The Hidden Dangers of Lubricant Starvation

1/27/2021 The Hidden Dangers of Lubricant Starvation
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The Hidden Dangers of Lubricant

Starvation
Jim Fitch, Noria Corporation
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For those who strive for lubrication-enabled reliability (LER), more than 95 percent of the opportunity
comes from paying close attention to the “Big Four.” These are critical attributes to the optimum
reference state (ORS) needed to achieve lubrication excellence. The “Big Four” individually and
collectively in uence the state of lubrication, and are largely controllable by machinery maintainers.
They are well-known but frequently not well-achieved. The “Big Four” are:
1. Correct lubricant selection

2. Stabilized lubricant health
3. Contamination control
4. Adequate and sustained lubricant level/supply
The rst three of the “Big Four” have bene ted from considerable industry attention, especially in
recent years. Conversely, the last one has gone relatively unnoticed yet is no less important. Therefore,
it will be the central focus of this article.
Over the past few decades, researchers and tribologists have compiled countless listings that rank the
chief causes of machine failure. We’ve published many of these in Machinery Lubrication magazine.
The lists ascribe the causes of abnormal machine wear to the usual suspects: contamination,
overheating, misalignment, installation error, etc. There’s typically a lubrication root-cause category
that is a catch-all for one or more causes that can’t be easily speci ed or named. I’ve seen terms used
like “inadequate lubrication” and “wrong lubrication.”
Understandably, it is di cult for failure investigators and analysts to trace back the exact sequence of
events beginning with one or more
We encourage youroot
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read ourEvidence of these
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course of failure or in a cover-up during the cleanup and repair. Having led several hundred such
investigations over the years, I’ve learned that one root cause in particular is too often overlooked -
lubricant starvation.
of lubrication professionals have seen the
81% effects of lubricant starvation in the

machines at their plant, according to a
recent survey at machinerylubrication.com
Although most everyone knows about this in principle and realizes the common sense of adequate
lubricant supply, it is frequently ignored because many typical forms of lubricant starvation are largely
hidden from view.
For instance, who notices the quasi-dry friction that accelerates wear each time you start an
automobile engine? This is a form of lubricant starvation. It’s not a sudden-death failure, but it is a
precipitous wear event nonetheless. Each time controllable wear goes uncontrolled, an opportunity is
lost to prolong service life and increase reliability.
The Nature of Lubricant Starvation

Machines don’t just need some lubricant or any lubricant. Rather, they need a sustained and adequate
supply of the right lubricant. Adequate doesn’t just mean dampness or the nearby presence of
lubricant. What’s de ned as adequate varies somewhat from machine to machine but is critical
nonetheless.
High-speed equipment running at full hydrodynamic lm has the greatest lubricant appetite and is also
the most punished when starved. Machines running at low speeds and loads are more forgiving when
lube supply is restricted. Even these machines can fail suddenly when severe starvation occurs.
The table below illustrates how lubricants reach frictional surfaces in numerous ways.
There are six primary functions of a lubricating oil. These are friction control, wear control,
temperature control, corrosion control, contamination control and transmittance of force and motion
(hydraulics). Each of these functions is adversely in uenced by starvation conditions.
The worst would be friction, wear and temperature control. Even partial starvation intensi es the
formation of frictional heat. It also slows the transport of that heat out of the zone. This is a
compounding, self-propagating condition that results in collapsed oil lms, galling, adhesive wear and
abrasion (Figure 1).
Figure 1. Starvation Illustrated
In the case of grease, starvation-induced heating (from friction) of the load zone accelerates grease
dry-out, which escalates starvation further. Heat rapidly drains oil out of the grease thickener, causing
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greater starvation.
Lubricating oil needs reinforcement, which is lost when ow becomes restricted or static. Flow brings
in bulk viscosity for hydrodynamic lift. In fact, lack of adequate lubricant supply is functionally
equivalent to inadequate viscosity from the standpoint of lm strength.
4 Keys to Solving Starvation Problems Using

Proactive Maintenance
1. Identify the required lube supply or level to optimize reliability.
2. Establish and deploy a means to sustain the optimized supply or level.
3. Establish a monitoring program to verify the optimized supply or level is consistently achieved.
4. Rapidly remedy non-compliant lube supply or level problems.
Oil ow also refreshes critical additives to the working surfaces. This reserve additive supply includes
anti-wear additives, friction modi ers, corrosion inhibitors and others. Lubricant starvation produces
elevated heat, which rapidly depletes additives.
Next, we know that wear particles are also self-propagating. Particles make more wear particles by
three-body abrasion, surface fatigue and so on. Impaired oil ow inhibits the purging of these particles
from the frictional zones. The result is an accelerated wear condition.
Finally, moving oil serves as a heat exchanger by displacing localized heat generated in load zones
outward to the walls of the machine, oil reservoir or cooler. The amount of heat transfer is a function
of the ow rate. Starvation impairs ow and heat transfer. This puts increasing thermal stress on the
oil and the machine.
Common Signs of Starvation

