Article 3 of 5 — Mining Industry

How Khash Would Implement ICML 55 Lubrication Management in Mining Through Noria-Style Consulting and Service Programs

I will continue using Khash as the lubrication-management implementation lead or consultancy program owner. This article is written for both surface mining and underground mining, including mobile fleets, fixed plant, crushing, conveying, grinding, mineral processing, dewatering, ventilation, and support systems.

1. Strategic intent: why mining requires a formal lubrication-management system

Mining is one of the harshest environments for lubricated assets. The lubrication program must protect equipment against abrasive dust, rock fines, water, mud, slurry, shock loading, high payloads, high vibration, long duty cycles, remote operating locations, temperature variation, poor access, washdown, fuel dilution, hydraulic contamination, and human-error risk during field servicing.

In surface mines, haul trucks, loaders, drills, shovels, conveyors, and crushers operate in dusty open environments where water, humidity, abrasive particles, high heat, and heavy loads accelerate wear. A 2026 Gulf Oil mining-lubrication article summarizes these dominant hazards as dust, water, fluctuating temperatures, abrasive debris, heavy loads, long haul-road exposure, and the difficulty of manual lubrication across large remote fleets. (gulfoilltd.com)

In underground mining, the lubrication challenge is different but equally severe: restricted access, high humidity, water spray, slurry contamination, poor ventilation zones, heat, low clearances, difficult lubricant transport, safety constraints, and very high downtime consequences. For Khash, the lubrication-management system must therefore be more than a PM program. It must be a risk-control system for asset availability, production continuity, safety, contamination control, lubricant consumption, component life, and maintenance cost.

ICML 55 is suitable because it is written specifically for lubricated asset management and is aligned with ISO 55000-style physical asset-management principles. ICML describes ICML 55 as a set of lubrication-specific standards that define requirements and guidelines for effective, audit-ready, certifiable management of lubricated mechanical assets. (info.lubecouncil.org)

For mining, Khash’s implementation objective should be:

To establish a governed, auditable, and technically engineered lubrication-management system that extends component life, reduces lubrication-related failures, controls contamination, optimizes lubricant consumption, improves mobile and fixed-plant availability, reduces safety exposure from manual lubrication, and integrates lubrication decisions into mine maintenance planning, condition monitoring, reliability engineering, procurement, contractor control, and management review.

2. ICML 55 interpretation for mining operations

ICML 55 should not be interpreted as a paperwork requirement. In mining, it must be translated into machine-level controls that survive real operating conditions.

ICML 55 management area	Mining-specific interpretation
Lubrication objectives	Improve fleet availability, reduce hydraulic failures, extend engine/transmission/final-drive life, reduce crusher/mill/conveyor failures, reduce lubricant waste, and reduce manual lubrication exposure.
Competency	Train lube technicians, field service crews, operators, planners, reliability engineers, warehouse teams, contractors, and OEM service providers.
Machine readiness	Add sample ports, breathers, filtration ports, sight glasses, auto-lube monitoring, grease-line protection, drain valves, magnetic plugs, guarded access, and safe sampling locations.
Lubricant selection	Engineer oils, greases, hydraulic fluids, final-drive fluids, open-gear lubricants, compressor oils, rock-drill oils, chain lubricants, and specialty fluids by duty, temperature, load, contamination, and OEM requirements.
Planned lubrication tasks	Replace generic PMs with calculated greasing, condition-based oil changes, clean top-up, filtration tasks, sampling tasks, and inspection standards.
Corrective lubrication tasks	Define abnormal-condition response for water, dust, high particle count, fuel dilution, overheating, foaming, blocked grease lines, auto-lube alarms, and wear debris.
Storage and handling	Control lubricant receipt, bulk storage, field lube trucks, service carts, underground transport, sealed transfer, contamination exclusion, and product identification.
Inspection and condition monitoring	Integrate oil analysis, grease analysis, filter debris, magnetic plug review, ultrasound greasing, thermography, vibration, telematics, onboard sensors, and operator inspections.
Troubleshooting and RCA	Investigate repeated hydraulic, final-drive, wheel-end, gearbox, bearing, crusher, mill, conveyor, and engine failures through lubrication failure modes.
Waste and environment	Reduce leaks, overgreasing, unnecessary oil changes, spill risk, used-oil mixing, contaminated water, and lubricant disposal volumes.
Metrics and audit	Track cleanliness, water, oil-analysis compliance, route compliance, auto-lube health, lube consumption, PM quality, failure reduction, and business impact.
Management review	Use monthly and quarterly lubrication governance meetings to remove barriers, fund machine-readiness upgrades, review RCA, and sustain improvements.

ICML states that ICML 55.1 defines what should be done, while ICML 55.2 explains how to implement the requirements with customization to the organization’s needs. That distinction is important for mining because implementation must be adapted separately for mobile fleets, fixed plant, underground assets, process plants, and contractor-maintained equipment. (info.lubecouncil.org)

3. Noria-style consulting and services model for mining

Khash should deliver the mining lubrication program using a phased Noria-style service model: Ascend Assessment, Engineering Design, and Program Implementation. Noria describes its Lubrication Program Development process as three phases, with typical timelines of approximately one week for Phase I Ascend Assessment, six to eight weeks for Phase II Engineering Design, and one to two years for Phase III Implementation. (Noria Corporation)

Noria’s Ascend Assessment is positioned as a comprehensive review of lubricants, hardware, training, and procedures, aligned with ISO 55001 and ICML 55.1; the Ascend chart is structured around three management rings, six weighted sections, and forty critical lubrication elements. (Noria Corporation) Khash should use this structure as the baseline maturity model, then expand it with mining-specific risk modules.

4. Phase 1 — ICML 55 / Ascend baseline assessment for a mine

The first phase should establish the current-state maturity of the lubrication program. In mining, the assessment must cover both the maintenance system and the field execution reality. Many lubrication failures occur not because the PM exists, but because the field environment makes the PM difficult, unsafe, contaminated, or inconsistent.

4.1 Assessment scope

Khash should assess:

Surface mobile fleet
Underground mobile fleet
Drills and blasting-support equipment
Electric rope shovels and hydraulic shovels
Draglines, where applicable
Haul trucks
Wheel loaders and excavators
Dozers, graders, and support equipment
Primary crushers
Secondary and tertiary crushers
Screens and feeders
Conveyors and transfer stations
Grinding mills and mill drives
Flotation, thickening, and mineral-processing equipment
Pumps and dewatering systems
Compressors
Ventilation fans
Lubricant warehouse and bulk storage
Field service trucks
Underground lube bays
Contractor workshops
Oil-analysis program
CMMS/EAM lubrication PMs
OEM maintenance contracts
Used-oil and environmental controls

4.2 Field assessment questions

Khash should not only ask “what lubricant is specified?” The assessment should ask:

Is the lubricant clean when received?
Is the lubricant clean when stored?
Is the lubricant clean when transferred?
Is the lubricant filtered before entering critical equipment?
Are field lube trucks contaminating oil?
Are grease cartridges and pails protected from dust?
Are grease fittings cleaned before use?
Are auto-lube systems actually delivering grease to every point?
Are blocked grease lines detected?
Are sample ports installed in representative locations?
Are oil samples drawn hot, live, and consistently?
Are oil-analysis reports converted into work orders?
Are final-drive, wheel-end, hydraulic, and engine compartments sampled correctly?
Are PM intervals adjusted based on severity, oil condition, contamination, and duty cycle?
Are underground assets using the same standards as surface assets?
Are contractors following the same lubricant controls as owner-maintained assets?
Are lubricant substitutions technically reviewed?
Are contamination failures coded and trended?
Are high-consumption assets investigated or simply refilled?
Are overgreasing and undergreasing both being measured?
Are lubrication tasks designed around technician safety and access?

