ICML 55.1 – Requirements for the Optimized Lubrication of Mechanical Physical Assets (River Publishers Series in Energy Engineering and Systems) [1 ed.] 8770040354, 9788770040358

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ICML 55.1 – Requirements for the Optimized Lubrication of Mechanical Physical Assets

ICML 55.1 – Requirements for the Optimized Lubrication of Mechanical Physical Assets

The International Council for Machinery Lubrication (ICML), USA Senior Editor Kenneth E. Bannister

River Publishers

Published 2023 by River Publishers River Publishers

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ICML 55.1 – Requirements for the Optimized Lubrication of Mechanical Physical Assets / International Council on Machinery Lubrication (ICML) – Senior Editor: Kenneth E. Bannister. ©2023 River Publishers. All rights reserved. No part of this publication

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Contents

Foreword

ix

Disclosures

xi

Acknowledgments Editorial Board . . . . . . . . . . . . . . . . . . . . . . . . . . . Contributors/Reviewers . . . . . . . . . . . . . . . . . . . . . . . ICML Board of Directors . . . . . . . . . . . . . . . . . . . . . . List of Figures

xiii xiii xiii xiv xv

List of Abbreviations

xvii

Introduction Purpose . . . . . . . . . . . . . . . . . . . Relationship with other standards . . . . . . Target users of this standard . . . . . . . . . Benefits of this standard . . . . . . . . . . . Application of ICML 55.1 . . . . . . . . . . Integration with other management systems

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xxi xxi xxi xxii xxii xxiii xxiii

1 Scope 1.1 Lubrication Life Cycle Activities . . . . . . . . . . . . . . . 1.2 Living Document . . . . . . . . . . . . . . . . . . . . . . .

1 3 3

2 Reference Publications 2.1 Normative . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Informative . . . . . . . . . . . . . . . . . . . . . . . . . .

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3 Terms and Definitions

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4 Lubrication Management Objectives

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vi Contents 5 Lubrication Management Plan(s) 5.1 Job Task Skills, Training, and Competency . . . . . . . . . 5.2 Machine Lubrication and Condition Monitoring Readiness 5.2.1 Machine lubrication . . . . . . . . . . . . . . . . . 5.2.2 Condition monitoring readiness . . . . . . . . . . . 5.3 Lubrication System Design and Selection. . . . . . . . . . 5.3.1 System design . . . . . . . . . . . . . . . . . . . . 5.3.2 Supplier selection . . . . . . . . . . . . . . . . . . 5.4 Planned and Corrective Maintenance Lubrication Tasks . . 5.4.1 Health and safety . . . . . . . . . . . . . . . . . . 5.4.2 Planned maintenance task elements . . . . . . . . . 5.4.3 Corrective maintenance tasks elements . . . . . . . 5.5 Lubrication Support Facilities and Tools . . . . . . . . . . 5.5.1 Lubricant and lubrication support facilities and

infrastructure . . . . . . . . . . . . . . . . . . . . 5.5.2 Tools, instrumentation (automation), and

consumables . . . . . . . . . . . . . . . . . . . . . 5.6 Machine and Lubricant Inspection . . . . . . . . . . . . . 5.7 Condition Monitoring and Lubricant Analysis . . . . . . . 5.8 Fault/Failure Troubleshooting and Root Cause Analysis . . 5.8.1 Fault analysis . . . . . . . . . . . . . . . . . . . . 5.8.2 Troubleshooting . . . . . . . . . . . . . . . . . . . 5.8.3 Root cause analysis . . . . . . . . . . . . . . . . . 5.9 Lubricant Waste Handling and Management . . . . . . . . 5.10 Energy Conservation and Environmental Impact . . . . . . 5.10.1 Energy conservation . . . . . . . . . . . . . . . . . 5.10.2 Environmental impact . . . . . . . . . . . . . . . . 5.11 Oil Reclamation and System Decontamination . . . . . . . 5.11.1 Oil reclamation . . . . . . . . . . . . . . . . . . . 5.11.2 System decontamination. . . . . . . . . . . . . . . 5.12 Program Management and Metrics . . . . . . . . . . . . . 5.12.1 Structure, authority, and responsibility . . . . . . . 5.12.2 Management outsourcing . . . . . . . . . . . . . . 5.12.3 Program documentation . . . . . . . . . . . . . . . 5.12.4 Information management . . . . . . . . . . . . . . 5.12.5 Communication, participation, and outsourcing . . 5.12.6 Change management . . . . . . . . . . . . . . . . 5.12.7 Metrics . . . . . . . . . . . . . . . . . . . . . . . . 5.12.8 Improvement actions . . . . . . . . . . . . . . . . 5.12.9 Contingency planning . . . . . . . . . . . . . . . .

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Contents vii

6 Additional Requirements 6.1 Legal Requirements . . . . . . . . . . . . . . . . . . . . . . 6.2 Audits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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7 Program Oversight and Management Review

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Index

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Foreword

The International Council for Machinery Lubrication (ICML) is a vendor-neutral, nonprofit organization. ICML serves the global industry as the world-class authority on machinery lubrication that advances the opti­ mization of asset reliability, utilization, and costs. In support of this mis­ sion, ICML created ICML 55.1 as a standard that states the requirements for the voluntary certification of lubricated mechanical asset management. The ICML 55.2, Guideline for the Optimized Lubrication of Mechanical Physical Assets, is a practical guide to help asset owners meet the requirements out­ lined in ICML 55.1. The companion document ICML 55.2 expands on the requirements of this document to help organizations augment and implement the requirements stated herein. ICML offers this standard in support of, and in compliance with, ISO 55001. The specific focus of ICML 55.1 is to state the requirements for effective lubrication management that in turn is intended to support the organization’s physical asset management plans.

ix

Disclosures

This ICML 55.1 document represents, to the most thorough degree possible, the consensus of the machine lubrication community pertaining to the scope and best practices associated with lubrication management. While this standard is intended to align with ISO 55001, as amended, and its subparts, this standard was developed and created independent of ISO 55001 and is neither explicitly nor implicitly endorsed by the International Organization for Standardization (ISO). ICML does not, with any measure of uncertainty, attest to or confirm conformity of this document as it pertains to ISO standards. The interpretation and implementation of this ICML standard is depen­ dent on the proper interpretation and implementation of the normative references identified in this standard, especially in relation to ISO 55001. Information within this standard is augmented by the listed informative references. ICML 55.1 is a voluntary standard. No liability shall be attached to the ICML, its directors, members, employees, contractors, or agents, including individual experts and members of its technical committees, for any personal injury, property damage, or other damage of any nature that may arise from the interpretation or implementation of any or all parts of this standard.

xi

Acknowledgments

The ICML gratefully acknowledges the efforts of its volunteers in the design, development, and implementation of this document. Special thanks are extended to members of the editorial board. Acknowledged lubrication indus­ try experts from across the globe are listed as contributors to and reviewers of this document. These industry experts have provided exceptional content clarity and insight. The ICML thanks its Board of Directors for their support of this document and their vision of the lubrication industry.

Editorial Board Rendela Wenzel, Eli Lilly and Company – USA

Jim Fitch, Noria – USA

Drew Troyer, Sigma Reliability – USA

Bryan Johnson, Arizona Public Service – USA

Leslie Fish, ICML – USA

Alec Meinke, Blue Buffalo – USA

Contributors/Reviewers Alec Meinke, Blue Buffalo – USA

Alessandro Paccagnini, Mecoil – Italy

Art Durnan, XRT Consultants LLC – USA

Ben Staats, West Fraser – Canada

Bennett Fitch, Noria – USA

Bob Scott, LubeWorks Ltd. – Canada

Bryan Johnson, Arizona Public Service – USA

Brian Ramatally, CASL – Trinidad/Tobago

Brian Schmidt, Chevron – USA

Bruce Hawkins, Emerson – USA

David Wooton, Wooton Consulting – USA

Esteban Lantos, Laboratorio Dr. Lantos – Argentina

Gerardo Trujillo, Noria Latín América – Mexico

Giuseppe Adriani, Mecoil – Italy

xiii

xiv

Acknowledgments

Grahame Fogel, Gaussian Engineering – South Africa Greg Livingstone, Fluitec – Canada Guang Ding, Lubrosoft Consulting – China/ Australia Ian McKinnon, Reliability Solutions – USA Jason Tranter, Mobius Institute – Australia Jeremy Wright, Advanced Technology Services – USA Jerry Putt, Goodyear (retired) – USA Jesus Terradillos, Bureau Veritas – Spain Jim Fitch, Noria – USA Joe Sharp, International Paper – USA Juan Lee, Center for Reliability Excellence – Philippines Kenneth Bannister, Engtech Industries – Canada Kevan Slater, KjSlater and Associates – Canada Lance Bisinger, Allied Reliability – USA Mark Barnes, Des-Case – USA Martin Williamson, KEW Engineering Ltd. – United Kingdom Mary Jo Cherney, GE Appliances – USA Matt Spurlock, Allied Reliability – USA Mattieu Berlinguette, Laurentide Controls – Canada Michael Holloway, ALS Tribology – USA Michael Hooper, The Eventful Group – New Zealand Mike Johnson, AMRRI – USA Rendela Wenzel, Eli Lilly and Company – USA Richard Wurzbach, MRG Laboratories – USA Rüdiger Krethe, OilDoc – Germany Toni de Sousa, Yellotec – South Africa Torbjorn Idhammar, IDCON – USA Udey Dhir, VAS Tribology – India Wayne Dearness, Oil & Toil Pty Ltd – Australia Wes Cash, Noria – USA Yuegang Zhao, Spectro Scientific – USA

ICML Board of Directors Bryan Johnson, Arizona Public Service – USA

Rendela Wenzel, Eli Lilly and Company – USA

David Lange, AAPG – USA

Rich Wurzbach, MRG Laboratories – USA

Jim Fitch, Noria – USA

Alec Meinke, Blue Buffalo – USA

Yuegang Zhao, Spectro Scientific – USA

List of Figures

Figure 1 Figure 2 Figure 3 Figure 4

ICML 55.1 and ISO 55000 employ the plan-do­ check-act management system. . . . . . . . . . Twelve ICML 55.1 interrelated lubrication program plan areas. . . . . . . . . . . . . . . . ICML 55.1 activities at different stages in the lubrication life cycle. . . . . . . . . . . . . . . The MLE body of knowledge aligns with the twelve areas of the ICML 55® Standard. . . . .

xv

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23

List of Abbreviations

ACA ASTM AW BAT BOK BOM BS&W CARRS CBM CC CM CMMS DF DMS DOE DOK EAM ECHA EFL EHD EP EPA FIFO FMEA FMECA FR FRACAS FRN FRP FTA FTIR GHS

Apparent cause analysis American Society for Testing and Materials Anti-wear Best available technologies Body of knowledge Bill of materials Bottom sediment and water Classification and records retention system Condition-based maintenance Carbon credits Condition monitoring Computerized maintenance management system Detectability factor Document management system Department of Energy Domain of knowledge Enterprise asset management European Chemicals Agency Environment friendly lubricant Elastohydrodynamic Extreme pressure Environmental Protection Agency First in, first out Failure mode and effects analysis Failure mode effects and criticality analysis Fire-resistant Failure reporting, analysis, and corrective action system Fault risk number Facility response plan Fault tree analysis Fourier transform infrared Global harmonized system xvii

xviii List of Abbreviations GNP HES HFRR IBC ICML ICP IIoT IoT ISO JIT KPI LIMS LLA LMP LMS LOER LOF LOFM LOTO LSV MIT MLA MLE MLT MOU MRO MTBF MTTF NLGI OCME ODI OEM OMC OSHA PAG PdM PET PF PM PPE