When you’re encountering chronic machine reliability problems, think through the “Big Four” and don’t
forget about No. 4. It may not be the type of oil, the age of the oil or even the contamination in the oil,
but rather the quantity of oil. How can you know? The chart on page 8 reveals some common signs of
lubricant starvation.
Lubricant Starvation Examples by Machine Type

Lubricant starvation can happen in a number of ways. Most are controllable, but a few are not. The
following abbreviated list identi es how lubricant starvation occurs in common machines.
Starved Engines
Dry Starts - Oil drains out down to the oil pan when the engine is turned off. On restart, frictional
zones (turbo bearings, shaft bearings, valve deck, etc.) are momentarily starved of lubrication
(Figure 2).
Figure 2. Dry Engine Starts
Cold Starts - Cold wintertime conditions slow the movement of oil in the engine during start-up.
This can induce air in the ow line due to cold-temperature suction-line conditions.
Low Oil Pressure - This can result from numerous causes, including worn bearings, pump wear,
sludge and extreme cold. Oil pressure is the motive force that sends oil to the zones requiring
lubrication.
Dribbling Injectors - Fuel injector problems can wash oil off cylinder walls and impair lubrication
between the piston/rings and the cylinder wall.
Common Signs of Lubricant Starvation
Clogged Spray Nozzles and Ori ces - Nozzles and ori ces direct oil sprays to cylinder walls,
valves and other moving components. Sludge and contaminants are able to restrict oil ow.
Starved Journal and Tilting-Pad Thrust Bearings

Oil Groove Problems - Grooves and ports channel oil to the bearing load zones. Grooves become
clogged with debris or sludge, restricting oil ow.
Restricted Oil Supply - Pumping and oil-lifting devices can become mechanically faulty. This also
may be due to low oil levels, high viscosity, aeration/foam and cold temperatures.
Sludge Dam on Bearing Leading Edge - Sludge can build up on the bearing’s leading edge and
restrict the oil supply.
Wet-Sump Bearing and Gearbox Starvation

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Figure 3. Common Splash Gear Drive
High Viscosity - Many oil-feed mechanisms (oil rings, slingers, splash feeders, etc.) are
hampered by viscosity that is too high (wrong oil, cold oil, etc.). Gears can channel through thick,
cold oil, interfering with splash and other feed devices.
Aeration and Foam - Air contamination dampens oil movement and impairs the performance of
oil-feed devices (Figure 4).
Figure 4. How Aeration Retards Oil Supply
Non-horizontal Shafts - This can cause drag on oil rings and may interfere with slinger/ inger
feedWe
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Bottom Sediment and Water (BS&W) - Sump BS&W displaces the oil level. On vertical shafts, the
bottom bearing can become completely submerged in BS&W.
Defective Constant-Level Oilers - This may be due to plugged connecting pipe nipples, mounting
errors (tilted, cocked, mounted on wrong side, etc.), wrong level setting, empty reservoir, etc.
(Figure 5).
Figure 5. Mounting Errors of Constant-Level Oilers
Defective Level Gauge Markings - Level gauges should be accurately calibrated to the correct oil
level.
Level Gauge Mounting and Viewing Issues - These may be hard to see, goosenecks, fouled
gauge glass, gauge vent problems, etc. (Figure 6).
Figure 6. What is wrong with this picture?
Starved Dry-Sump Circulating Systems

Restricted Oil Returns - Plugged or partially plugged oil returns will redirect oil ow away from
the bearing or gearbox being lubricated. Sometimes called drip-and-burn lubrication, the
condition is usually caused by sludge buildup or air-lock conditions in the gravity drain lines
returning to the tank.
Worn Oil Pump - When oil pumps wear, they lose volumetric e ciency ( ow decay results).
Restricted Pump Suction Line - Strainers and pickup tubes can become plugged or restricted.
This can aerate the uid, cause cavitation and lead to loss of prime.
Clogged/Restricted Oil Ways and Nozzles - Oil-feed restrictions due to sludge, varnish and
jammed particles can starve bearings and gears (Figure 7).
Figure 7. Plugged Oil Flow
Entrained Air and Foam - Oil pumps and ow meters perform poorly (or not at all) when sumps
become contaminated with air (Figure 4).
Lack of Flow Measurement - Components sensitive to oil supply require constant oil ow
measurement.
Defective or Miscalibrated Flow Meters - Flow meters, depending on the type and application,
can present a range of problems regarding calibration.
Low Oil Pressure - Oil follows the path of least resistance. Line breaks and open returns starve
oil from higher resistance ow paths and the machine components they serve.
Starved Spray-Lubed Chains and Open Gears