4.3 Assessment outputs

The Phase 1 deliverable should include:

ICML 55 / Ascend maturity score
Mine lubrication risk map
Critical asset list
Lubricated component register gap review
Lubricant inventory and consolidation review
Oil-analysis effectiveness review
Grease and auto-lube system review
Field service truck contamination audit
Lube-room and warehouse audit
Underground lube bay audit
Mobile fleet PM review
Fixed plant PM review
Machine-readiness audit
Contractor lubrication audit
Lubrication-related failure history review
Quick-win list
Long-term roadmap
Cost-justification model
KPI baseline
Implementation priority ranking

5. Phase 2 — Engineering Design for mining lubrication

Noria’s Engineering Design phase surveys lubricated assets onsite, collects asset data, and builds dynamic procedures using operating conditions, OEM requirements, and reliability-focused best practices. It also provides lubricant recommendations, hardware recommendations, data management, and procedures for inspections, relubrication, top-ups, sampling, changeouts, modification instructions, and filtration. (Noria Corporation)

For Khash, Phase 2 should convert the assessment into engineered work instructions and physical asset modifications.

5.1 Required engineering data

For each asset and lubricated component, Khash should capture:

Asset ID
Component ID
Lubrication point ID
Component type
Manufacturer and model
OEM lubricant specification
Current lubricant
Recommended lubricant
Oil capacity or grease volume
Operating temperature
Ambient temperature range
Load severity
Speed
Duty cycle
Environment: dust, water, mud, slurry, temperature, altitude, underground humidity
Failure history
Criticality
Access constraints
Safety constraints
Sampling method
Filtration method
Breather type
Fill method
Drain method
Top-up method
Inspection points
Current PM task
Engineered PM task
Condition-monitoring method
Contamination target
Alarm limits
Hardware modifications required

5.2 Mining-specific engineering outputs

The Engineering Design package should include:

Lubricated asset hierarchy
Lubrication point master list
Mobile fleet compartment matrix
Fixed plant lubrication matrix
Lubricant selection and consolidation study
Approved lubricant list
Contamination-control standards
Oil-analysis test slate by compartment
Sample-point installation standards
Grease-volume and interval calculations
Auto-lube system inspection procedures
Field lube truck cleanliness standard
Underground lube bay standard
Bulk storage and transfer standard
Filter-cart and filtration plan
Final-drive and wheel-end sampling standard
Hydraulic cleanliness standard
Crusher lubrication standard
Conveyor lubrication standard
Mill lubrication standard
Shovel and excavator lubrication standard
Haul-truck lubrication standard
Drilling equipment lubrication standard
CMMS PM task library
Route design
KPI dashboard
Training matrix
RCA templates
Management-of-change process

6. Phase 3 — Program Implementation

Noria describes implementation as the phase where assets are updated with the right products and equipment, while new procedures, management practices, and KPIs are integrated into daily lubrication work. Noria also notes that LubePM can manage changing procedures and inspections dynamically as the program evolves. (Noria Corporation)

For Khash, implementation in mining should be staged, because mines are distributed, high-pressure, and production-driven environments. The program should begin with a pilot, prove value, then expand by asset class and area.

6.1 Recommended mining pilot areas

Khash should select pilot areas where lubrication risk and business value are high:

Haul truck engines, hydraulics, transmissions, final drives, differentials, wheel ends, and automatic lubrication systems
Hydraulic shovels or electric rope shovels
Primary crusher lubrication systems
Critical conveyor drives, pulleys, and take-up systems
SAG mill, ball mill, or HPGR lubrication systems
Underground LHDs, drills, and bolters
Dewatering pumps and ventilation fans
Field lube truck and bulk storage system

6.2 Implementation controls

The implementation should include:

Installed breathers
Installed sample ports
Quick-connect filtration ports
Filtered oil transfer
Dedicated and sealed transfer containers
Field lube truck upgrades
Grease-gun calibration
Auto-lube alarm review
Grease-line inspections
PM procedure replacement
Oil-analysis alarm restructuring
CMMS task updates
Technician field coaching
Operator inspection training
Contractor alignment
Monthly KPI reporting
RCA enforcement
Management review

7. Mining asset segmentation and lubrication risk controls

Mining contains two large lubrication populations: mobile equipment and fixed plant. Khash should manage them differently but under one ICML 55 governance system.

7.1 Haul trucks

Typical lubricated systems:

Diesel engine
Transmission
Torque converter
Final drives
Differentials
Wheel ends
Hydraulic system
Steering system
Brake cooling system
Suspension cylinders
Hoist cylinders
Fan drives
Alternator and accessory bearings
Automatic lubrication system
Steering linkages
Pins and bushings
Dump-body pivots

Dominant lubrication risks:

Dust ingestion
fuel dilution
soot loading
coolant ingress
water contamination
hydraulic particle contamination
high payload shock loading
brake and wheel-end heat
final-drive wear debris
overextended oil drains
contaminated field top-up
incorrect compartment lubricant
auto-lube injector failure
missed pins and bushings
unsafe manual lubrication access

Caterpillar’s fluid-analysis guidance identifies engines, transmissions, hydraulics, final drives, differentials, gearboxes, and compressors as lubricated systems where oil sampling can detect wear metals, oil condition, particles, and contaminants such as water, fuel, glycol, and dirt. (cat.com) Khash should use that compartment-based logic across the haul fleet, regardless of OEM brand.

Khash’s haul-truck controls

Build a compartment matrix for every truck model.
Assign test slates by compartment, not one generic oil-analysis package.
Require hot, live, consistent samples from engines, transmissions, hydraulics, final drives, differentials, and wheel ends.
Use clean sampling hardware and flush procedures.
Track oil-analysis severity by compartment and truck ID.
Apply condition-based drain intervals only after trend stability is proven.
Use filtered top-up through dedicated connections.
Control field service truck cleanliness.
Audit auto-lube system delivery at every major PM.
Verify injector movement, pressure response, reservoir level, blocked lines, broken lines, and grease purge.
Use grease-volume calculations for manual points not included in auto-lube.
Track lubricant consumption per truck, per engine hour, and per compartment.
Investigate abnormal top-up, not merely refill.
Convert oil-analysis red alarms into work orders with due dates.
Link final-drive and wheel-end alarms to inspection windows before catastrophic failure.