Gross national product Health, environment and safety High-frequency reciprocating rig Intermediate bulk container International Council for Machinery Lubrication Inductively coupled plasma Industrial Internet of Things Internet of Things International Organization for Standardization Just-in-time Key performance indicator Laboratory information management system Laboratory lubricant analyst Lubrication management plan Lubrication management system Lubrication operation effectiveness review List of failures List of failure modes Lock out-tag out Linear sweep voltammetry Massachusetts Institute of Technology Machine lubricant analyst Machinery lubrication engineer Machinery lubrication technician Memorandum of understanding Maintenance, repair, and overhaul Mean time between failures Mean time to failure National Lubricating Grease Institute Overall condition monitoring effectiveness Operator-driven inspection Original equipment manufacturer Overall machine criticality Occupational Safety and Health Administration Polyalkylene glycol Predictive maintenance Polyethylene terephthalate Potential failure, also known as P-F Preventive maintenance Personal protective equipment

List of Abbreviations xix

QR R&O R&R RACI RCA RCFA RCM RDE REACH RFID ROI RPN RPVOT RTF RUL SDS SEM SLA SOP SPCC SSS SVHC SWOT TBN TDS TPM TSCA TSEA UIN VGP

Quick response (code) Rust and oxidation Repeatability & reproducibility Responsible, accountable, consulted and informed Root cause analysis Root cause failure analysis Reliability-centered maintenance Rotating disc electrode Registration, evaluation, authorisation and restriction of chemicals Radio frequency identification Return on investment Risk priority number Rotary pressure vessel oxidation test Run-to-failure Remaining useful life Safety data sheet Scanning electron microscope Service level agreement Standard operating procedures Spill prevention, control, and countermeasure Spares, storage, and standby Substances of very high concern Strengths, weaknesses, opportunities and threats Total base number Total dissolved solids Total productive maintenance Toxic Substances Control Act Task safety and environmental analysis Unique identification number Vessel general permit

Introduction

This document is one from a series of three standards on lubrication pro­ gram management that was developed in support of asset management. The documents are produced and maintained by the International Council for Machinery Lubrication (ICML) for use by its members and by lubricant prac­ titioners throughout the world. This document describes and defines specific focus areas of assets that are used to support the function of a facility or an organization’s lubrication program. The primary intent of the requirements outlined within this standard is to aid the lubrication practitioner in obtaining and sustaining a high level of machinery reliability at an acceptable and sustainable cost. The elements required to achieve this objective exceed those required to maintain quality machinery lubrication. Program elements are designed to ensure the contin­ uous improvement of an organization’s lubrication program in a sustainable manner. Implementation of the requirements of this standard is expected to result in a successful, cost-effective, continuously improving, sustainable, and high-quality lubrication program.

Purpose This ICML standard provides an overview of lubrication management sys­ tems and processes that are applicable to the effective management of phys­ ical assets related to lubrication. It is intended, but not warranted, that this document is in accordance with the international standard ISO 55001, as amended, and its subparts. This standard identifies and defines the need for the use of wellestablished best practices that are applicable to a wide range of lubricated mechanical assets.

Relationship with other standards This standard is intended as a companion document to be used in association with ICML 55.2, Guideline for the Optimized Lubrication of Mechanical xxi

xxii Introduction Physical Assets, and ICML 55.3, Auditors’ Standard Practice and Policies Manual. ICML 55.1 is intended for use in support of physical asset management in accordance with the international standard ISO 55001 and its subparts as amended. As such, the structure and language of this standard have been generally harmonized with ISO 55001 as appropriate to assure strategic and operational alignment. Steps taken by an asset owner to achieve compliance with ICML 55.1 should also be viewed as steps toward ultimate compliance with ISO 55001. It should be noted that while this standard is intended to align closely with ISO 55001 and its subparts as amended, it is entirely the work product and the exclusive intellectual property of the ICML and is neither explicitly nor implicitly endorsed by the International Organization for Standardization or any other standards body.

Target users of this standard This ICML standard is intended for use by: a. Those who desire to improve the lubrication management practices of their lubricated mechanical assets pursuant to the realization of optimal organizational value as described by ISO 55001 and its amendments and subparts. b. Those involved in the establishment, implementation, maintenance, and improvement of a lubrication management system as a part of their physical asset management system as described by ISO 55001 and its amendments and subparts. c. Those involved in the planning, design, implementation, and review of lubrication management activities. These include local resources or out­ side service providers or advisers that provide contractual onsite sup­ port and/or services.

Benefits of this standard The adoption of ICML 55.1 requirements, as augmented by ICML 55.2 guidelines, will enable the organization to achieve its objectives of effectively and efficiently managing its physical lubrication and lubricant asset policies, strategies, and plans. The application of a lubrication management system for the organization’s mechanical assets assures that these objectives can be achieved consistently and sustainably within the physical asset management plan over time.

Introduction xxiii

Application of ICML 55.1 This standard is intended to support an organization’s lubrication program and associated machines and systems in support of their overall physical asset management system defined by ISO 55001 and its amendments and subparts. ICML 55.1 (supported by its ICML 55.2 guideline document) is appli­ cable to any business that owns and manages a substantial base of physical asset components comprised of lubricated mechanical assets. In particular, this standard applies to rotating and reciprocating machines, powertrains, and hydraulic systems as well as their lubricated subcomponents. The requirements set forth in ICML 55.1 are indistinguishably linked and should be read and implemented in their entirety. ICML 55.1 is pre­ scriptive in a general or specific sense depending on the section or clause. It describes the requirements for what should be done rather than how to do it. In this manner, the processes used for successful implementation can often be achieved through multiple methods. The following verbal forms are employed within the ICML 55.1 stan­ dard and shall be understood as follows: a. b. c. d.

“shall” indicates a requirement. “should” indicates a recommendation. “may” indicates a permission. “can” indicates a possibility or a capability.

Disclaimer: Every effort was made to create a standard that is, in general, applicable to the lubricated physical assets located in a typical industrial facility, plant, or factory. It is not possible to anticipate or consider every application, machine environment, or circumstance associated with each of the potential applications of this ICML standard. As such, this standard shall not be interpreted as a substitute for principles of management that are based upon sound judgment in achieving reliable, safe, and economical asset per­ formance. Additionally, this standard does not account for applicable laws and regulations that could impact machinery operation or its maintenance.

Integration with other management systems The alignment of ICML 55.1 with other management systems and their asso­ ciated standards was a priority in the development of this standard. Particular emphasis was placed on harmonizing this ICML standard with ISO 55000, ISO 55001, and ISO 55002 standards for asset management. To support this alignment, ICML 55.1 has adopted the plan-do-check-act management system

xxiv Introduction

Figure 1 ICML 55.1 and ISO 55000 employ the plan-do-check-act management system. Designed by PresentationGo.com

of the aforementioned ISO documents (Figure 1). This system produces best practices, as it represents key steps of a continuous self-improvement feed­ back loop. The system’s important elements are described as follows: Plan: Establish a lubrication management strategy with objectives and the plans necessary to deliver results in accordance with the organization’s lubri­ cation management policy, and in support of its physical asset management and strategic plan(s). Do: Establish the enablers required to implement the lubrication management plan(s) in support of the organization’s physical asset management plan(s). Check: Monitor and measure the outcomes or results of program perfor­ mance when compared to the lubrication management policy and its strategy and objectives. Record, report, and trend the results. Act: Take actions to ensure that the lubrication management objectives, as they relate to the organization’s physical asset management plan, are achieved and continuously improved upon.

1

Scope

ICML 55.1 specifies the requirements for a lubrication management system that are needed to support the organization’s physical asset management sys­ tem. The scope of ICML 55.1 is described by the following: a. PHYSICAL ASSETS that employ lubricants to reduce friction, wear, corrosion, heat generation, and energy consumption and/or to facilitate the transfer of mechanical energy for accomplishing work. b. FINISHED TRIBOLOGICAL FLUID PRODUCTS that are derived from the blending of certain base oil API categories I-V and additives. These lubricants may be installed and placed into service in industrial machines (fixed and mobile plant), military machinery, aviation, aerospace, rail, and marine. These lubricants may be identified by generic terms such as motor oils, hydraulic fluids, general lubricating or circulating oils, brake fluids, chain/wire rope lubricants, gear oils, food-grade lubricants, and lubricating greases. This list is not intended to be all-inclusive. c. ORGANIZATIONAL ASSETS that can be described as other than machinery and that also function in support of lubricated physical assets are included within the scope. These assets include personnel assigned in support of the management program. Policies, procedures, and facilities that store and manage lubricants are other examples of non-machinery assets. Management also serves as a key asset, vital to the success of a lubricant asset management plan and program. This standard excludes certain fluids and materials from its scope, includ­ ing fuels, coolants, metal-working fluids, pastes, fogging agents, preservative fluids, coating materials, heat transfer fluids, brake fluids, cosmetic lubri­ cants, additives independent of the finished lubricant, solid lubricants (e.g., powders and surface treatments used as coating rather than to reduce friction between surfaces in motion), electrical transformer oils, and anti-seize com­ pounds. This list is not all-inclusive of all fluids and materials originating from a petroleum or petroleum-like base and those that do not serve a lubri­ cation function. 1

2 Scope

Figure 2 Twelve ICML 55.1 interrelated lubrication program plan areas. Designed by PresentationGo.com

The use of this standard is intended to align with the goals, policies, and objectives of the asset owner. Assets related to lubricants or lubrication can be broadly described in general categories that are familiar within an industrial process or facility. The ICML 55.1 lubrication management system focuses on twelve areas of emphasis (Figure 2). Each of these twelve asset focus areas is uniquely described in Section 5.0 of this standard. Each element of Figure 2 is identified as follows: a. b. c. d. e. f. g.

SKILLS: Job Task, Training, and Competency MACHINE: Machine Lubrication and Condition Monitoring Readiness LUBRICANT: Lubricant System Design and Selection LUBRICATION: Planned and Corrective Maintenance Tasks TOOLS: Lubrication Support Facilities and Tools INSPECTION: Machine and Lubricant Inspection LUBRICANT ANALYSIS: Condition Monitoring and Lubrication Analysis

1.2 Living Document 3

h. i. j. k. l.

TROUBLESHOOT: Fault/Failure Troubleshooting and RCA WASTE: Lubricant Waste Handling and Management ENERGY: Energy Conservation and Environmental Impact RECLAIM: Oil Reclamation and System Decontamination MANAGEMENT: Program Management and Metrics

1.1 Lubrication Life Cycle Activities Application of this standard shall require the organization to establish, imple­ ment, and maintain processes and/or procedures in support of its overall lubri­ cation management plan(s). Lubrication program management, as it relates to asset management, requires an ongoing life cycle management philosophy for each of the twelve plan focus areas. The control and management of the ongoing activities surrounding these elements require integration and coop­ erative alignment while supporting the overall lubrication program. These elements, when properly aligned, constitute the lubricant and/or lubrication asset plan life cycle. Examples of implementation are included in Figure 3 and listed below: a. The specification and/or acquisition and/or analysis of lubricants and/or lubrication-related systems. b. The receipt and/or storage of lubricants and/or lubrication-related systems. c. Application and/or maintenance of lubricants and/or lubrication-related systems. d. Disposal, reclamation, and/or reuse of lubricants and/or lubricationrelated systems.