Defective Auto-lube Settings - This relates to correctly setting the lube volume and frequency.
Defective Spray Targets/Pattern - The oil spray needs to fully wet the target location. Spray
nozzles can lose aim and become clogged (Figure 8).
Gummed Chain Joints - Many chains become heavily gummed, which prevents oil from
penetrating the pin/bushing interface.
Starvation from Grease Single- and Multi-Point Auto Lubrication

Wrong Regrease Settings - Regreasing settings should enable adequate grease replenishment at
each lube point.
Cake-Lock - This occurs when grease is being pumped. Under certain conditions, the grease
thickener movement is restricted. Oil ows, but the thickener is log-jammed in a line or
component passage (Figure 9).
Defective Injector Flow - This is due to wrong injector settings or restricted injector
displacement.
Restricted Line Flow - Exceedingly long lines,

narrow lines, numerous bends, ambient heat
or cold, etc., can lead to partial or complete
blockage of grease ow.
Single-point Lubricator Issues - These
include malfunctioning lubricators from
various causes.
Starvation from Manual

Lubrication Issues
Grease Gun Lubrication - This may include an
inaccurate volume calibration, a faulty
grease gun mechanism, the wrong relube
frequency, an incorrect relube volume or an
improper relube procedure.
Manual Oil Lubrication - This would include
the wrong relube frequency, volume or
procedure. Figure 8. Correct Lubricant Spray Patterns
Lube Preventive Maintenance (PM) - Missed on Open-Gear Tooth Flanks
PMs may be due to scheduling, management
or maintenance culture issues.
The Crux of the Problem

Lubricant starvation is an almost silent destroyer.
While there are telltale signs, they generally aren’t
recognized or understood. Of course, there are
varying degrees of starvation. Complete starvation
is sudden and blatant. However, more moderate
partial starvation is what tends to go unnoticed
until failure. Then, other suspect causes (the
bearing, lubricant, operator, etc.) may be falsely
blamed.
Precision lubrication supply is a fundamental Figure 9. Cake-Lock

attribute of the optimum reference state and is Grease Starvation
included in any engineering speci cation for
lubrication excellence. It’s one of the “Big Four” and thus is overdue for signi cant attention.
About the Author
Jim Fitch
Jim Fitch, a founder and CEO of Noria Corporation, has a wealth of experience in lubrication, oil
analysis, and machinery failure investigations. He has advise... Read More
Machinery Lubrication (8/2012)
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1/27/2021 The Hidden Dangers of Lubricant Starvation

Like 17 Sha Tweet  Print

The Hidden Dangers of Lubricant

We encourage you to read our updated Privacy Policy Hide

1. Correct lubricant selection

of lubrication professionals have seen the

81% effects of lubricant starvation in the

The Nature of Lubricant Starvation

We encourage you to read our updated Privacy Policy Hide

Figure 1. Starvation Illustrated

4 Keys to Solving Starvation Problems Using

Common Signs of Starvation

Lubricant Starvation Examples by Machine Type

We encourage you to read our updated Privacy Policy Hide

Figure 2. Dry Engine Starts

We encourage you to read our updated Privacy Policy Hide

Common Signs of Lubricant Starvation

Starved Journal and Tilting-Pad Thrust Bearings

Wet-Sump Bearing and Gearbox Starvation

Figure 3. Common Splash Gear Drive

Figure 4. How Aeration Retards Oil Supply

Figure 5. Mounting Errors of Constant-Level Oilers

Figure 6. What is wrong with this picture?

Starved Dry-Sump Circulating Systems

Figure 7. Plugged Oil Flow

Starved Spray-Lubed Chains and Open Gears

Starvation from Grease Single- and Multi-Point Auto Lubrication

Restricted Line Flow - Exceedingly long lines,

Starvation from Manual

The Crux of the Problem

Precision lubrication supply is a fundamental Figure 9. Cake-Lock

We encourage you to read our updated Privacy Policy Hide

About the Author

Machinery Lubrication (8/2012)

We encourage you to read our updated Privacy Policy Hide

Engine Oils and Their Lubricant Consolidation:

Oil Storage Containers and

Product Unboxing - The Conserver® Oil Puri cation Unit

Product Unboxing - perma STAR VARIO Automatic Lubricators

Product Unboxing - Oil Safe® Lustor Lubrication Storage Systems

Single-point Lubricator Buyer’s Guide

Product Unboxing: Hy-Pro Compact O ine Filter

Product Unboxing - Vaisala Indigo520 Transmitter & MMP8 Probe

Product Unboxing - Vaisala MM70 Meter & MMT162 Transmitter

How to Cost Justify a Lubrication Program

Keeping your Lubrication Program in the Crosshairs

Keeping your Lubrication Program in the Crosshairs

Lubricant Storage and Handling

Get More Info

Other Noria Sites

1328 E. 43rd Court, Tulsa, OK 74105 ∙ © 2021 Noria Corporation

We encourage you to read our updated Privacy Policy Hide

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