7.2 Hydraulic shovels, electric rope shovels, and excavators

Typical lubricated systems:

Hydraulic pumps
Hydraulic motors
Main hydraulic tank
Swing gearboxes
Propel gearboxes
Hoist, crowd, and swing machinery
Open gears and racks
Slew bearings
Boom, stick, and bucket pins
Wire ropes
Gear reducers
Electric motor bearings
Compressor systems
Centralized lubrication systems

Dominant lubrication risks:

Hydraulic fluid contamination
water ingress
pump and valve wear
high-pressure leakage
pin and bushing wear
open-gear contamination
grease starvation
broken grease lines
high shock loading
poor access
large reservoir contamination during maintenance
high downtime consequence

Khash’s controls

Set hydraulic ISO cleanliness targets by valve and pump sensitivity.
Install high-efficiency breathers on hydraulic reservoirs.
Install offline filtration loops on large hydraulic tanks.
Use pressure, return, and kidney-loop filtration with differential-pressure monitoring.
Fit representative sample ports.
Use online particle counters on the most critical hydraulic systems.
Use water sensors where humidity or washdown risk is high.
Standardize hydraulic oil analysis for particle count, water, viscosity, acid number, elemental metals, FTIR oxidation, and additive health.
Sample swing and propel gearboxes regularly for ferrous debris and viscosity.
Inspect open gears for lubricant film, contamination paste, pitting, scoring, and tooth-contact pattern.
Verify centralized lubrication delivery to every pin, bushing, bearing, and open-gear spray point.
Protect grease lines from rock damage, heat, abrasion, and poor routing.
Use ultrasound or temperature trending where manual greasing remains.
Conduct RCA on repeated pin/bushing, hydraulic pump, or swing-drive failures.

7.3 Drilling equipment

Typical assets:

Rotary blasthole drills
Down-the-hole drills
Top hammer drills
Jumbo drills
Roof bolters
Compressors
Hydraulic systems
Feed chains
Rotation gearboxes
Drill-head bearings
Rock-drill lubrication systems
Centralized grease systems
Water injection systems

Dominant lubrication risks:

Rock dust
water spray
compressed-air oil carryover
hydraulic contamination
vibration
shock loading
feed-chain wear
incorrect rock-drill oil
emulsification
neglected small gearboxes
dust-contaminated grease fittings

Khash’s controls

Define correct rock-drill oil by OEM, air pressure, temperature, water exposure, and antiwear requirement.
Monitor compressor lubricant condition and oil carryover.
Filter hydraulic oil before top-up.
Install desiccant breathers on hydraulic reservoirs.
Use sealed grease-transfer methods.
Clean fittings before greasing.
Inspect feed chains and rotation heads on route.
Track drill penetration performance against lubrication abnormalities where useful.
Sample hydraulic, compressor, rotation gearbox, and feed gearbox oils by duty severity.
Include drill auto-lube systems in the same inspection rigor as haul trucks and shovels.

7.4 Underground LHDs, trucks, bolters, and utility vehicles

Typical lubricated systems:

Diesel engine or electric drive systems
Transmissions
Axles
differentials
final drives
hydraulic systems
brake systems
articulation joints
boom pins
bucket pins
steering joints
central lubrication systems
compressors
cooling fans

Dominant lubrication risks:

high humidity
water spray
mud and slurry
restricted access
poor visibility
heat
ventilation constraints
contaminated underground top-up
lubricant transport contamination
service bay contamination
safety exposure during manual lubrication

Khash’s controls

Create underground-specific lubricant storage and transfer standards.
Use sealed, labeled, dedicated containers underground.
Minimize open oil transfer.
Use filtered bulk dispensing in underground service bays.
Install protected grease manifolds where safe access is poor.
Use automatic lubrication for articulation, pins, and bushings where technically justified.
Track auto-lube faults daily.
Use corrosion-resistant fittings and protected lines.
Increase water testing for humid and wet zones.
Adjust sampling frequency for assets operating in wet headings.
Use condition-based replacement for hydraulic and drivetrain oils only when contamination is controlled.
Audit contractor service practices underground.

7.5 Crushers and screens

Typical lubricated assets:

Gyratory crushers
Jaw crushers
Cone crushers
Sizers
Roll crushers
Impact crushers
Vibrating screens
Apron feeders
Grizzly feeders
Hydraulic adjustment systems
Lubrication power units
Gearboxes
Bearings
Eccentric assemblies

Dominant lubrication risks:

high shock loading
rock dust
silica contamination
vibration
misalignment
high bearing load
lubricant starvation
wrong viscosity
oil foaming
high temperature
water ingress during washdown
contamination after liner changes
inadequate filtration
poor sample points

Khash’s controls

Treat primary crusher lube systems as A-class assets.
Install live-zone sample ports.
Install desiccant breathers on reservoirs.
Use offline filtration.
Track filter differential pressure.
Monitor oil temperature and pressure alarms.
Use oil analysis for viscosity, water, ISO particle count, acid number, oxidation, ferrous debris, PQ index, and elemental metals.
Inspect magnetic plugs and filter debris after abnormal vibration or oil-analysis alarms.
Use maintenance contamination control during liner changes.
Define flushing criteria after major rebuilds.
Review oil cooler leaks where water is detected.
Use grease selected for high shock load and dust exposure on grease-lubricated bearings.
Use ultrasound-assisted greasing where bearing speed makes overgreasing a risk.

7.6 Conveyors and material handling systems

Typical lubricated systems:

Conveyor gear reducers
Head pulley bearings
Tail pulley bearings
bend pulley bearings
take-up bearings
idlers
apron feeders
belt feeders
chain conveyors
stackers and reclaimers
tripper drives
slew drives
winches
brake systems
couplings

Dominant lubrication risks:

dust
water
outdoor exposure
inaccessible bearings
long routes
missed points
overgreasing
undergreasing
incorrect grease
gearbox breathing contamination
misalignment
leaking reducers
poor oil-level control
lubricant cross-contamination

Khash’s controls

Classify conveyor components by criticality and accessibility.
Use automatic lubrication on remote or unsafe bearings where justified.
Calculate grease volumes and intervals for pulley bearings.
Use grease fittings with caps and clear labels.
Use route-based inspection of purge condition, bearing temperature, noise, and seal condition.
Install desiccant breathers and sight glasses on critical gear reducers.
Use quick-connect ports for filtered top-up.
Replace vague “check gearbox oil” PMs with specific level, condition, leak, breather, and top-up criteria.
Track conveyor reducer oil consumption.
Use condition-based oil changes for critical reducers.
Use vibration and thermography with lubrication data to identify lubrication-related bearing distress.