1.2 Living Document The lubricant management plan should be considered a living document. Designing, constituting, and implementing the plan’s twelve primary ele­ ments can be viewed as twelve components of an overall lubricant manage­ ment plan. These elements should be aligned to support the objectives and goals of the physical asset management plan. Each element may be imple­ mented by local resources or may be outsourced to outside services. The implementer or enabler of any portion of the plan may change at the discre­ tion of the organization. The responsibility, however, to manage the plan’s objectives and details resides with the organization. Continuous improvement principles, when applied through life cycle analysis and its management, will identify opportunities to improve elements

4 Scope

Figure 3 ICML 55.1 activities at different stages in the lubrication life cycle. Designed by freepik.com

of the lubrication management plan. As the need for plan revision is identi­ fied, the plan should be reviewed for the possible impact of required changes. Documentation should be in place prior to implementing the change. A docu­ ment revision process that includes the reason(s) for making needed changes should be employed.

2

Reference Publications

Documentation in support of, or used to derive, the requirements of this stan­ dard is listed below.

2.1 Normative API Standards API 1509, Engine Oil Licensing and Certification System BSI British Standards PAS 55-1, 55-2, Asset Management (withdrawn) EN Standards EN 16646, Maintenance within physical asset management, as amended, and its subparts IEC Standards IEC 60300, Dependability management – Part 1: Guidance for manage­ ment and application, as amended, and its subparts ISO Standards ISO 9000, Quality management systems ISO 55000, Asset management – Overview, principles, and terminol­ ogy, as amended, and its subparts ISO 55001, Asset management – Management systems – Requirements, as amended, and its subparts ISO 55002, Asset management – Management systems – Guidelines for the application of ISO 55001, as amended, and its subparts ISO 17065, Conformity assessment – Requirements for bodies certify­ ing products, processes, and services ISO 19001, Guidelines for auditing management systems 5

6 Reference Publications ISO 17021-3, Conformity assessment – Requirements for bodies pro­ viding audit and certifying of management systems, Part 3: Competence requirements for auditing and certification of quality management systems ISO 18436, Condition monitoring and diagnostics of machines – Requirements for qualification and assessment of personnel

2.2 Informative ASTM Standards D4178, Standard Practice for Calibrating Moisture Analyzers D4378, Standard Practice for In-Service Monitoring of Mineral Turbine Oils for Steam, Gas, and Combined Cycle Turbines D6224, Standard Practice for In-Service Monitoring of Lubricating Oil for Auxiliary Power Plant Equipment D6439, Standard Guide for Cleaning, Flushing, and Purification of Steam, Gas, and Hydroelectric Turbine Lubrication Systems D7418, Standard Practice for Set-Up and Operation of Fourier Transform Infrared (FT-IR) Spectrometers for In-Service Oil Condition Monitoring D7669, Standard Guide for Practical Lubricant Condition Data Trend Analysis D7686, Standard Test Method for Field-Based Condition Monitoring of Soot in In-Service Lubricants Using a Fixed-Filter Infrared (IR) Instrument D7690, Standard Practice for Microscopic Characterization of Particles from In-Service Lubricants by Analytical Ferrography D7720, Standard Guide for Statistically Evaluating Measure and Alarm Limits when Using Oil Analysis to Monitor Equipment and Oil for Fitness and Contamination D7874, Standard Guide for Applying Failure Mode and Effect Analysis (FMEA) to In-Service Lubricant Testing D7917, Standard Practice for Inductive Wear Debris Sensors in Gearbox and Drivetrain Applications

2.2 Informative 7

D7918, Standard Test Method for Measurement of Flow Properties and Evaluation of Wear, Contaminants, and Oxidative Properties of Lubricating Grease by Die Extrusion Method and Preparation D7973, Standard Guide for Monitoring Failure Mode Progression in Plain Bearings D8112, Standard Guide for Obtaining In-Service Samples of Turbine Operation-Related Lubricating Fluid D8128, Standard Guide for Monitoring Failure Mode Progression in Industrial Applications with Rolling Element Ball Type Bearings D8185, Standard Guide for In-Service Lubricant Viscosity Measurement E2412, Standard Practice for Condition Monitoring of Used Lubricants by Trend Analysis Using Fourier Transform Infrared (FT-IR) Spectrometry D217, Standard Test Methods for Cone Penetration of Lubricating Grease D445, Standard Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and Calculation of Dynamic Viscosity) D664, Standard Test Method for Acid Number of Petroleum Products by Potentiometric Titration D665, Standard Test Method for Rust-Preventing Characteristics of Inhibited Mineral Oil in the Presence of Water D892, Standard Test Method for Foaming Characteristics of Lubricating Oils D974, Standard Test Method for Acid and Base Number by ColorIndicator Titration D1092, Standard Test Method for Measuring Apparent Viscosity of Lubricating Greases D1401, Standard Test Method for Water Separability of Petroleum Oils and Synthetic Fluids D1500, Standard Test Method for ASTM Color of Petroleum Products (ASTM Color Scale) D1742, Standard Test Method for Oil Separation from Lubricating Grease During Storage

8 Reference Publications D2265, Standard Test Method for Dropping Point of Lubricating Grease Over Wide Temperature Range D2272, Standard Test Method for Oxidation Stability of Steam Turbine Oils by Rotating Pressure Vessel D2711, Standard Test Method for Demulsibility Characteristics of Lubricating Oils D2782, Standard Test Method for Measurement of Extreme-Pressure Properties of Lubricating Fluids (Timken Method) D2783, Standard Test Method for Measurement of Extreme-Pressure Properties of Lubricating Fluids (Four-Ball Method) D2982, Standard Test Methods for Detecting Glycol-Base Antifreeze in Used Lubricating Oils D3524, Standard Test Method for Diesel Fuel Diluent in Used Diesel Engine Oils by Gas Chromatography D3707, Standard Test Method for Storage Stability of Water-in-Oil Emulsions by the Oven Test Method (Withdrawn 2016) D4172, Standard Test Method for Wear Preventive Characteristics of Lubricating Fluid (Four-Ball Method) D4291, Standard Test Method for Trace Ethylene Glycol in Used Engine Oil D4327, Standard Test Method for Anions in Water by Suppressed Ion Chromatography D4739, Standard Test Method for Base Number Determination by Potentiometric Hydrochloric Acid Titration D5185, Standard Test Method for Multielement Determination of Used and Unused Lubricating Oils and Base Oils by Inductively Coupled Plasma Atomic Emission Spectrometry (ICP-AES) D6006, Standard Guide for Assessing Biodegradability of Hydraulic Fluids D6046, Standard Classification of Hydraulic Fluids for Environmental Impact D6184, Standard Test Method for Oil Separation from Lubricating Grease (Conical Sieve Method)

2.2 Informative 9

D6185, Standard Practice for Evaluating Compatibility of Binary Mixtures of Lubricating Greases D6232, Standard Guide for Selection of Sampling Equipment for Waste and Contaminated Media Data Collection Activities D6304, Standard Test Method for Determination of Water in Petroleum Products, Lubricating Oils, and Additives by Coulometric Karl Fischer Titration D6481, Standard Test Method for Determination of Phosphorus, Sulfur, Calcium, and Zinc in Lubrication Oils by Energy Dispersive X-ray Fluorescence Spectroscopy D6595, Standard Test Method for Determination of Wear Metals and Contaminants in Used Lubricating Oils or Used Hydraulic Fluids by Rotating Disc Electrode Atomic Emission Spectrometry D6810, Standard Test Method for Measurement of Hindered Phenolic Antioxidant Content in Nonzinc Turbine Oils by Linear Sweep Voltammetry D6971, Standard Test Method for Measurement of Hindered Phenolic and Aromatic Amine Antioxidant Content in Nonzinc Turbine Oils by Linear Sweep Voltammetry D7155, Standard Practice for Evaluating Compatibility of Mixtures of Turbine Lubricating Oils D7214, Standard Test Method for Determination of the Oxidation of Used Lubricants by FT-IR Using Peak Area Increase Calculation D7279, Standard Test Method for Kinematic Viscosity of Transparent and Opaque Liquids by Automated Houillon Viscometer D7647, Standard Test Method for Automatic Particle Counting of Lubricating and Hydraulic Fluids Using Dilution Techniques to Eliminate the Contribution of Water and Interfering Soft Particles by Light Extinction D7670, Standard Practice for Processing In-Service Fluid Samples for Particulate Contamination Analysis Using Membrane Filters D7684, Standard Guide for Microscopic Characterization of Particles from In-Service Lubricants

10 Reference Publications D7685, Standard Practice for In-Line, Full Flow, Inductive Sensor for Ferromagnetic and Nonferromagnetic Wear Debris Determination and Diagnostics for Aeroderivative and Aircraft Gas Turbine Engine Bearings D7686, Standard Test Method for Field-Based Condition Monitoring of Soot in In-Service Lubricants Using a Fixed-Filter Infrared (IR) Instrument D7688, Standard Test Method for Evaluating Lubricity of Diesel Fuels by the High-Frequency Reciprocating Rig (HFRR) by Visual Observation D7690, Standard Practice for Microscopic Characterization of Particles from In-Service Lubricants by Analytical Ferrography D7718, Standard Practice for Obtaining In-Service Samples of Lubricating Grease D7843, Standard Test Method for Measurement of Lubricant Generated Insoluble Color Bodies in In-Service Turbine Oils using Membrane Patch Colorimetry ISO Standards ISO 1643, Industrial automation systems and integration – Product data representation and exchange Application module: Assembly module with interconnect component ISO 4406, Hydraulic fluid power – Fire-resistant (FR) fluids – Requirements and guidelines for use ISO 4406, Hydraulic fluid power – Fluids – Method for Coding the Level of Contamination by Solid Particles ISO 12924, Lubricants, industrial oils, and related products (Class L) – Family X (Greases) – Specification ISO 12925, Lubricants, industrial oils, and related products (class L) – Family C (gears) – Part 1: Specifications for lubricants for enclosed gear systems ISO 13381, Condition monitoring and diagnostics of machines – Prognostics – Part 1: General guidelines ISO 16232, Road vehicles – Cleanliness of components of fluid circuits – Part 1: Vocabulary

2.2 Informative 11

ISO 16889, Hydraulic fluid power – Filters – Multi-pass method for evaluating filtration performance of a filter element ISO 17025, General requirements for the competence of testing and calibration laboratories ISO 21018, Hydraulic fluid power – Monitoring the level of particulate contamination of the fluid – Part 1: General principles Publications AISE (2010). The Lubrication Engineers Manual, 4th Edition Armstrong, P., Idhammar, T. (editor) (2008). Maintenance Planning and Scheduling, IDCON, Inc. Bannister, K. (2007). Lubrication for Industry, 2nd Edition, Industrial Press Bloch, H., Bannister, K. (2016). Practical Lubrication for Industrial Facilities, 3rd Edition, CRC Press Bloch, H.P., Geitner, F.K. (1994). An Introduction to Machinery Reliability Assessment, 2nd Edition, Gulf Publishing Co. Drexel, W., Mang, T. (2017). Lubricants and Lubrication, 3rd Edition, Vol. 1, Wiley-VCH Fitch, J., Troyer, D. (2010). Oil Analysis Basics, 2nd Edition, Noria Corporation Fitch, J., Scott, R. (2013). Daily One-Minute Lubrication Inspections and Field Tests, Noria Corporation Gresham R., Totten, G. (2009). Lubrication and Maintenance of Industrial Machinery, CRC Press Gulati, R. (2009). Maintenance and Reliability Best Practices, Industrial Press Idhammar, I, et al. (1992). Preventive Maintenance/Essential Care and Condition Monitoring, IDCON, Inc. Idhammar, C. (2006). Results Oriented Reliability and Maintenance Management, IDCON, Inc. Joel Levitt, J. (2009). The Handbook of Maintenance Management, 2nd Edition, Industrial Press

