, increased wear, and ultimately equipment failure. Addressing these fallacies in lubrication engineering is essential for extending equipment life, reducing unplanned downtime, and optimizing operational efficiency. 

Proper training, adherence to best practices, and regular oil analysis can help organizations avoid common pitfalls and achieve better equipment reliability. Here are some of the biggest misconceptions and their best-practice counterparts:

1. “More lubrication is always better”

• Fallacy: Adding more lubricant will ensure better performance and reduce wear.
• Reality: Over-lubrication can cause issues such as overheating, seal damage, and increased energy consumption due to higher friction. For example, in bearings, excessive grease can lead to elevated temperatures and premature failure. Proper lubrication levels based on equipment specifications are crucial.

2. “Any oil will do”

• Fallacy: As long as a machine is lubricated, the specific type or grade of oil doesn’t matter.
• Reality: Using the wrong lubricant can result in inadequate protection, excessive wear, or even catastrophic failure. Put another way, different equipment requires specific lubricant properties to operate efficiently. For instance, hydraulic systems require oils with anti-foaming additives, while gearboxes need oils with high load-carrying capacity. 

3. “Lubrication lasts indefinitely”

• Fallacy: Once lubricated, equipment doesn’t need additional lubrication for a long time.
• Reality: Lubricants degrade over time due to factors like heat, oxidation, contamination, and mechanical stress. Regular re-lubrication and oil analysis are essential to monitor the lubricant’s condition and ensure optimal equipment performance.

4. “All greases are the same”

• Fallacy: Grease is grease, and any type will work for any application.
• Reality: Greases vary widely in properties, such as viscosity, dropping point, and additives. For example, high-temperature applications require greases with high thermal stability, while low-speed applications may need greases with high load-carrying properties. Choosing the wrong grease can lead to ineffective lubrication, grease breakdown, and equipment damage.

5. “Mixing lubricants is harmless”

• Fallacy: Mixing different lubricants or greases will have no negative impact, either on the lubricants or on machine health.
• Reality: Mixing incompatible lubricants can cause chemical reactions that alter the lubricant’s properties, such as viscosity, corrosion protection, and stability. For instance, mixing oils with different base stocks can lead to sludge formation or reduced lubrication performance, risking equipment failure.

6. “Synthetic lubricants are always better”

• Fallacy: Synthetic oils and greases are universally superior and suitable for all applications.
• Reality: Choosing lubricants should be based on the specific operational needs of the machine. While synthetic lubricants offer excellent performance under extreme conditions, they may not be necessary or cost-effective for all applications. In some cases, mineral oils can be sufficient and more economical for less demanding environments. 

7. “Once a lubrication schedule is set, it doesn’t need adjustment”

• Fallacy: A fixed lubrication schedule established initially will remain effective indefinitely.
• Reality: Lubrication needs can change over time due to factors such as wear, environmental changes, or shifts in operating conditions. Regular analysis of lubrication schedules and adapting to real-world conditions are essential to maintain effective lubrication.

8. “Lubricants don’t need contamination control”

• Fallacy: Lubricants are self-cleaning, and contamination isn’t a major concern.
• Reality: Contaminants such as dirt, water, and metal particles can cause significant wear and reduce lubricant effectiveness. For example, a small amount of dirt can lead to abrasive wear in bearings. Proper filtration, storage, and contamination control practices are critical for maintaining lubricant quality.

9. “Thicker oil provides better protection”

• Fallacy: Using thicker oil means better protection and durability.
• Reality: Choosing the correct viscosity grade for the operating temperature and load conditions is essential, as oil viscosity must match the specific operating conditions of the equipment. Too thick an oil can increase friction, reduce efficiency, and hinder proper oil flow in tight spaces, particularly at low temperatures. 

10. “Color is a reliable indicator of oil condition”

• Fallacy: The color of oil indicates its condition and remaining life.
• Reality: Oil color change is not always an accurate indicator of its condition or contamination level. Darkening may occur due to oxidation or additive depletion but does not necessarily mean the oil is unusable. Regular oil analysis, including tests for viscosity, acidity, and contaminants, provides a more accurate assessment of oil condition.

11. “New oil is clean oil”

• Fallacy: Freshly purchased oil is always free of contaminants.
• Reality: New oil can contain particles or contaminants introduced during production, packaging, or handling. Filtering new oil before adding it to equipment is a best practice to ensure clean lubrication and reduce the risk of introducing contaminants.

12. “One-time lubricant selection is sufficient for equipment’s life”

• Fallacy: Once a lubricant is selected for a machine, it will remain the best choice for its entire operational life.
• Reality: Changes in machine operating conditions, updates in lubricant formulations, or advancements in lubrication technology may call for revisiting and updating lubricant choices periodically.