7.7 Grinding mills, HPGRs, and mineral-processing drives

Typical assets:

SAG mills
ball mills
rod mills
HPGRs
mill girth gears
pinion bearings
trunnion bearings
slide-shoe bearings
main gearboxes
inching drives
lube oil systems
hydraulic jacking systems
lubrication spray systems
flotation agitators
thickeners
clarifiers
slurry pumps
process pumps
gear reducers

Dominant lubrication risks:

large oil volumes
water ingress
slurry contamination
gear-tooth distress
high load
slow speed
shock loading
bearing film loss
poor spray pattern
filter bypass
cooler leaks
oil aeration
high downtime consequence

Khash’s controls

Treat SAG/ball mill lube systems as top-priority lubrication assets.
Use high-viscosity EP or synthetic gear oils where appropriate and OEM-approved.
Monitor open-gear lubricant film on girth gears.
Verify spray nozzle coverage, spray timing, pumpability, and tooth-contact coverage.
Monitor oil pressure, flow, temperature, and filter differential pressure.
Install offline filtration and dehydration for large reservoirs.
Use live-zone sample ports before filters for wear diagnosis.
Use downstream sample ports to verify filtration effectiveness.
Analyze oil for viscosity, acid number, oxidation, water, particle count, elemental metals, PQ, ferrous debris, foam, air release, and demulsibility where water is credible.
Inspect magnetic plugs and filter debris.
Tie mill vibration, temperature, oil-analysis, and shutdown inspection findings into one reliability review.
Develop startup lubrication verification procedures for mill bearings and gears.
Define emergency action for low oil pressure, high oil temperature, or water ingress.

7.8 Pumps, dewatering, and slurry systems

Typical assets:

Slurry pumps
centrifugal pumps
vertical turbine pumps
dewatering pumps
gland-water systems
gearbox-driven pumps
bearing housings
electric motors
hydraulic power packs
process agitators

Dominant lubrication risks:

water ingress
slurry contamination
seal failure
bearing housing contamination
overgreasing motor bearings
underlubrication in remote pump stations
misalignment
cavitation-related vibration
high humidity
poor route access

Khash’s controls

Use bearing isolators or upgraded seals where ingress is chronic.
Use sight glasses and proper bearing housing oil levels.
Use oil mist or centralized systems where justified.
Set motor greasing volumes by bearing type and speed.
Use ultrasound-assisted greasing on motors and high-speed pump bearings.
Inspect bearing housings for water, foam, milkiness, darkening, and leakage.
Use oil analysis on critical pump bearing housings and gearboxes.
Combine vibration, temperature, and lubricant-inspection data.
Conduct RCA on repeat bearing failures rather than repeatedly replacing bearings.

7.9 Ventilation fans, compressors, and utilities

Typical assets:

Main mine ventilation fans
booster fans
compressors
blowers
cooling systems
generators
substations with auxiliary equipment
gearboxes
motor bearings
fan bearings
coupling systems

Dominant lubrication risks:

high criticality
high speed
bearing overheating
overgreasing
poor air release
oil oxidation
varnish in compressor systems
moisture ingress
poor shutdown preservation
difficult access

Khash’s controls

Treat ventilation fans as safety-critical lubrication assets.
Use engineered greasing procedures for motor and fan bearings.
Avoid overgreasing through calculated volumes and ultrasound feedback.
Use oil analysis for compressors, including viscosity, oxidation, acid number, water, particles, and wear metals.
Monitor compressor varnish/deposit risk where oil chemistry and temperature make it credible.
Control filter changes by differential pressure and oil condition, not only calendar time.
Use vibration and thermography with lubrication inspections.
Include emergency fan assets in lubrication readiness audits.

8. Lubricant selection and consolidation strategy

Mining operations often accumulate excessive lubricant SKUs due to mixed fleets, multiple OEMs, contractor equipment, legacy products, and emergency substitutions. Khash should rationalize the lubricant list carefully. The goal is controlled simplification, not blind consolidation.

8.1 Major lubricant families in mining

Lubricant family	Typical applications
Heavy-duty diesel engine oils	Haul trucks, loaders, drills, dozers, generators
Transmission and drivetrain fluids	Powershift transmissions, torque converters, axles
Final-drive and differential oils	Haul trucks, loaders, dozers, graders
Hydraulic oils	Shovels, excavators, drills, LHDs, fixed-plant hydraulics
Fire-resistant hydraulic fluids	High-risk underground or hot-area systems where specified
EP gear oils	Crushers, conveyors, mills, pumps, gear reducers
Synthetic gear oils	High-load, high-temperature, long-drain, or energy-critical gearboxes
Open-gear lubricants	Shovel swing racks, draglines, mills, large open gears
Heavy-duty EP greases	Pins, bushings, bearings, undercarriage, conveyors
Calcium sulfonate complex greases	Wet, shock-loaded, corrosion-prone points
Moly greases	Slow-speed, high-load pins and bushings where OEM-approved
Electric motor greases	Motors, fans, pumps, compressors
Compressor oils	Plant air, drill compressors, instrument air
Rock-drill oils	Pneumatic rock drills and drills requiring specific mist/air-line lubrication
Wire-rope lubricants	Shovels, draglines, hoists, winches
Chain lubricants	Feeders, conveyors, chains
Specialty lubricants	Couplings, anti-seize, assembly lubricants, sliding pads

8.2 Oil selection parameters

For each oil application, Khash should define:

OEM specification
viscosity grade
viscosity at actual operating temperature
base oil type
oxidation stability
shear stability
load-carrying capacity
antiwear or EP chemistry
wet brake compatibility where applicable
frictional requirement for transmissions
seal and elastomer compatibility
yellow-metal compatibility
demulsibility
air release
foam tendency
filterability
cleanliness target
water tolerance
cold-start pumpability
high-temperature stability
compatibility with existing oil
drain interval basis
sample interval
approved alternate

8.3 Grease selection parameters

For grease applications, Khash should define:

NLGI grade
base-oil viscosity
thickener type
dropping point
mechanical stability
water washout resistance
corrosion protection
EP and antiwear performance
solid lubricant content, where required
pumpability through auto-lube systems
temperature range
bearing speed factor
shock-load capacity
compatibility with existing grease
purge requirement
environmental exposure
application method
grease-line length and diameter
injector compatibility

8.4 Consolidation rules

Khash should not consolidate:

wet brake fluids into generic gear oils
hydraulic oils without pump, valve, seal, and filterability review
final-drive oils without OEM and frictional compatibility review
rock-drill oils into ordinary engine or hydraulic oils
open-gear lubricants into standard grease
electric motor greases into heavy moly pin grease
high-speed bearing grease into slow-speed bushing grease
underground fire-risk fluids without EHS and OEM review
biodegradable or environmentally acceptable lubricants without water-stability and OEM review

The final deliverable should be an Approved Lubricant List with product code, application class, OEM approval, viscosity or NLGI grade, approved alternate, storage code, transfer code, changeover restrictions, and management-of-change rules.