12 Reference Publications Latino, M.A., Latino, R.J., Latino, K. (2011). Root Cause Analysis, 4th Edition, CRC Press Lubricant and Lubrication Product Procurement, Edited by Jason Sowards, Reliable Plant Management Series, Noria Lubricant Selection, Edited by Jason Sowards, Reliable Plant Management Series, Noria Lubricant Storage and Handling, Edited by Jason Sowards, Reliable Plant Management Series, Noria Lubrication Maintenance Tasks and Tools, Edited by Jason Sowards, Reliable Plant Management Series, Noria Lubrication Program and Reliability Metrics, Edited by Jason Sowards, Reliable Plant Management Series, Noria Lubrication Program Safety, Edited by Jason Sowards, Reliable Plant Management Series, Noria Lubrication Requirements for Standby and Stored Machinery, Edited by Jason Sowards, Reliable Plant Management Series, Noria Lubricant Waste and Disposal, Edited by Jason Sowards, Reliable Plant Management Series, Noria Methods for Extending Lubricant Service Life, Edited by Jason Sowards, Reliable Plant Management Series, Noria Modifying Machinery for Proper Lubrication, Edited by Jason Sowards, Reliable Plant Management Series, Noria Mitchell, J.S. (2012). Physical Asset Management Handbook, 4th Edition, Reliability Web Mobley, R.K. (1999). Root Cause Failure Analysis, Newnes Mortier, R.M., Fox, M.F., Orszulik, S.T. (2010). Chemistry and Technology of Lubricants, 3rd Edition, Springer Moubray, J. (1997). Reliability-centered Maintenance, 2nd Edition, Industrial Press National Lubricating Grease Institute (1996). Lubricating Grease Guide, 4th Edition

2.2 Informative 13

Palmer, D. (2013). Maintenance Planning and Scheduling Handbook, 3rd Edition, McGraw Hill Pirro, D.M., Webster, M., Daschner, E. (2016). Lubrication Fundamentals, 3rd Edition, CRC Press Rizvi, S.Q.A. (2009). A Comprehensive Review of Lubricant Chemistry, Technology, Selection, and Design, ASTM International Scott, R., Fitch, J., Luegner, L. (2012). The Practical Handbook of Machinery Lubrication, Noria Corporation The Japan Institute of Plant Maintenance (1997). Autonomous Maintenance for Operators, Productivity Press Toms, L.A., Toms, A.M. (2008). Machinery Oil Analysis, 3rd Edition, STLE Totten, G. (2003). Fuels and Lubricants Handbook, ASTM International Totten, G. (2006). Handbook of Lubrication and Tribology, Volume I, 2nd Edition, Taylor & Francis Wireman, T. (2015). Maintenance Work Management Processes, Volume 3, Reliability Web Wireman, T. (2014). Operator-Driven Reliability, Volume 6, Reliability Web Wireman, T. (2008). Preventive Maintenance, Volume 1, Industrial Press

3

Terms and Definitions

Abnormal: a condition related to a lubricant or machine that is identified and requires additional investigation, monitoring, or correction. Asset: an object, person, entity, or quality that has both current and future value as it (they) pertains to lubricants. Assets may be tangible or intangible irrespective of financial value. Asset management: the balancing of costs, opportunities, and risks against the desired asset’s performance toward achieving organizational objectives (ref. ISO 55000(x)). Criticality analysis: a systematic approach to evaluate potential risks and their associated consequences to the organization. Criticality anal­ ysis considers the potential consequences of an adverse event, the likelihood of the event’s occurrence, and the effectiveness of controls to prevent and/or predict the event. Critical physical asset: a physical asset that is deemed critical to the busi­ ness as a result of criticality analysis. Potential consequences of a degraded or failed critical asset may affect safety, environment, cus­ tomer satisfaction, profit, and/or other aspects of the organizational mission. Dynamic physical asset: a mechanical physical asset with surfaces that are in relative motion. This includes rotating and reciprocating equipment. Failure mode and effects analysis: FMEA is a step-by-step process that utilizes inductive reasoning to hypothesize all possible failures in the design, manufacturing, or assembly process of a product or service so it (they) may be appropriately targeted for asset management. Failure reporting, analysis, and corrective action system: FRACAS is a systematic method for collecting and analyzing failure data utilizing adductive or deductive reasoning methods. FRACAS is the empirical companion to the more hypothetical FMEA. Root Cause Analysis (RCA) is a component of FRACAS.

15

16 Terms and Definitions Fleet: used to denote multiple facilities owned or managed by an organiza­ tion. It may also denote multiple assets owned or managed by an organization, such as a fleet of trucks. Fixed and mobile assets: used to differentiate between permanently installed (fixed) or portable physical assets (mobile). Linear asset: an asset whose length across a geographical distance plays a crucial role in its management and maintenance. Examples include rail tracks and pipelines. Lubricant analysis: the sampling (or inspection) and analysis of a lubricant to ascertain the condition and fit for its use within the system being lubricated. This is frequently also referred to as oil analysis. Lubricant: a substance such as oil, grease, or a solid that is capable of reduc­ ing friction, heat, and wear when it is introduced as a film between solid surfaces that move in relative motion. Lubrication: the act of introducing a material such as oil, grease, or solid to create a film barrier between surfaces that are in relative motion for the purpose of minimizing friction, heat, and wear. Lubrication management enabler: an item or an activity that is external to the lubrication process but is supportive of its successful implemen­ tation, maintenance, and objectives. Lubrication management objectives: the goals set forth for lubricant and lubrication applications that, when applied, can be expected to cre­ ate an improved performance in the reliability of physical assets, to reduce the costs of operating the physical assets, and/or to improve the safety and/or environmental performance of the lubrication process. Lubrication management strategy: the organization’s strategy for the acquisition, storage, application, management, and disposal of lubri­ cants in a manner that supports the organization’s physical asset management strategy. Lubricant life cycle management requirements: requirements associ­ ated with the specification, acquisition, receipt, storage, application, maintenance, disposal, and/or reclamation of lubricants and lubrica­ tion systems. Lubrication-related systems: systems required to support the effective and efficient application, maintenance, and management of lubricants. Objective assessment: an assessment of the organization’s documentation, execution, and use of follow-up information to improve the lubrica­ tion program plan.

Terms and Definitions 17

Optimum condition: the organization’s identified required state for each one of various aspects or attributes of lubrication management that maintain and support achieving the organizational objectives at an optimized level. Taken all together, these conditions can generally be referred to as the organization’s “best practices.” P–F curve: a common way to represent the life cycle performance behavior of an asset (pump, motor) or asset component (belt, bearing) before actual functional failure has occurred. It is commonly used to illus­ trate the P–F interval which is a point in time between when a failure in progress is detected (P) and when the functional failure of the asset occurs (F). Physical asset: an item of economic, commercial, or exchange value that has material existence. Physical assets typically refer to discrete prop­ erty, equipment, and inventory. Physical asset management: the management of dynamic and static physi­ cal assets, including equipment and plants. Physical asset management objectives: an assessment of the organiza­ tion’s documentation, execution, and use of follow-up information to improve its physical asset management plan. Predictive maintenance: diagnostic and condition monitoring techniques employed to determine the current condition of in-service physical assets and identify degrading conditions, faults, or failures and pre­ dict remaining useful life (RUL), and when corrective maintenance should be performed. Proactive maintenance: activities designed to detect, control, and remediate the underlying conditions (root causes) that lead to faults and degra­ dation of physical assets. Manpower resource utilization ratio: a measure of the productivity of chargeable or billable hours. Normal: a lubricant or machine that is operating without an identified degraded condition and that is performing acceptably. Static physical assets: physical assets that do not move, such as vessels, tanks, and pipes. These are also known as fixed assets. Tribology: the science and technology associated with surfaces in relative motion, including friction, wear, and lubrication. Weibull analysis: a statistical tool that provides a distribution of failure rate that is proportional to time.

4

Lubrication Management Objectives

The organization shall establish, document, implement, maintain, and con­ tinuously improve a lubrication management plan and the system(s) required to implement the plan in a manner that is in accordance with the require­ ments set forth in this ICML standard. The lubrication plan(s) and system(s) described by ICML 55.1 shall be compliant with and supportive of the orga­ nization’s physical asset management plan and its organizational strategy, as specified in ISO 55001. The organization shall establish a lubrication policy and strategy to sup­ port associated lubrication program objectives in a manner that complies with the organization’s safety, environmental, and quality objectives as defined in the lubrication management plan. This enables the effective execution and control of the lubrication activities specified in this ICML standard document. The lubrication management policy, strategy, and objectives shall address all aspects of lubrication management across the lubrication life cycle spectrum. The organization should select a process to define its pre­ ferred state and to aid in establishing goals and objectives. The identification of optimum conditions is an example of such a process, though not a specific requirement for this function.

19

5

Lubrication Management Plan(s)

A lubrication management plan shall be established, documented, managed, and maintained to satisfy the organization’s lubrication asset management strategy and system management plan in support of its overall physical asset management plan. Twelve specific focus areas or plan elements were described within the scope section of this document (Figure 2) and listed again in Figure 4. Each of these elements requires its own unique lubrica­ tion management plan. When these elements are considered collectively, they become the organization’s lubrication asset management strategy and man­ agement plan [1]. Achieving the objectives contained within this overarching plan is expected to support the organization’s physical asset management objectives. Note 1: Lubrication management plan(s) may be developed at a level of (a) specific lubricated components, (b) systems of general physical assets, or (c) larger physical asset portfolios or fleets. Multi-tiered plans may be put in place, provided they can be integrated or linked to support the overall lubrication management strategy and objectives that they are intended to achieve. The development of a lubrication management plan(s) shall be structured in a manner to support life cycle activities with the impact of actions of one life cycle phase upon the other phases or activities considered. Developing, optimizing, and integrating lubrication management plan(s) is an iterative process that starts with the development or update of the lubrication manage­ ment strategy. As it can be challenging to find success by implementing all plan elements at once, the lubrication management plan(s) shall be optimized with the actionable objectives prioritized. Multiple plans should be jointly optimized and prioritized by taking overall value into account. Resource requirements, interdependencies, failure modes (ranked by probability), and risks (including criticality, cost of repair, environmental impact, and safety) are other aspects of prioritization and criteria used for ranking. 21

22 Lubrication Management Plan(s) The lubrication management plan(s) shall include documentation of: a. The specific tasks and actionable items required to optimize machine reliability, cost, risk, and performance of the lubricants and/or lubrica­ tion system(s). b. The designation of responsibilities and authorities for the implementa­ tion of such actions. c. The skill levels of personnel required for implementing the actions. These may be either locally controlled or obtained from offsite services. d. The means and timescales by which these actions are to be achieved. When developing the lubrication management plan(s), the organization shall ensure that appropriate arrangements, functional policies, standards, pro­ cesses and/or procedures, lubrication management enablers, and resources are made available for the efficient and cost-effective implementation of the plan(s). The lubrication management plan(s) shall be made available or com­ municated to all relevant stakeholders at a level of detail appropriate to their participation or business interests related to the delivery of the plan(s). It is essential that the plan(s) be practical and realistically implemented to support a best practice or other similar employed philosophy. The lubri­ cation management plan(s) shall include actions to improve the lubrication management system. The lubrication management plan(s) shall be reviewed periodically by the organization to ensure that they remain effective and consistent with the lubrication management strategy and objectives. The processes and/or procedures for the implementation of lubricant and/or lubri­ cation-related management plan(s) and for the control of life cycle activities shall: a. Be consistent with the lubrication management policy, strategy, and objectives. b. Ensure that cost, risk, and lubricant and/or lubrication system perfor­ mance are controlled across all lubricant and lubrication-related system life cycle phases. c. Be sufficient to ensure that operations and activities are carried out under prescribed conditions.

