RCL Process

Copyright 2010 Allied Reliability, Inc.

Reliability Centered Lubrication

Matt Spurlock, CMRPDirector of Lubrication ServicesAllied Reliability, Inc.


What would you do with more free

time?



What is Reliability Centered Lubrication?

a process used to determine the lubrication and contamination control requirements of any physical asset in its operating context allowing for means of condition monitoring thus having the ability to impact the overall asset health of the lubricated component.



RCL Process Map



Current State Analysis

1.0Work Management

2.0Work Execution

3.0Quality Assurance / Quality Control

4.0Program Management

5.0Lubrication Hardware

6.0Materials Management

7.0Human Resources

8.0Health, Safety & Environment

9.0Plant

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Work Management

Identification, documentation, planning & scheduling of tasks to meet the Lubrication requirements of the physical assets.

Work ExecutionPerformance and close out of scheduled Lubrication Work Orders.

Quality Assurance / Quality Control

Verification of Lubrication task effectiveness, predominantly using Oil Analysis. Includes feedback of results and improvement requirements into the appropriate systems.

Program Management

Exercise of the management function over the Lubrication Program, including Planning, Leading, Organizing, Deciding & Controlling.

Lubrication Hardware

Components of the physical assets to be Lubricated that facilitate carrying out Lubrication & QA/QC tasks, controlling Contamination, etc.

Materials ManagementPurchase, storage, issue, dispensing & optimization of suitable quantities and types of Lubricants and consumables.

Human Resources

Appropriate numbers of personnel with the necessary skills and competencies assigned to carry out the Lubrication tasks.

Health, Safety & Environment

Company and statutory Health, Safety & Environmental requirements, systems and procedures.

PlantPhysical assets with a requirement for Lubrication, for which the Lubrication Program is established.



Walkdown

Attributes, quantities and Current state

Indicate recommended

state

Contamination control



Program Design

Manpower Est Annual Lubricant UseActivity Hours/Yr Lubricant Ounces GallonsRegrease 220.48 ALBIDA GREASE EP 2 1031.97Oil Sampling 36 ALVANIA GREASE CGOil Change 1160 ALVANIA RL 2 14.04Visual Insp 2521.4 STAMINA GREASE RLS 2 73.14Total 3937.88 RETINAX TL 00 408

MOBIL DTE AA 16OMALA FLUID RL 220 100.5OMALA OIL HD 220 10OMALA OIL HD 320 15PULSALUBE 3TURBO T 68 400TELLUS 32 360TELLUS 46 1000

Calculations for grease quantities

and intervals

Lubricant recommendations

Modification assignments



Confirm Design/Project

Approval

Specialty and one off design work

Review data for consistency

Project implementation

approval

What ways does it fail to fulfill its functions?• Lubrication Related

• Incorrect Lubricant• Wrong viscosity• Incorrect additives

• Under lubricated• Over lubricated• Overextended oil change

• Contamination• Process Debris• Moisture• Environmental dirt

What causes each functional failure?

• Lack of training• Lack of complete job plans &

procedures• Lack of calculated re-lubrication

quantities and intervals• Inadequate contamination control

measures

What can be done to predict or prevent each failure?

• Oil Analysis/Grease Analysis• Contamination Control Measures• Calculated re-grease• Scheduled visual inspections• Lubrication procedures• Documented routing/planning



Implementation

(Lube Storage Design)

Lube route development

Sample Route

Creation

Remote Analysis

Training and Mentoring

Tech's





Lubrication Integrated into Asset Health



Other Lubrication Options

Lube Room Design

Parts Procurement

Support

Specific Lubricant

recommendation

Corporate Lubrication Program Standards

Development

Corporate Oil Analysis Program

Standards Development

General Lubrication and Contamination Control ConsultingOil Analysis



QUESTIONS?

Contact :

Matt Spurlock

Director of Lubrication Services

[email protected]

317-910-4443

mailto:[email protected]

Documents

RCL Process