9. Contamination-control strategy for mining

Contamination control is the heart of mining lubrication. Khash should design contamination control around the full lubricant lifecycle:

Supplier delivery
Mine warehouse
Bulk tanks
Field lube trucks
Service bays
Underground lube bays
Transfer containers
Machine fill points
Breathers and seals
Maintenance rebuilds
Sampling
Disposal and reclamation

9.1 Particle contamination

Mining dust contains abrasive rock fines and silica-rich particles that are especially destructive in hydraulic systems, engines, gearboxes, bearings, and final drives. Gulf’s 2026 mining article identifies abrasive dust and debris from blasting and haul roads as contamination sources that clog filters and accelerate wear. (gulfoilltd.com)

Khash should implement:

Sealed bulk tanks
Tank breathers
Bulk tank filtration loops
Filtered dispensing
Dedicated transfer hoses
Dust-proof quick connects
No open buckets or funnels
Sealed grease storage
Grease fitting caps
Field lube truck filtration
Clean hose-end storage
Fill-point cleaning procedure
Filter carts for critical top-ups
Maintenance cleanliness controls during component replacement
Post-maintenance flushing and baseline sampling

9.2 Water contamination

Water enters mining equipment through washdown, rain, condensation, wet haul roads, process water, slurry, underground humidity, cooler leaks, and poor drum storage. Gulf notes that water from washdown, wet ground, rainwater infiltration, and process use can wash away lubricant films, increase corrosion, and contribute to downtime. (gulfoilltd.com)

Khash should implement:

Desiccant breathers
sealed hatches
bottom drains
BS&W bowls
water sensors
crackle testing
Karl Fischer testing for critical systems
vacuum dehydration for large reservoirs
centrifuges or coalescers where appropriate
heat-exchanger leak checks
covered oil storage
underground humidity controls where practical
water-ingress RCA after repeated alarms

9.3 Cleanliness targets

Final targets must be set by OEM requirements, component sensitivity, risk, and baseline capability. However, Khash can use the following as initial engineering targets:

Asset class	Suggested initial cleanliness target
Servo/proportional hydraulic systems	ISO 15/13/10 or cleaner
Critical mobile hydraulics	ISO 16/14/11 to 17/15/12
General mobile hydraulics	ISO 18/16/13
Shovel hydraulic systems	ISO 16/14/11 to 17/15/12
Crusher lube systems	ISO 17/15/12 to 18/16/13
Mill lube systems	ISO 17/15/12 to 18/16/13
Critical gearboxes	ISO 18/16/13
Conveyor reducers	ISO 19/17/14
Compressors	ISO 16/14/11 to 17/15/12
Engines	OEM soot, particle, contamination, and wear limits rather than ISO alone
Open gears and pins	Film control, purge condition, wear debris, and contamination-paste inspection more important than ISO particle count

10. Machine lubrication readiness

Khash should treat missing hardware as a program defect. A mine cannot perform precision lubrication on equipment that lacks the correct sample points, breathers, drains, safe access, or filtration connections.

10.1 Required oil-system hardware

For critical oil-lubricated assets:

Desiccant breathers
Hybrid breathers for high-dust and high-humidity zones
Expansion chambers where thermal breathing is severe
Quick-connect fill ports
Quick-connect filtration ports
Live-zone sample ports
Return-line sample ports
Drain valves
magnetic drain plugs
magnetic debris collectors
sight glasses
columnar level gauges
BS&W bowls
filter differential-pressure indicators
offline filtration loops
online particle counters for critical hydraulics
moisture sensors
temperature sensors
pressure sensors
guarded sample access points
spill containment points

10.2 Required grease-system hardware

For grease-lubricated points:

Protected grease fittings
fitting caps
remote grease manifolds
grease relief fittings
purge paths
automatic lubrication pumps
injectors or metering valves
pressure gauges
low-level alarms
blocked-line detection
broken-line detection
injector-cycle confirmation
protected grease lines
color-coded fittings
QR or barcode point labels
dedicated grease guns by product
calibrated grease guns

10.3 Field lube truck readiness

The field lube truck is often the largest contamination vector in a mine. Khash should specify:

Dedicated compartments by lubricant
tank breathers
tank filtration
kidney-loop filtration
dispensing filters
sealed hose reels
clean dry couplers
hose-end caps
sample points on truck tanks
spill containment
product labeling
color and shape coding
onboard particle-count verification for critical fluids
water-detection checks
grease storage protection
used-oil segregation
maintenance schedule for the lube truck itself
cleanliness audit checklist

11. Oil analysis, grease analysis, and condition monitoring

Oil analysis in mining must be compartment-specific. A haul truck engine, final drive, hydraulic tank, transmission, and wheel end do not have the same failure modes, alarm limits, or sampling intervals.

11.1 Test slate by mining asset class

Asset / compartment	Routine tests	Exception / advanced tests
Diesel engines	viscosity, soot, oxidation, nitration, sulfation, TBN/TAN as applicable, fuel dilution, water, glycol, wear metals, contaminants	ferrography, particle quantifier, coolant leak confirmation, fuel dilution confirmation
Hydraulic systems	ISO particle count, water, viscosity, acid number, FTIR, elemental metals, additive trend	patch microscopy, varnish potential, filter debris, servo-valve deposit analysis
Transmissions	viscosity, oxidation, water, particle count, wear metals, additive trend	frictional property review, ferrography, clutch debris analysis
Final drives/differentials	viscosity, water, particle count, PQ index, ferrous debris, elemental metals, oxidation	analytical ferrography, magnetic plug debris analysis
Wheel ends	viscosity, water, particle count, ferrous debris, wear metals	ferrography, inspection after abnormal temperature
Crusher lube systems	viscosity, water, particle count, acid number, oxidation, wear metals, PQ	ferrography, filter debris, foam/air release
Mill lube systems	viscosity, water, particle count, acid number, oxidation, ferrous debris, PQ, additive trend	demulsibility, foam, air release, ferrography
Conveyor gearboxes	viscosity, water, particle count, wear metals, oxidation	ferrography for abnormal wear
Compressors	viscosity, acid number, oxidation, water, particles, wear metals	varnish/deposit analysis, RULER/MPC where applicable
Grease-lubricated bearings	grease condition, contamination, wear debris, water, oxidation	worked penetration, FTIR, microscopy, thickener condition

11.2 Sampling frequency

Criticality	Example assets	Frequency
A-class mobile compartments	haul truck engines, transmissions, final drives, hydraulics, wheel ends	every PM, every 250–500 hours, or more frequently during instability
A-class fixed plant	primary crusher, mill lube systems, critical conveyors, ventilation fans	monthly or biweekly if risk is high
B-class assets	secondary crushers, support fleet, general hydraulic systems, key pumps	monthly to quarterly
C-class assets	minor reducers, low-criticality small equipment	semiannual, annual, or exception-based
Post-maintenance	rebuilt engines, gearboxes, hydraulic systems, final drives	baseline sample after commissioning and follow-up after early operation
Abnormal condition	water, overheating, noise, high vibration, filter bypass, visible debris	immediate confirmation sample

11.3 Oil-analysis workflow

Khash should enforce the following closed-loop process:

Sample collected from correct point.
Sample labeled with asset, compartment, lubricant, hours, top-up, and condition.
Lab performs correct test slate.
Alarm limits compare to compartment-specific baseline.
Report is reviewed by trained personnel.
Action is assigned: monitor, resample, inspect, filter, dehydrate, change oil, repair, or RCA.
Work order is created for corrective action.
Corrective action is closed with evidence.
Follow-up sample verifies effectiveness.
Failure mode is coded for KPI analysis.