5.1 Job Task Skills, Training, and Competency The lubrication program management plan shall contain job task skills, train­ ing, and competency element. This element shall support and be aligned with the lubrication management plan.

5.1 Job Task Skills, Training, and Competency 23

Figure 4 The MLE body of knowledge aligns with the twelve areas of the ICML 55® Standard.

It is imperative that individuals responsible for the management, super­ vision, and/or execution of the lubrication program possess the requisite knowledge, skill set, and qualifications (e.g., training and certifications) to sustainably implement the program. The organization shall assure that indi­ viduals meet these objectives by obtaining adequate training and/or edu­ cation to meet defined job functions. Success in meeting this objective is demonstrated through certification testing and continued competent job per­ formance. The requirement of maintaining competent, certified personnel may be satisfied when using either local or outsourced labor.

24 Lubrication Management Plan(s) Proper and up-to-date knowledge and skills are a foundational element for achieving the objectives set forth by the organization’s lubrication man­ agement policy, strategy, and plans. Remediation of this resource shall be achieved in the areas identified to be deficient. To achieve this objective, the organization shall [1]: a. Educate, train, and qualify individuals designated as lubrication pro­ gram managers/engineers to the body of knowledge set forth by ICML for the Machinery Lubrication Engineer (MLE)® or equivalent. b. Educate, train, and qualify lubrication tech­ nicians designated to execute routine lubri­ cation tasks as defined in work procedures

and job descriptions (task-based training)

and to the body of knowledge set forth by

ICML for the Level I Machinery Lubrication

Technician (MLT I) certification, ICML

badge certifications, or equivalent.

c. Educate, train, and qualify senior lubrica­ tion technicians who are responsible for supervising the execution of routine lubri­ cation tasks and executing more complex, periodic lubrication tasks to the body of knowledge set forth by ICML for the Level II Machinery Lubrication Technician (MLT II), ICML badge certifications, or equivalent. d. Educate, train, and qualify lubrication condition monitoring technicians who are responsible for executing routine lubricant analysis activities as defined in work procedures and job descriptions to the body of knowl­ edge set forth by ICML for the Level I Machine Lubricant Analyst (MLA I), ICML badge certifications, or equivalent. e. Educate, train, and qualify lubrication condition monitoring technicians who are responsible for supervising the execution of routine lubricant analysis tasks and evaluating lubricant analysis results per the body of knowledge set forth by ICML for the Level II Machine Lubricant Analyst (MLA II), ICML badge certifications, or equivalent. f. Educate, train, and qualify lubrication condition monitoring technicians who are responsible for the management of lubricant analysis data and advanced machine failure diagnostics to the body of knowledge set forth by ICML for the Level III Machine Lubricant Analyst (MLA III), ICML badge certifications, or equivalent. g. Educate, train, and qualify lubrication technicians who are responsible for the onsite testing of condition monitoring lubrication samples to

5.1 Job Task Skills, Training, and Competency 25

h.

i.

j.

k. l. m. n. o.

the body of knowledge set forth by ICML for the Level I Laboratory Lubricant Analyst (LLA I), ICML badge certifications, or equivalent. Educate, train, and qualify lubrication technicians who are responsible for the onsite testing of condition monitoring lubrication samples to the body of knowledge set forth by ICML for the Level II Laboratory Lubricant Analyst (LLA II), ICML badge certifications, or equivalent. Educate, train, and qualify lubrication technicians who are respon­ sible for the onsite testing of condition monitoring lubrication sam­ ples to the body of knowledge set forth by ICML for the Level III Laboratory Lubricant Analyst (LLA III), ICML badge certifications, or equivalent. Provide appropriate lubrication training [2] or equivalent ICML badge certifications for mechanical, electrical, and craftspeople, foremen, and supervisors who support the execution of lubrication tasks and strategies that are described or defined in work procedures and job descriptions. Provide appropriate training for engineers [2] who are responsible for the design, specification, acquisition, and commissioning of lubricated components and/or machines. Provide summary education to senior plant and corporate management [2] to ensure alignment with the lubrication asset management plan as it supports the organization’s physical asset management objectives. Provide other specialized training on relevant lubrication topics or equivalent ICML badge certifications as dictated by the operating and environmental context of the machines and plants. Provide refresher courses and other educational opportunities to sup­ port the continuous improvement of knowledge and skills for lubrica­ tion professionals and technicians [3]. Ensure that certifications used in support of the lubrication program remain current. Note 1: The titles used in this section are general in nature. Organizational differences may exist in the description or role function. Education and training in complementary fields, including various aspects of reliabil­ ity engineering and machine condition monitoring, are elements within the job task skills, training, and competency element and are evaluated on a case-by-case basis. Note 2: Specific training objectives that are organizationally sustain­ able are a required element of the training plan. Note 3: The organization should consider ongoing participation within the lubricant industry to remain informed of innovation or changes in industry focus. This can be accomplished through participation in

26

Lubrication Management Plan(s)

industry work groups, refresher training, conferences, and seminars and by regularly reading industry periodicals, magazines, and books.

5.2 Machine Lubrication and Condition Monitoring Readiness The lubrication program management plan shall have a machine lubrication and condition monitoring readiness element. This element shall support and be aligned with the lubrication management plan. Machinery lubrication is a complex process that requires knowledge of the machine design and operating conditions. Variations that occur (for instance, through the use of lubricant viscosity and additive content) may still afford acceptable lubrication. With continued degradation, however, these variations may lead to long-term reliability or economic consequences. The choice of lubricant and its service period should be optimized to balance reliability and cost. Condition monitoring of the in-service lubricant provides diagnostic information that can be used to determine if the lubricant continues to meet its minimum performance and economic requirements. The lubricant also carries particulates that may originate from either the machine in the form of wear debris or ingressed foreign material. These particulates can be measured and monitored to estimate the current and future reliability of the machine. 5.2.1 Machine lubrication Fully formulated (finished) lubricants should be specified to match the machine’s design requirements. The physical and chemical properties of the lubricant should be considered when making this determination. The lubri­ cant selection may include the specification of key base oil, physical, chem­ ical, safety, and performance properties. Minimum and maximum limits should be defined in the specification of a lubricant as required. These limits should be verified prior to the use of the lubricant. Examples of key proper­ ties or machine and organizational requirements include: a. Compatibility of the lubricant with machine parts and other materials the lubricant comes in contact with, such as seals. b. Grease thickener type, additives, and base oil viscosity and type. c. Safety requirements (e.g., food safety, toxicity, flammability, volatility, and flash point). d. Environmental protection (e.g., aqueous toxicity and biodegradability).

5.2 Machine Lubrication and Condition Monitoring Readiness 27

The organization should seek to minimize the number of lubricants stored or stocked and the number of suppliers used. It has been widely demonstrated that increased cost efficiency and reduced error are achieved when organizations employ a process to reduce the number of storage vessels/packages and func­ tionally similar vendor products [1]. Furthermore, consolidation of lubricants reduces the complexity of performing routine lubrication maintenance tasks by limiting the number of lubricants associated with a task while also reducing the risk of cross-mixing incompatible or out-of-specification lubricants. Specialty lubricants may be appropriate for some applications. The use of either synthetic oil or mineral-based oil that would meet machine operat­ ing requirements is an example of this. In many cases, the use of conventional quality lubricants is the most appropriate choice. When making lubricant selection decisions, the following inputs should be considered for optimum results and benefits: a. The range of operating conditions that are imposed on a lubricant, including mechanical, electrical, chemical, radiation, and/or thermal stresses or exposures [2]. b. The machine-specific operating conditions, including load, pressure, speed, and temperature. c. Standby or intermittent use operating conditions. d. Environmental conditions, including average and range of ambient tem­ perature, humidity, localized sources of radiant heat, airborne contami­ nation, and radiological exposures. e. The potential entry points for ingress of contamination include particu­ late, water, chemical, or process fluids that cross-mix with other lubri­ cants, etc. f. Machine reliability requirements as determined by criticality analysis of the asset, FMEA details, FRACAS information, and RCA. These elements should be defined within the organizational asset management strategy. g. The required (optimized) service life or replacement interval of the lubricant in the context of operational needs. h. Accessibility and maintainability to complete routine and periodic lubrication maintenance tasks. i. Environmental impact associated with the application and disposal of lubricants. j. Special safety considerations and industry-specific requirements that may include but not be limited to toxicity, food-grade, and fireresistance requirements. k. Organizational energy conservation policies and objectives.

28 Lubrication Management Plan(s) l. Lubricant availability, accessibility, or supply constraints. m. Budgetary constraints. Note 1: Lubricant consolidation objectives do not always align with lubricant performance objectives. Where consolidation goals sig­ nificantly deviate from machine operating requirements, adverse consequences may result. When this affects lubricant performance, consolidation efforts should be given lower priority. Note 2: This includes the design, specification, and acquisition and/or enhancement of specified lubricants. A lubricant is considered to have key functional properties in the context of machine operating conditions and machine requirements that include the lubricant’s chemical, phys­ ical, and performance properties as they relate to machine lubrication requirements. Ancillary factors that must also be considered include lubrication supply systems (and associated consumable supplies) and lubricant condition control and purification systems (and associated consumable supplies). 5.2.2 Condition monitoring readiness Monitoring the machine requires provisions to obtain representative lubri­ cant samples [1]. Obtaining samples can be intrusive to the machine and may, in some cases, require the machine to be turned off. The best proto­ col is to sample when the machine is operating (moving fluid) to avoid par­ ticles, water, and other impurities from settling during quiescent or static conditions. Monitoring may be accomplished using correctly located sample ports/valves or by using tools capable of obtaining representative oil samples. Dedicated sensors are another option that may be used to obtain information about the condition of the lubricant and/or the machine. Note 1: Maintaining lubricants, lubrication systems, and the control of lubricant systems through condition monitoring requires the implemen­ tation of planned activities and the optimized use and location of sam­ pling ports and/or methods.

5.3 Lubrication System Design and Selection The lubrication program management plan shall have a lubrication system design and selection element. This element shall support and be aligned with the lubrication management plan.

