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Lubrication Audit salient points
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Lubrication Audit
Sabita Mishra
Figure 2 Ref. AIMAN (Italian Association of Maintenance Engineers)and IRI (International Research Institute) in conjunction with SKF
Factors that Enable Lubrication Excellence
• People Preparedness. People are trained to modern lubrication skill standards and have certified competencies.
• Machine Preparedness. Machines have the necessary design and accouterments for quality inspection, lubrication, contamination control, oil sampling, etc.
• Precision Lubricants. Lubricants are correctly selected across key physical, chemical and performance properties, including base oil, viscosity, additives, film strength, oxidation stability, etc.
• Precision Lubrication. Lubrication procedures, frequencies, amounts, locations, etc., are precisely designed to achieve the reliability objectives.
• Oil Analysis. This includes optimal selection of the oil analysis lab, test slate, sampling frequency, alarm limits, troubleshooting rationale, etc.
Advantages of an Audit Identify duplication of lubricants Learn about your hidden lubrication costs Learn of potential safety and environmental issues Cost out the R.O.I. of automating some of your
critical production equipment Up-dated manuals as required for your current
automated lubrication system A customized plan to reduce cost, improve
productivity and safety, listing the opportunities in priority sequence
Equipment Survey Overview Develop an equipment list Routine inspection, equipment survey and visual inspection Identify and label equipments with equipment number and
description Equipment pictures Machine criticality assessment and operating parameters Identify lubricant sections from the OEM manual Technical data sheet for the selected lubricant for the equipment Selected lubricant MSDS Leakage reports Equipment temperature environment Oil sampling as required Lubrication inspection, top offs Reliability, mean time between failure data on the equipments Safety and operational hazards
Equipment Assessment
Lubricant Survey Overview Lubricant technical selection practices Lubricant application practices Oil analysis program practices Condition control practices Lubrication practices standardization (SOPs) Long term lubricant stability Lubrication survey and lubricant vendor selection Consolidate lubricants Set lubrication preventive maintenance (PM) frequency Root cause mapping and correction Program effectiveness reporting Program management and personal development
Lubricant Survey Overview (Cont’d)
Eliminate unnecessary oil changes Eliminate premature aging of lubricants Verifying, defining lubrication practices Verifying, defining re-lubrication activities like volumes,
frequencies, route sequences, machine upgrades etc. Purchase necessary lubrication equipment and tools Perform financial analysis review and establish a cost basis Reduce the number of lubricants in use and thereby reduce the
chances for mis-application and cross contamination Contamination control practices Upgrading knowledge level Develop a lubrication manual
Lubricant Selection Chart
Storage and Handling Survey Overview Lubricant delivery, storage and handling practices should be
followed Wasteful practices of products, duplication and excess inventory
should be eliminated Storage room temperature extremes should be avoided Fluctuating temperatures should be avoided Containers should not be stored in a humid environment First in first out (FIFO) system should be maintained such that
stocks are rotated properly All new drums should be filtered to an appropriate level. Use a
ß3=200 filters for lubricants below 150 cSt @ 40⁰C. Use ß6=100 filters for lubricants above 150 cSt @ 40⁰C
All drums and containers should be labeled and color coded and filtered drums should be labeled as such with the date of filtration.
Storage and Handling Survey Overview Filtered drums should be fit with an appropriate air filter to offer
air flow a path of least resistance allowing moisture and solid particulate to be captured prior to entering the drum.
When new oil is transferred to the top-up container, it should be transferred through a filter.
Oils should be stored in fluid storage racks Fluid storage racks should have oil and air filtration Proper dispensing containers should be used and stored in an
explosion proof cabinet Drums should be stored horizontally and covered to keep excess
moisture and dirt from settling on them. The openings (bungs) should be at 3 and 9 o’clock positions to minimize the amount of breathing in the drums
Drums should be fitted with dispensing taps with covers
Storage and Handling Practices
Storage and Handling Practices
Storage and Handling Practices
Safety Survey Overview MSDS are available and are reviewed Lock out procedures are followed Leakage control Spill response is in place Handling practices maintain a safe environment Lubrication equipment use is understood Sampling procedures are followed Training to ensure effectiveness and consistency Proper documentation and reports and manuals Proper fire hazard precautions are taken
Typical Checklist for an Audit
Typical Audit
Oil storage and dispensing:-Oils stored in fluid storage racksFluid storage racks have oil filtrationFluid storage racks have air filtrationUse of proper dispensing containersLubricant stocks properly rotatedBulk oil changes performed using a filter carts
Typical Audit
Oil sampling techniques:-Oil sampling procedures are documentedNew oil deliveries are sampledOil sampling ports are properly locatedProper oil sampling hardware is installedSample ports are properly labeledAutomatic monthly scheduled oil change in place
Typical Audit
Contaminant ingression control:-Proper air breathers are installed on equipmentAdditional offline filtration is installed on critical
equipmentLubrication ports are installedOff line filter carts are available and employed
regularlyWater stripping equipment is availableOffline filtration and oil filter changes are
performed on condition
Typical Audit
Oil analysis program:-Proper sampling frequencies are definedOil analysis test slates are well definedProper limits and targets are employed by
machine typeOil analysis data is effectively communicated
through the companyA process exists for troubleshooting exception
conditions
Typical Audit
Program Management:-Equipment criticality assessed and determinedRegular and condition based PMs in placeOil changes are based on condition Qualified and trained technicians dispense
lubricantsPM schedules are tracked in a databaseTrend charts showing sample/analysis
performance are publicly displayed
Continuous Improvement
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