12. Automatic lubrication systems in mining

Automatic lubrication is often essential in mining because many lubrication points are dangerous, inaccessible, numerous, or exposed to severe contamination. SKF describes automatic lubrication systems as a way to provide precise lubricant replenishment to individual machines or complete plants; SKF also notes that automatic lubrication for dump trucks can enable round-the-clock operation while minimizing human-error risk. (skf.com)

Khash should not install automatic lubrication and assume the problem is solved. Auto-lube systems must themselves be maintained, inspected, and audited.

12.1 Auto-lube applications

High-value applications:

Haul truck chassis points
shovel pins and bushings
excavator boom/stick/bucket pins
LHD articulation joints
underground truck chassis points
conveyor pulley bearings
crushers and feeders
dragline and shovel open gears
stacker/reclaimer slewing systems
mill open gears
remote pump stations
mobile equipment operating long shifts

12.2 Auto-lube failure modes

Khash should train teams to look for:

empty reservoir
wrong grease
grease too stiff for temperature
grease separation
blocked injector
blocked line
broken line
leaking line
failed pump
failed controller
damaged wiring
pressure switch failure
low battery or power issue
grease not reaching bearing
grease purging at manifold instead of component
crushed line
wrong injector size
excessive lubricant consumption
no physical purge despite normal controller signal

12.3 Auto-lube audit procedure

For each system:

Verify lubricant product.
Inspect reservoir level.
Check pump operation.
Review alarm history.
Confirm injector cycling.
Check system pressure.
Inspect every line.
Confirm delivery at sample points or purge points.
Check for broken or crushed lines.
Verify correct injector size.
Inspect fittings and manifolds.
Compare lubricant consumption to expected consumption.
Create corrective work orders for defects.

13. Precision lubrication task engineering

Khash should replace all vague PM instructions with auditable procedures.

13.1 Poor PM language to eliminate

“Grease truck.”
“Lubricate shovel.”
“Check oil.”
“Top up if required.”
“Service gearbox.”
“Change hydraulic oil annually.”
“Use standard grease.”
“Inspect crusher lube system.”

13.2 Required structure for a grease task

Each grease task should define:

asset ID
lubrication point ID
component type
grease product code
grease quantity in grams
grease gun strokes after calibration
auto-lube or manual method
frequency by hours, cycles, or condition
cleaning requirement before application
running or stopped condition
purge requirement
ultrasound requirement where applicable
access requirement
safety controls
abnormal signs
corrective action triggers
documentation requirement

13.3 Required structure for oil top-up

Each top-up task should define:

compartment
lubricant code
target level
operating condition for level check
top-up volume
maximum allowable top-up before leak investigation
filtered transfer requirement
connection point
transfer container or lube truck compartment
contamination-control steps
sample requirement after abnormal top-up
CMMS entry requirement

13.4 Required structure for oil change

Each oil-change task should define:

pre-change sample
drain method
drain temperature condition
low-point drain requirement
inspection of magnetic plug
reservoir or housing cleaning requirement
filter replacement
breather replacement
flushing criteria
filtered refill
post-fill sample
baseline sample record
restart inspection
used-oil segregation
follow-up sample interval

14. Model procedure: haul truck final drive lubrication

Purpose

Prevent final-drive failure by controlling lubricant condition, contamination, temperature, wear debris, and correct fill level.

Routine inspection

Check for external leakage.
Inspect breather condition.
Inspect final-drive temperature trend where available.
Check magnetic plug at planned interval.
Verify no unfiltered top-up occurred.
Record abnormal noise, temperature, vibration, or leakage.

Oil sampling

Sample at defined service interval.
Use a clean, consistent sampling point.
Record truck hours, compartment hours, lubricant hours, top-up volume, and recent maintenance.
Test viscosity, water, particle count, iron, PQ index, elemental wear metals, oxidation, and additive condition.
Compare to truck-specific and compartment-specific trend.

Corrective actions

High iron or PQ: inspect magnetic plug, evaluate gear/bearing distress, resample, and schedule inspection.
High water: inspect seals, breather, washdown exposure, and storage/transfer practices.
High particle count: inspect fill method, breather, seals, and maintenance contamination.
Viscosity low: check wrong oil addition, shear, fuel/solvent contamination, or overheating.
Viscosity high: check oxidation, contamination, wrong oil, or thermal stress.
Repeated top-up: investigate leak rather than continue refilling.

RCA triggers

repeated high ferrous debris
abnormal temperature
repeated water alarms
repeated seal failures
final-drive replacement before expected life
catastrophic failure
wrong lubricant addition
extended drain without supporting oil-analysis data

15. Model procedure: primary crusher lubrication system

Purpose

Protect crusher bearings, eccentric assemblies, gears, and hydraulic/lube systems from contamination, lubricant degradation, and wear.

Daily operator checks

Check lube oil level.
Check oil supply pressure.
Check oil return temperature.
Check filter differential pressure.
Check cooler performance.
Inspect for leaks.
Inspect breather condition.
Observe sight glass for foam, dark oil, water haze, or debris.
Record alarms.

Weekly lubrication technician task

Inspect breather and replace if saturated.
Check offline filtration operation.
Inspect sample port and quick-connect condition.
Review top-up volume.
Drain water from low point if detected.
Inspect magnetic debris collector if installed.
Verify filter bypass indicators.
Confirm no open-container top-up occurred.

Monthly condition-monitoring task

Draw live-zone sample under operating conditions.
Test viscosity, water, ISO particle count, acid number, oxidation, elemental metals, PQ, and ferrous debris.
Compare to baseline and rate-of-change limits.
Generate corrective work orders for contamination, water, viscosity shift, or wear alarms.

Corrective action triggers

particle count above target
water above target
oil temperature above limit
filter bypass
rapid iron/PQ increase
foaming or air entrainment
repeated oil top-up
abnormal vibration
visible debris
post-maintenance contamination after liner or component replacement

16. Model procedure: shovel hydraulic system cleanliness control

Purpose

Protect hydraulic pumps, valves, cylinders, motors, and servo/proportional components from contamination-induced wear and instability.

Controls

Keep reservoir sealed.
Use desiccant breather.
Filter all new oil into bulk storage.
Filter all top-up oil into machine.
Maintain pressure and return filters.
Run kidney-loop filtration during service windows.
Sample from live-zone port.
Use ISO cleanliness alarm limits.
Track water and particle trends.
Investigate repeated filter plugging.
Control maintenance cleanliness during hose, pump, cylinder, and valve replacement.