5.3 Lubrication System Design and Selection 29

The design and specification of lubrication systems, whether as original equipment or later added/modified, shall support the organization’s objec­ tives for equipment reliability, operability, and maintainability [1]. Worker safety, stakeholder needs, environmental protection, and regulatory require­ ments shall be considered when making design/selection decisions. 5.3.1 System design Lubrication systems shall be designed and specified to: a. Provide access for low-risk inspections at the machine and safe access for technicians performing the inspections. Human sensory inspections or the use of inspection tools, instruments, or aids are acceptable. b. Manage access in a manner to minimize risk at the machine and safe access for technicians to acquire samples for lubricant analysis. c. Provide access for low-risk inspections at the machine and safe access for technicians performing the inspections to allow retrieval of system operating information including flow rate, pressure, level, spray pattern, filter differential pressure, fluid property sensor readings, etc. d. Provide access for low-risk activities at the machine and safe access for technicians performing planned lubrication tasks, such as oil changes, grease repacking, filter changes, breather changes, flushing, purging, loop offline filtration, dehydration, etc. e. Provide access for low-risk activities at the machine and safe access for technicians performing planned condition monitoring tasks that sup­ plement effective lubrication. These tasks may include surface and/or airborne ultrasonic analysis, vibration analysis, thermometric and/or thermographic analysis, etc. f. Provide for the effective, efficient, and safe-to-perform machine design modifications that restrict ingress of, or remove contamination from, lubricants or headspace zones. This may include the installation/ retrofitting of breather(s), quick-connect fittings, filters, separators, etc. g. Machine reliability requirements as determined by asset criticality anal­ ysis, FMEA details, FRACAS information, and RCA. h. Provide the appropriate or optimized quantity of the specified lubricant [2] to the lubricated surfaces in the machine to assure proper and reli­ able operation in terms of friction, heat, corrosion, and wear. i. Assure that the lubricant is delivered in optimum condition with respect to defined machine design and operating conditions and/or environmen­ tal constraints.

30 Lubrication Management Plan(s) j. Enable the effective, efficient, and safe execution of routine mainte­ nance tasks. These may include oil top-offs and top-ups, re-greasing, inspections, monitoring, sampling, and other adjustments. k. Allow clear identification of lubricant types specified for use within the machine and/or subdefined lubrication points. Labels, barcodes, and RFID are examples of options that may be used for this identification. l. Allow for labels which, when used, shall be affixed in a manner to make them intuitive and easy to use while also ideally incorporating the fol­ lowing elements: i. Codes of colors, shapes, and symbols related to: 1. Chemical/Safety 2. Lubricant product information ii. Asset identifiers iii. Quantity requirements iv. Other local requirements m. Include sensors [3] to monitor lubricant and/or machine conditions that may be revealed by the lubricant. These may include sensors for particle counting or moisture level/percent saturation measurements. Sensors may be used to measure viscosity, lubricant chemistry, the accumula­ tion of machine wear particles in the oil, and other issues. n. Provide for contingencies such as expected or unexpected loss of lubri­ cant from the machine. Contingencies may include drip pans, berms/ containment areas, grease traps, oil spray/mist coalescing devices, spill containment cleanup kits, etc. Note 1: Parts and components utilized in the design of the lubrication system should be standardized to improve maintainability, simplify inventory management, and reduce the cost of inventory management. Note 2: This may be accomplished with the manual application, cir­ culating oil systems, drip oilers, automatic greasing systems, oil spray systems, oil mist systems, etc. Note 3: It is desirable to include the specifications for sensor products in the original equipment design specifications; however, retrofit of sen­ sors into equipment is often the only option. The design and function of lubrication sensors is an emerging industry. The function, reliability, and cost of sensors should be considered. 5.3.2 Supplier selection The lubricant is a critical component (or consumable part) within the machine. The proper selection of the lubricant supplier can become a critical factor in

5.3 Lubrication System Design and Selection 31

achieving effective lubrication and machine reliability [1]. The selection of a lubricant supplier should, at minimum, take into consideration the following factors: a. The range and quality of lubricants offered. b. Lubricant testing capability offered, to include condition monitoring service. c. The ability and willingness to provide certification of conformity. d. Having up-to-date Safety Data Sheet (SDS) or other safety information and providing this information in a timely manner when changes occur. e. Providing timely information when lubricants are no longer manufactured. f. Capability to provide compatible replacement lubricants when obsoles­ cence is identified. g. Geographic coverage or service area (especially important for multi­ plant operations, linear assets, mobile equipment, etc.) h. Willingness or ability to supply and deliver any specialty lubricants that are required, but which are marketed under another brand name. i. Willingness or ability to concurrently supply other chemical or hydro­ carbon fluids include fuel, heat transfer fluids, coolants, solvents, and pastes. j. Bulk and package volume and related options. k. Availability to supply accessible and competent technical support. l. Willingness to guarantee the performance of their lubricants. m. Cost of the lubricant [2]. n. Lead time of lubricant deliveries and willingness to maintain an inven­ tory of critical lubricants, in close proximity, to minimize delay in emergency situations. o. Avoid selecting and procuring lubricants as a commodity item [2]. Note 1: It is advisable when selecting a lubricant supplier and/or award­ ing a lubricant supply contract to assemble a representative group of stakeholders with varied interests and needs to choose the supplier. This is especially applicable to organizations that are geographically diverse and/or those that include a variety of different operational platforms and/or divisions. Note 2: Lubricant expenses typically represent a very small percent­ age of the maintenance budget for physical assets. However, lubrication failures are the root cause of a significant percentage of preventable failures of physical assets. Cost should not be the primary consideration when selecting a lubricant supplier.

32

Lubrication Management Plan(s)

Caution: Great care should be taken to avoid treating the selection and procurement of lubricants as a commodity item.

5.4 Planned and Corrective Maintenance Lubrication Tasks The lubrication program management plan shall have a planned and correc­ tive maintenance lubrication task element. This element shall support and be aligned with the lubrication management plan. Planned lubrication maintenance tasks are tasks that are performed on a recurring, time-based interval (the terms “preventive,” “routine” and “peri­ odic” are sometimes used in lieu of “planned” maintenance but have a similar meaning). Corrective maintenance tasks are performed to address emerging maintenance or nonrepetitive time-based conditions. Each of these task types may have identical work instruction steps, prerequisites, tool requirements, and implementation duration. The primary difference in the tasks is how they are scheduled. For example, an oil change may occur at a specific time once each year if time-based. Conversely, if this same activity or task, with the same steps performed, is scheduled based upon a degraded lubricant con­ dition, it is corrective-based. In this case, it occurs only upon the identified need to restore the lubricant condition through its replacement. The forecast implementation date for corrective maintenance could be immediate or slot­ ted for a more convenient point in the future. Appropriately qualified lubrication technicians, maintenance mechan­ ics, or operators execute these tasks. Planned routine lubrication tasks may be completed while the machine is operating (defined as runtime) or while the machine is not in operation (downtime). Machines in standby are considered available for immediate use and are managed as runtime equipment [1]. Note 1: The location and sensitivity of the machine may influence the management of the task and its implementation, as the machine’s design and function may require compliance with the organization’s Task Safety and Environmental Analysis (TSEA) and/or any other asso­ ciated policies for safety and environmental responsibility. 5.4.1 Health and safety Compliance with all organizational and government regulations, policies, processes, and procedures associated with health and safety, and related to the creation and execution of all lubrication tasks, is required. When creating TSEA, the task developer shall consider the following lubrication manage­ ment-specific factors:

5.4 Planned and Corrective Maintenance Lubrication Tasks 33

a. Minimum personal protective equipment (PPE). b. SDS guidance. c. Proper disposal and waste management of lubricants and lubrication management-related consumables. d. Slip, trip, and fall risks account for the lubricants’ traction effect on walking surfaces. e. Lubricant hazards or toxicity. f. Microbial safety risks and control of transmission to other vessels, tools, or machines. g. Fluid pressure and fluid injection risks into the bloodstream. h. Inhalable lubricant mists in the work environment. i. Lubricant and lubrication-specific confined space risks. j. Lubricant and lubrication-specific fire and combustion risks. k. Potential electrocution risks. l. Other general mechanical risks associated with the execution of the lubrication management plan(s). General Note: The organization should consider aligning its lubri­ cation health and safety management practices with ISO 45001 and ISO 14001, as amended, and their subparts. 5.4.2 Planned maintenance task elements Planned lubrication tasks may be organized into optimized routes and work packets in a manner that complies with the organization’s maintenance plan­ ning, scheduling, and work management policies as set forth in the organiza­ tion’s physical asset management plan. The execution of routine lubrication tasks should include stored or laid-up components and machines to reduce the effects of static degradation mechanisms, such as corrosion or fretting. The definition and interval for such tasks must be adjusted as appropriate. Appropriately qualified (lubrication) technicians, maintenance mechan­ ics, or operators shall execute planned lubrication tasks. Planned lubrication tasks intend to achieve one or more of the following objectives: a. Follow safe work practices. b. Preserve and optimize the reliability and safety of the lubricated com­ ponents, machines, or systems. c. Satisfy operational needs to include managing the timing of the perfor­ mance of tasks from a production perspective. d. Optimize energy conservation.

34 Lubrication Management Plan(s) e. Minimize environmental impact. f. Prevent or control the ingress of particles, moisture, chemical, and/or other contaminants, and achieve an optimized level of contamination control. g. Preserve and optimize the integrity and function of the lubricant provid­ ing service to the lubricated component, device, or machine. h. Prevent or control the internal loss of lubricants to the presence of com­ bustion exhaust gases, coolant fluids, fuels, compressed gases, process fluids/solids/gases, and/or internal compartments. i. Prevent or control the loss of lubricants through external leakage to machine work areas or the environment. j. Collect pertinent data or information to assess the condition of the lubri­ cant and/or evaluate the condition and health of lubricated components and/or machines. k. Identify the presence of particles, moisture, chemical, and/or other contaminants. Commonly planned (predetermined and scheduled) lubrication tasks may include the following elements: a. Fill or place lubricant in dispensing devices, sumps, reservoirs, and/or lubricated components and/or machines. b. Inspect the lubricant, the lubricant dispensing or application device, the lubricant condition control device, the lubricated component or machine, and/or the area where the lubricated component or machine resides. c. Change reusable or disposable components that are necessary for effective lubrication of lubricated components or machines. Examples include filters, lubricant application devices, breathers, etc. d. Extract a representative sample of lubricant [1] for field or laboratory analysis to evaluate the physical, chemical, and/or performance proper­ ties of the lubricant. e. Extract a representative sample of lubricant [1] to detect and quantify the presence of dust, water, chemical, or other contaminants that might compromise the performance of the lubricant and/or damage the lubri­ cated components or machines. f. Extract a representative sample of lubricant [1] to identify and analyze abnormal wear in lubricated components and machines. g. Remove foreign material and particulate to improve cleanliness through filtration or other approved methods to meet lubrication program plan requirements.

5.4 Planned and Corrective Maintenance Lubrication Tasks 35

Note 1: Lubricant samples may be extracted from different points on the component or machine depending on the objectives set forth in the scheduling of the sampling task. Samples that are extracted as planned lubrication tasks are drawn from a previously designated sampling loca­ tion while the machine is operating under similar conditions. The repet­ itive nature of this sampling task supports data trending from lubricant analysis and condition monitoring. Unlike samples taken as planned lubrication tasks, exception samples are taken in response to a report­ able condition that requires confirmation and troubleshooting. When designing planned lubrication tasks, the organization should: a. Include the safety of personnel, cost justification, and the risk manage­ ment of machine assets. b. Ensure that the tasks are aligned with the organization’s physical asset management plan. c. Optimize the development of routine lubrication tasks to assure reason­ able control of lubricant health and to preserve its condition. When setting task intervals, the following should be considered: a. Personnel safety to include appropriate permits or risk assessments and associated requirements. b. The estimated P–F interval for the lubricant and/or machine for com­ mon failure modes. c. The failure risk profile for the lubricant and/or lubricated component or machine [2]. d. The availability of data to support runtime/miles-kilometers/cycles and/ or condition-based task interval decisions. e. The plant machinery operating history. f. Production constraints. Task design and selection should consider internal/external expert opinion and operating experience. Additional attributes or processes to consider include: a. Component or machine supplier recommendations. b. Vendor warranty requirements. c. Inductive engineering analysis methods utilizing FMEA, which may include reliability-centered maintenance (RCM) initiative or other engi­ neering analysis methods that, when applied, will drive equipment reli­ ability improvements as appropriate.

36 Lubrication Management Plan(s) d. Engineering analysis methods utilizing FRACAS, which may include application apparent cause analysis (ACA) and/or RCA. e. Required access and/or accessibility to the task location point and the required operating state (runtime or downtime). f. Required operating state (runtime or downtime). Note 2: Factors used to set performance intervals may include opera­ tion severity and runtime (miles-kilometers, cycles, etc.) This applies to either the lubricant or the machine. Advanced engineering reliabil­ ity tools such as Mean Time to Failure (MTTF), Mean Time Between Failures (MTBF), Weibull Analysis, etc., may be used to provide addi­ tional information in making these assessments. Clearly worded and documented procedures created for planned lubrication tasks should provide sufficient detail and clarity to assure that the tasks are completed correctly and consistently, and with an appropriate degree of pre­ cision. Documented lubrication procedures for these tasks should include: a. Task description and summary. b. Task purpose and objectives. c. Required knowledge, skill(s), and/or qualifications to implement the task. d. Estimated or actual time to complete the task. e. Tools, parts, and consumables required for working the task. f. Prework/job preparation to include safety or other organization briefing requirements. g. Requirements to meet site safety measures. This may include a sum­ mary of standard TSEA for the task and required job site observations or inspections to assure safety and environmental compliance. h. A mandatory sequence of activities (as appropriate). i. Unique attributes of the task including lubricant type, max/min lubri­ cant final volume, and max/min dispensing rates during addition, etc. j. Required documentation entry fields for use during or after task com­ pletion to include worker observations/experience provided for contin­ uous improvement program use. k. Postwork cleanup requirements. l. Postwork inspection and follow-up reporting requirements. 5.4.3 Corrective maintenance tasks elements Appropriately qualified (lubrication) technicians, maintenance mechanics, or operators shall execute periodic (nonrecurring) lubrication tasks. These are

5.4 Planned and Corrective Maintenance Lubrication Tasks 37

tasks that are completed on an emergent or nonscheduled, time-based inter­ val. These tasks are identified by condition assessments that may range from issues identified through predictive maintenance or discovery of a machine failure. Corrective maintenance tasks may be triggered by inspection or oper­ ator alerts. Corrective maintenance lubrication tasks are intended to achieve one or more of the following objectives: a. Preserve the reliability of the machine/lubricated machine component, or remediate the fault or failure condition (failure mode). b. Preserve or restore the integrity of the lubricant that is providing service to the lubricated component or machine. c. Address the ingress of dust, moisture, chemical, and/or other contami­ nants to avoid damage to the lubricated component or machine. This is commonly accomplished through filtration and similar methods. d. Address the ingress of dust, moisture, chemical, and/or other contam­ inants to avoid compromising the performance of the lubricant. This may be accomplished through methods such as filtration, dehydration, or replacement of the lubricant. e. Collect data or information pertinent to assessing the condition of the lubricant or machine. The information obtained may identify the pres­ ence of dust, moisture, chemical, and/or other contaminants or help establish the condition and health of lubricated components within a machine. Common outcomes of corrective maintenance lubrication tasks may result in the need for: a. b. c. d. e.

Restoration of the correct lubricant level in a machine’s sump or reservoir. Purging bottom sediment and water from a machine’s sump or reservoir. Changing/replacing the lubricant in machines. Improving lubricant cleanliness. Adding lubricant to total-loss lubrication devices or systems, including bottle oilers, oil mist systems, single-point lubricators, auto-lubricators, or centralized lubrication systems. f. Replacing or maintaining filters, air breathers, gaiters/boots, gaskets, filter banks, and/or other contaminant removal or exclusion devices that cannot be maintained as a matter of routine. g. Cleaning sumps, reservoirs, piping, supply lines, etc. h. The redesign, replacement, and/or rebuild of lubricant application devices, lubricant condition control devices, lubricant monitoring devices, or other components or systems necessary to assure the proper lubrication of lubricated components and machines.

38 Lubrication Management Plan(s) i. Flushing of the lubrication system during the commissioning of the lubricated component and/or machine and/or after a rebuild or overhaul of the lubricated component and/or machine [1]. j. System varnish removal (de-varnishing), water removal (dehydrating), gas extraction (degassing), or other lubricant reclamation/recondition­ ing practices. k. Performing detailed and often invasive inspections of the lubricated component and/or machine. l. Obtaining samples from sampling ports for troubleshooting, or to acquire additional oil for further testing. m. Reconstructing lubricant additives by the addition of additive concentrates or by bleed-and-feed (or similar methods to improve lubricant properties by progressively removing a fraction of the old oil while simultaneously replacing it with new oil without disturbing operation) [2]. n. Reclaiming lubricants to restore their physical, chemical, and perfor­ mance properties [2]. Note 1: Flushing may be executed in compliance with ASTM D6439,

ASTM D4174, ISO 23309, ISO 164310, and many other similar

standards.

Note 2: Lubricant reclamation often entails additive reconstruction,

which should only be done under the supervision of appropriate experts

who possess or can obtain the necessary analytical data required to con­ firm the successful completion of the task.

When designing, specifying, and executing corrective maintenance lubrica­ tion tasks, the organization should consider the following: a. Component or machine supplier recommendations to include warranty requirements. b. Inductive analysis methods utilizing FMEA, which is often conducted while completing RCM, or other initiatives or methods that drive equip­ ment reliability improvements as appropriate. c. Suitable reasoning methods such as FRACAS, which may or may not include the application of apparent cause analysis (ACA) and/ or RCA. d. Required access and/or accessibility to the task location point and the required operating state (runtime or downtime). Corrective maintenance lubrication tasks do not have recurring intervals that are based upon a schedule of time/miles-kilometers/cycles. Corrective

5.4 Planned and Corrective Maintenance Lubrication Tasks 39

maintenance lubrication tasks are scheduled and then performed in response to nonconforming conditions derived from testing and/or inspections, or in response to a catastrophic failure event or an impending event. Corrective maintenance task documentation should consider the following: a. Optimizing resources to minimize organizational impact. This may include the availability of anticipated spare parts. b. Assuring the reasonable control of lubricant and lubricated compo­ nent’s health. c. Compliance/alignment with the organization’s physical asset manage­ ment plan. d. Whether the task construction complies with the organization’s mainte­ nance planning, scheduling, and work management policies as set forth within the organization’s physical asset management plan. e. Whether the task documentation has sufficient detail and clarity to assure that the task is completed correctly, and with an appropriate degree of precision. Documented procedures for corrective maintenance lubrication tasks should provide significant detail of task complexities due to the likelihood of a rela­ tively rare occurrence, and limited prior experience by maintenance person­ nel. Elements for documentation may include: a. Detailed TSEA for the task and required job site observations to assure safety and environmental compliance. This should include confined space and required permits/risk evaluations as appropriate. b. Required authorizations to commence work. c. A detailed task description and summary. d. Task purpose and objectives. e. Estimated or actual time to complete the task. f. Required knowledge, skill(s), and/or qualifications to complete the task. g. Tools and materials (including parts and consumables) required for completing the task. h. Prework preparation, including scaffolding, staging of materials, etc. i. Work permits or other site requirements. j. Clear, objective, and detailed work instructions including pictures, drawings, and other visual aids [3]. k. Definition of all specifications, tolerance, quantity, and quality details (e.g., lubricant type, max/min lubricant volume, max/min dispense rate, etc.) l. Observations required to ensure that the task was successfully executed.

40 Lubrication Management Plan(s) m. Required work quality checks and sign-offs. n. Postwork cleanup. o. Postwork inspection and follow-up requirements. Note 3: Corrective maintenance lubrication tasks are often a compound compilation of multiple subtasks. Special attention must be paid to the sequencing of subtasks to clearly identify the order of steps to be done and/or which subtasks may be completed in parallel. General Note: Intensive and intrusive lubrication-related inspections should be performed in the first one-third of a major shutdown/turn­ around/outage event. This is to allow time for discovery and recovery, and to address anticipated provisional findings or follow-on work with­ out compromising the shutdown schedule. Contingency plans must be created to address all foreseeable observations derived from the inspec­ tions, including critical decision points.

5.5 Lubrication Support Facilities and Tools The lubrication program management plan shall have a lubrication support facility and tools element. This element shall support and be aligned with the lubrication management plan. The organization shall ensure that tools, facilities, and equipment are properly maintained, calibrated, renewed, or replaced. The organization shall establish and maintain processes and procedures to control these maintenance and calibration activities. Well-maintained and calibrated tools, facilities, and equipment are essential for: a. The implementation of the lubrication management plan(s). b. Achieving the required function and performance from lubricants and/ or lubrication-related systems. c. The monitoring and measurement of lubricant condition and/or lubrica­ tion system performance. 5.5.1 Lubricant and lubrication support facilities and infrastructure Lubricants and lubrication-related systems, parts, consumables, etc., shall be received, stored, and dispensed in a manner that assures the appropriate quantity of required lubricants is available and in the appropriate condition to support the mission, strategy, and objectives set forth for the lubrication management plan.

5.5 Lubrication Support Facilities and Tools 41

The proper storage of lubricants, lubrication systems, lubrication parts, and lubrication-related consumables is essential for the effective, efficient, and safe execution of lubricant tasks. Investment in the necessary infrastruc­ ture is required to support lubricant storage and its management. Lubricant support facilities and infrastructure should include: a. A lubrication room that provides sufficient space and control of ambi­ ent conditions to maintain the lubricant assets in optimal condition. b. The management and dispensation of lubricants, lubrication tools, fil­ ters, breathers, and other lubrication accessories. c. Restricted access to the population that can obtain lubricants, to reduce the risk of poor lubricant management. d. Satellite storage areas, which may be created for large facilities by plac­ ing smaller/additional storage areas throughout the facility. Satellite storage facilities include tanks, piping systems, and mobile units (min­ ing, construction, etc.) e. Satellite facilities (when used) that comply with the same requirements as the primary lubricant storage area. f. Lubricant containers that are properly sized and of acceptable quality to support program requirements. g. A staging area that allows for support of lubrication tasks. h. Clear identification of lubricant types on each permanent, portable lubricant container [1]. i. Methods to receive and inspect new lubricants that minimize the risk of spillage and contaminant ingestion. j. Methods for lubricant stock rotation (e.g., first in, first out). k. A process to ensure that lubricants are not stored for extended periods prior to use. l. A process to determine if new lubricants meet specification requirements. m. A process to decontaminate or reject lubricants is deemed to be unac­ ceptable upon receipt. n. Sample points that provide effective, efficient, and safe access for the sampling of stored lubricants. o. A sampling process of stored lubricants that minimizes the risk of con­ taminant ingestion. p. A process to manage lubricant samples for testing. q. Effective, efficient, and safe access to allow periodic filtration and/or conditioning when required. r. Containment areas to collect incidentally spilled or leaked lubricants to avoid safety and/or environmental risks.