Corrective action triggers

particle count above target
water alarm
repeated filter differential-pressure alarms
pump noise
valve sticking
slow hydraulic response
cylinder scoring
overheated oil
oil darkening or oxidation
foaming
repeated top-up

17. Storage, handling, and field service design

17.1 Main lubricant warehouse

The main mine lube warehouse should include:

dust-controlled enclosed storage
bunded bulk tanks
desiccant breathers
dedicated filtration loops
dedicated dispensing lines
color-coded lubricant identification
shape-coded transfer system where possible
sealed drums and totes
FIFO inventory control
shelf-life control
receiving inspection
quarantine area
sample bottle storage
grease-gun storage
filter storage
spill kits
used-oil segregation
SDS access
approved product list display
lubricant issue log

17.2 Field service truck standard

Each lube truck should be treated as a mobile lube room. It should have:

dedicated tanks
dedicated pumps
tank breathers
tank sample ports
filtration on dispense
sealed hose reels
caps on couplers
product labels
spill containment
hose cleanliness checks
water drain points
regular particle-count checks
tank-cleaning schedule
calibrated metering
lubricant transfer log
inspection checklist

17.3 Underground service bay standard

Underground lubrication areas should include:

sealed lubricant storage
dust and water protection
filtered dispensing
safe lighting
clear product labels
spill containment
used-oil collection
dedicated grease storage
transfer containers with lids
no open funnels
washdown separation from lubricant storage
fire and ventilation controls
contractor compliance checks

18. CMMS, lubrication software, and route governance

Khash should integrate the lubrication program into the CMMS/EAM and a lubrication-specific platform such as LubePM. Noria’s Engineering Design page describes LubePM as the central delivery platform for procedures, asset data, recommendations, implementation management, approvals, and metrics during Lubrication Program Development. (Noria Corporation)

18.1 Required lubrication master data

Each lubrication point should have:

mine area
asset ID
component ID
point ID
lubricant code
volume
frequency
application method
route assignment
task duration
safety requirement
sample point
contamination target
criticality
procedure link
abnormality codes
corrective action trigger
photo or diagram
responsible role

18.2 Route design principles

For mining, routes should be designed by:

geography
safety access
equipment availability
shift pattern
clean versus dirty tasks
surface versus underground location
mobile versus fixed plant
shutdown versus running condition
skill requirement
sampling priority
lubrication product family

Khash should avoid combining clean oil sampling with dirty greasing tasks unless contamination controls are strict. Hydraulic sampling after greasing a dusty conveyor route is a common contamination-control failure.

18.3 Work management integration

The CMMS should manage:

lubrication PMs
oil sampling work orders
filter changes
breather replacements
auto-lube inspections
abnormal oil-analysis follow-up
contamination corrective actions
leak repair
hardware modifications
lube-room audits
lube truck inspections
underground bay audits
RCA actions
shutdown lubrication work
training tasks

19. Training and competency program

Khash should build a role-based competency matrix. Mining lubrication is execution-sensitive; classroom training alone is insufficient.

Role	Required competency
Mine general manager	lubrication business case, production risk, KPI review, funding decisions
Maintenance manager	PM compliance, backlog, field execution, contractor control
Reliability engineer	oil analysis, contamination control, RCA, criticality, lifecycle cost
Mobile maintenance supervisor	compartment-based lubrication, field service control, lube truck audits
Fixed plant supervisor	crushers, conveyors, mills, pumps, filtration, oil analysis
Lube technician	precision greasing, clean transfer, sampling, filtration, auto-lube inspection
Field service technician	lube truck cleanliness, compartment filling, sampling, spill control
Operators	daily inspections, auto-lube alarms, leaks, abnormal temperature/noise
Warehouse staff	lubricant receipt, storage, FIFO, contamination exclusion, approved product list
Underground crews	sealed transfer, wet-zone contamination control, auto-lube checks
Contractors	site lubrication standards, approved lubricants, sampling discipline
EHS	spills, waste oil, fire-risk fluids, underground lubricant handling, manual-lube safety

Training modules should include:

lubrication fundamentals
viscosity and film formation
grease selection
grease-gun calibration
calculated greasing
auto-lube troubleshooting
oil sampling
contamination control
hydraulic cleanliness
field lube truck cleanliness
oil-analysis interpretation
final-drive and wheel-end failure modes
crusher and mill lubrication
open-gear inspection
lubricant storage and handling
spill response
lubrication RCA
CMMS/LubePM route execution

20. Lubrication-focused RCA for mining

Khash should create mandatory RCA triggers and a failure taxonomy.

20.1 Mandatory RCA triggers

catastrophic haul-truck engine failure
final-drive failure before expected life
repeated wheel-end failures
hydraulic pump or valve failures
repeated shovel pin and bushing failures
auto-lube system failure causing component damage
crusher lube system contamination event
mill bearing or gear distress
repeated conveyor pulley bearing failure
repeated gearbox high particle count
repeated water contamination
unapproved lubricant substitution
wrong compartment fill
filter bypass or collapse
field lube truck contamination
underground lube bay contamination
major lubricant spill
repeated overgreasing or undergreasing failure
failed oil-analysis response that led to breakdown

20.2 RCA taxonomy

Root causes should be classified under:

wrong lubricant
wrong viscosity
wrong grease
wrong additive chemistry
lubricant incompatibility
wrong compartment fill
overextended drain interval
underlubrication
overgreasing
blocked grease line
failed auto-lube pump
failed injector
broken grease line
dust ingress
water ingress
fuel dilution
coolant ingress
hydraulic cross-contamination
poor breathers
poor seals
contaminated top-up
dirty field lube truck
poor sampling
poor oil-analysis interpretation
no corrective work order
poor maintenance cleanliness
filter bypass
poor storage
contractor noncompliance
training gap
access limitation
design deficiency
operating overload
maintenance-induced contamination

21. Environmental, waste, and safety management

Mining lubrication has direct environmental and safety implications. Khash should include EHS in the lubrication-management system, not treat it as a separate compliance topic.

21.1 Environmental controls

Track lubricant consumption by asset and area.
Track used-oil generation.
Segregate used oils by type.
Prevent mixing of hydraulic oil, engine oil, gear oil, and contaminated fluids.
Reclaim or filter large-volume oils where technically justified.
Dehydrate oil before disposal decisions.
Control spills during field servicing.
Use secondary containment for bulk tanks.
Audit lube trucks for leak control.
Reduce overgreasing.
Control grease purge near water pathways.
Manage underground oil storage and disposal separately.
Document disposal vendors and manifests.

21.2 Safety controls

Reduce manual lubrication exposure through automatic lubrication where justified.
Use remote grease points in hazardous areas.
Design safe sample points.
Avoid climbing, reaching, or working near moving belts for lubrication tasks.
Separate running inspections from shutdown lubrication.
Define lockout requirements.
Provide spill-response tools in service areas.
Train technicians on high-pressure grease injection hazards.
Control fire risk from lubricant leaks near hot surfaces.
Manage underground lubricant transport safely.

22. Mining lubrication KPIs

22.1 Leading indicators

lubrication PM compliance
route quality score
oil-analysis sample compliance
oil-analysis abnormality closure time
percentage of critical assets with sample ports
percentage of critical assets with correct breathers
percentage of assets meeting cleanliness targets
percentage of assets meeting water targets
filtered top-up compliance
lube truck cleanliness audit score
lube warehouse audit score
underground lube bay audit score
auto-lube system inspection compliance
auto-lube alarm closure time
grease-gun calibration compliance
lubricant cross-contamination incidents
wrong-fill incidents
filter-cart usage compliance
training completion by role
RCA completion rate
corrective action closure rate

22.2 Lagging indicators

haul truck lubrication-related downtime
shovel hydraulic failures
final-drive failures
wheel-end failures
crusher lubrication failures
conveyor bearing failures
mill lube system failures
hydraulic pump and valve failures
lubricant consumption per operating hour
grease consumption per operating hour
used-oil volume
emergency oil changes
component life versus expected life
maintenance cost from lubrication-related failures
production loss from lubrication-related downtime
MTBF of critical lubrication-sensitive assets

22.3 Business KPIs

Khash should also present financial indicators:

avoided downtime value
reduction in component rebuild cost
lubricant consumption reduction
oil drain extension value
reduced disposal cost
reduction in emergency maintenance
increased equipment availability
improved planned-maintenance ratio
avoided safety exposure hours from manual lubrication

23. Management review and governance

ICML 55 implementation must be governed. Khash should create a monthly tactical review and quarterly strategic review.

Monthly lubrication tactical review

Participants:

maintenance supervisors
reliability engineers
lube technicians
oil-analysis coordinator
planner
warehouse representative
contractor representative
OEM support where relevant

Agenda:

overdue lubrication PMs
oil-analysis red alarms
contamination targets
auto-lube defects
lube truck audit results
wrong-fill incidents
lubricant consumption abnormalities
open corrective actions
upcoming shutdown lubrication tasks
training gaps
near misses and safety observations

Quarterly management review

Participants:

mine manager
maintenance manager
reliability manager
operations manager
supply chain
EHS
finance
Khash/Noria program lead

Agenda:

KPI dashboard
benefits captured
top ten lubrication risks
capital hardware needs
RCA trends
contractor performance
oil-analysis program performance
lube storage and handling audit trends
implementation roadmap progress
management-of-change log
business-case update
next-quarter priorities

24. Implementation roadmap for a mining operation

Stage 0 — Charter and scope

Deliverables:

lubrication-management policy
ICML 55 implementation scope
mine area boundaries
mobile fleet scope
fixed plant scope
underground scope, if applicable
sponsor and governance team
asset hierarchy source
baseline data request
EHS constraints
business objectives
communication plan

Stage 1 — Assessment

Deliverables:

ICML 55 / Ascend maturity assessment
mobile fleet lubrication audit
fixed plant lubrication audit
underground lubrication audit
lube warehouse audit
field lube truck audit
oil-analysis audit
auto-lube system audit
machine-readiness audit
lubricant inventory review
contractor lubrication audit
quick-win list
business case
implementation roadmap

Stage 2 — Engineering Design

Deliverables:

lubricated asset register
lubrication point master list
compartment matrix by mobile fleet model
fixed plant lubrication matrix
lubricant selection and consolidation plan
approved lubricant list
contamination-control standard
oil-analysis program manual
grease-analysis program for critical assets
sampling hardware design
filtration plan
lube truck design standard
underground lube bay standard
auto-lube inspection standard
crusher lubrication standard
conveyor lubrication standard
mill lubrication standard
hydraulic cleanliness standard
precision lubrication procedures
CMMS PM task library
lubrication route library
training matrix
KPI dashboard
RCA templates
hardware modification BOM

Stage 3 — Pilot implementation

Recommended pilot sequence:

Haul truck compartment-based oil analysis and filtered top-up
Field lube truck cleanliness upgrade
Primary crusher lubrication system
Shovel hydraulic and auto-lube systems
Critical conveyor drives and pulley bearings
Mill lube system and open-gear lubrication
Underground LHD/drill lubrication controls

Pilot deliverables:

installed sample ports and breathers
filtered transfer systems
clean field lube truck
revised PMs
trained technicians
oil-analysis baseline
auto-lube audit process
weekly progress review
KPI dashboard
documented savings opportunities

Stage 4 — Mine-wide rollout

Deliverables:

fleet-wide route deployment
fixed plant route deployment
underground deployment
lube warehouse upgrade
field lube truck upgrades
contractor standardization
CMMS integration
oil-analysis optimization
filtration expansion
hardware installation program
monthly KPI governance
RCA enforcement
management-of-change control

Stage 5 — Sustainment and ICML 55 readiness

Deliverables:

internal audit checklist
evidence records
management-review records
corrective-action register
KPI trend analysis
maturity reassessment
updated business case
ICML 55 conformance-readiness review
continuous-improvement backlog

25. Final consulting deliverable package for the mining industry

Khash’s final mining-industry ICML 55 implementation package should include:

Mining Lubrication Management Policy
ICML 55 Lubrication Management Plan
Surface Mobile Fleet Lubrication Standard
Underground Mobile Fleet Lubrication Standard
Fixed Plant Lubrication Standard
Lubricated Asset Register
Lubrication Point Master List
Mobile Fleet Compartment Matrix
Asset Criticality Ranking
Lubricant Selection and Consolidation Study
Approved Lubricant List
Contamination-Control Standard
Hydraulic Cleanliness Standard
Oil-Analysis Program Manual
Grease-Analysis Program for Critical Bearings
Sampling Port Installation Plan
Field Lube Truck Cleanliness Standard
Main Lube Warehouse Design
Underground Lube Bay Design
Filtered Transfer and Top-Up Standard
Auto-Lube System Inspection Standard
Haul Truck Lubrication Procedure Set
Shovel and Excavator Lubrication Procedure Set
Drill Lubrication Procedure Set
Crusher Lubrication Procedure Set
Conveyor Lubrication Procedure Set
Mill and Open-Gear Lubrication Procedure Set
Pump and Fan Lubrication Procedure Set
CMMS PM Task Library
Lubrication Route Library
Training and Competency Matrix
Lubrication RCA Templates
Lubricant Waste and Spill Control Procedure
Contractor Lubrication Compliance Standard
KPI Dashboard
Audit and Management Review Procedure
12–24 Month Implementation Roadmap

26. Mining-industry conclusion

For mining, Khash should implement ICML 55 as a field-execution reliability system. The largest risks are not only incorrect lubricant selection; they are contamination during field service, unfiltered top-up, poor lube truck cleanliness, weak oil-analysis response, missed auto-lube failures, dust and water ingress, wrong-fill events, unsafe access, and lack of closed-loop corrective action.

The highest-value technical priorities are:

haul truck compartment-based oil analysis, final-drive and wheel-end protection, hydraulic cleanliness, field lube truck contamination control, automatic lubrication verification, crusher and mill oil cleanliness, conveyor bearing precision greasing, open-gear film control, underground lubricant handling, contractor standardization, and lubrication-focused RCA.

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