42 Lubrication Management Plan(s) s. Separation of new and used lubricants. When kept in near proximity, clearly marked containers for storing used oil to avoid reuse. t. A disposal plan to ensure proper handling and management of waste per the organization’s safety and environmental compliance standards and requirements. u. Safety provisions such as appropriately positioned eyewash stations and ventilation. v. Ready access to SDS/MDS sheets. w. Local and national environmental regulations available for use. Note 1: Labels shall be intuitive and easy to use. One approach is to incorporate a color/shape/symbol code-based system so as to minimize the risk of cross-contamination. Other systems that meet this intent are also acceptable. 5.5.2 Tools, instrumentation (automation), and consumables The work tools, instrumentation, and consumables required to support the execution of the lubrication management plan(s) should: a. Be specified to comply with recognized performance and quality standards. b. Be specified to meet the requirements of the lubrication management plan(s) for which they are intended. c. Be stored properly to assure availability, accessibility, and proper oper­ ational performance. d. Be routinely calibrated to recognized standards. e. Be evaluated for acceptable expected performance. The use of interlab­ oratory testing, gauge R&R (Repeatability & Reproducibility) analysis, and/or similar methods to demonstrate accuracy should be considered. Tools are necessary to apply the right lubricant at the right time and in the right condition to assure the effective lubrication of components and machines. The proper selection of work tools, instruments, and consumables is necessary to support the optimum requirements of the lubrication plan, as the execution of lubrication tasks relies on the use of proper tools. These tools include but are not limited to: a. Grease and oil dispensing devices, grease nipples, quick-coupling devices, flow volume and pressure indicating devices, etc. b. Offline loop or full volume filtration and other decontamination devices. c. Sampling valves and their associated hardware.

5.6 Machine and Lubricant Inspection 43

d. Portable devices used for the extraction of representative lubricant sam­ ples for either onsite or offsite analysis. e. Instruments and other hardware required to support inspection or test­ ing tasks associated with onsite lubricant analysis. f. Contaminant exclusion and/or consumables, such as breathers and filters. g. Consumables for cleaning up incidental lubricant spills. h. Shop rags, lint-free cloths, gloves, and/or barrier cream, along with other consumable items.

5.6 Machine and Lubricant Inspection The lubrication program management plan shall have a machine and lubri­ cant inspection element. This element shall support and be aligned with the lubrication management plan. An inspection provides immediate feedback on the machine’s current state and allows recognition of changing conditions. Data gathered from various other planned inspections are combined and related or unified along with other condition monitoring data. These data streams may originate from predictive maintenance tasks such as lubricant analysis, vibration, acoustics, or informa­ tion obtained from sensors such as temperature, flow, pressure logs, etc. In addi­ tion, inspection is used to assure proper lubrication of lubricated components and machines, and to contribute to the organization’s knowledge and under­ standing concerning the health of the lubricated components and machines. Gathering equipment performance data is a type of inspection that is normally scheduled and implemented within planned tasks. The data obtained and evaluated may reveal deficiencies that require corrective maintenance. The corrective actions may be performed in conjunction with other planned work tasks. In other cases, the deficiency may require only corrective main­ tenance to address the deficiency. Inspections are used to support RCA functions associated with the symptoms of the component/machine failure and/or impending failure of the lubricant or lubrication system. Inspection, in the context of lubrication and the health of lubricated machines, should provide the organization with infor­ mation about: a. The volume of lubricant in the machine by the use of level gauges, sight glasses, dipsticks, or inspection portals/hatches. b. The temperature of the machine by the use of gauges and/or tem­ perature guns (noncontact thermometers), heat guns, pyrometers, and

44 Lubrication Management Plan(s)

c. d. e. f. g. h. i. j. k. l. m. n. o. p. q. r.

thermography cameras to detect changes in temperature and localized hot spots. Fluid pressure using portable or machine-installed gauges or transducers. Filter condition using pressure differential gauges and bypass indicators. Changing lubricant color and clarity. Abnormal indications of entrained air and surface foam. Evidence of emulsified or free water. Presence of tank or reservoir bottom sediment and water. The serviceable condition of breathers and vents. Leakage past gaskets, seals, actuators, fittings, unions, ports, and hoses. Headspace conditions in tanks, reservoirs, gear cases, etc. The presence of foam, varnish, sludge, and excessive turbidity. Potential contaminant ingress sites, e.g., hatches, clean-out covers, vents, seals, etc. Dirt and other contaminants on the machine exterior. Abnormal machine operating sounds. Abnormal machine operating movements, such as looseness or exces­ sive vibration. Excessive wear debris generation as evidenced in bottom sediment, magnetic plugs, and chip collectors. Whether labeling remains legible.

The inspection plan used in support of this element should be a detailed and comprehensive document. Key features and functional elements should define a level of acceptability. This overarching document should be used as a higher-tier document that can be abridged or streamlined for use by inspec­ tion technicians and operators. Inspection findings and discoveries should be reported to the appropriate management. The inspection plan should include the following topical elements: a. Multiple disciplines: Inspections should be cross-disciplinary in design. Inspection activities may include lubrication, mechanical main­ tenance, electrical, safety, and operational inspections. b. Common goals: An inspection should routinely gather information that supports an assessment of the health and conditions of the machine as well as individual machine components, including the lubricant. Inspection and other condition monitoring activities and technologies should conform or be aligned with the lubrication program and reliabil­ ity and asset management objectives. c. Alignment to ranked failure modes: The inspection plan should define and document the questions that inspections are supposed to

5.6 Machine and Lubricant Inspection 45

d.

e.

f.

g.

h. i.

answer. For instance, what inspection tasks and methods provide alerts to common failures in progress? Also, how does inspection recognize and then alert the organization to root causes associated with each of these ranked failure modes? The inspection plan should provide a check to confirm all inspection methods and tasks are aligned to a prominent failure mode or can be directed at its root cause. Machine inspection ownership: The inspection plan defines who owns the inspection responsibility. (The best choice is often the machine oper­ ator, as he/she is the person who works physically close to the machines and can recognize subtle differences between normal and abnormal. In other cases, the best choice may be an inspection technician who works full-time in many or all disciplines of condition monitoring, such as vibration or lubrication analysis.) Inspection points: Inspection points are physical locations on the machine that must be clearly defined within the inspection plan. These could be couplings, shaft/seal interfaces, breathers, hose connections, sight glasses, gauges, etc. Some inspection points may need to be cre­ ated or installed as required to fully achieve the inspection objective. These might include the addition of inspection windows, gauges, test points, sample valves, sediment bowls, etc. Inspection tasks and methods: Inspections can be simple (e.g., deter­ mine the oil level from the sight glass) or more complex (e.g., use a laser point [1] to determine the abnormal presence of particle contamination). If the task or method involves many steps or requires special techniques or tools, the inspection plan must reference a procedure. Both the “nor­ mal” and “abnormal” conditions must be defined to ensure that the inspections and data collection have the most impact, as well as to alert those doing the inspections of any potential issues while in the field. Inspector skills, training, and qualifications: Inspection requires qualified inspectors who possess the required knowledge and skills needed to perform the tasks and methods in the inspection plan, pursu­ ant to the asset management and lubrication management strategy. An inspector must qualify to perform inspections. Tools needed: The inspection plan (or the referenced procedure) should list each of the tools needed as many tools or inspection aids enable types of inspections that otherwise could not be performed. Inspection findings and data collection: Data collection must be uni­ form and structured. The type of inspection data to be collected and the manner in which it will be reported need to be included in the inspec­ tion plan.

46 Lubrication Management Plan(s) j. Inspection routes: Inspection routes should be documented in the inspection plan. This is especially helpful when a specialized inspection instrument or tool is used on only a few machines and inspection points. k. Health and safety issues: All inspection procedures should fully cover any relevant health and safety issues. l. Metrics and compliance: The inspection plan should define how inspection findings are reported, individually and collectively, to main­ tenance and management personnel. Inspection compliance in terms of whether the inspections were performed timely and effectively should be logged and reported. Note 1: The use of a laser point is one option to obtain this information. The organization should routinely conduct audits of the inspection plan. There are five potential inspection states. Some involve routine inspec­ tion and some involve on-condition or condition-directed inspections of lubricated components and machine parts. A comprehensive inspection pro­ gram should include or consider the importance of all five states. These are: a. Inspection of spares, storage, and equipment: Machines may become heavily damaged by contamination, corrosion agents, and vibration during storage and when kept on standby. An inspection might conclude that: i. All shafts and couplings have protective coatings still in place. ii. Lube lines and components are tightly sealed (caps, plugs, etc.) iii. Hatches and covers are tight and secure. iv. Reservoirs and sumps are clean and free of water and sludge. v. Shafts are being rotated frequently [2]. vi. Dirt and other debris have not accumulated on exterior surfaces. vii. Parts and small assemblies are sealed (e.g., plastic sheets/bags) and oriented correctly. viii. Parts and small assemblies are used in a first in, first out manner to prevent the excessive storage time of common spare parts such as bearings. ix. Proper positioning of safety equipment such as guards, gates, or other barriers. x. Labels or other processes that are particular to the storage con­ dition that would not be obvious to the inspector, such as “full vapor phase inhibitor” with application date or dated sign-offs that demonstrate the performance of storage requirements such as peri­ odic shaft rotations.

5.7 Condition Monitoring and Lubricant Analysis 47

b. Postinstallation/refurbishment inspections: Many machines are more prone to failure at start-up, after repair, or at the time of commissioning. Start-up inspections might include: i. Temperature (all critical zones, components, and surfaces). ii. Vibration. iii. Balance and alignment. iv. Gauge readings (temperature, pressure, vacuum, flow, speed, prox­ imity, etc.) v. Differential filter pressure. vi. Magnetic plug collections. vii. Oil level, color, and clarity at all sight glasses. viii. Leak zones. c. Run inspections: Run or runtime inspections cover the extensive pro­ gram of monitoring the machine during normal operating conditions. d. Stop inspections: Access to certain components or interior zones may only be available when machines have stopped running (downtime) or during changeovers, outages, and other scheduled maintenance. Access to inspect gear teeth, sump walls, couplings, shaft seals, bottom sedi­ ment and water (BS&W) bowls, magnetic plugs, bearing clearances, and shaft play are examples. e. Repair inspections: During machine or component repairs or rebuilds, access to the interior zones can be achieved. Findings from repair inspec­ tions can be valuable to assess root cause conditions (e.g., mechanical alignment, contamination, lubricant starvation, etc.) and RUL. Note 2: In-storage maintenance may require relubrication when turn­ ing a shaft (e.g., electric motors).

5.7 Condition Monitoring and Lubricant Analysis The lubrication program management plan shall have a condition monitoring and lubricant analysis element. This element shall support and be aligned with the lubrication management plan. Lubricant analysis is a primary condition monitoring technique within the lubrication management plan. Lubricant analysis provides import­ ant test data and other information related to the condition of the lubri­ cant or machine to assure proper lubrication of lubricated components and machines. This information contributes to the organization’s knowledge and understanding of the health of the lubricated components and the machines themselves.

48 Lubrication Management Plan(s) The most beneficial lubricant testing occurs with tests based on stan­ dardization. The use of standardized test methods and practices is vital, as the resulting documents contain information that can be used to determine the accuracy of the test data. Accuracy of test data is defined as test precision, which comprises the repeatability or reproducibility of its results. ASTM has developed numerous standards that provide requirements to test or manage the lubricant as it relates to lubrication machine asset management. Many ASTM condition monitoring standards are identified in Section 2.2. Lubricant test results, data trends, and field inspections along with other condition monitoring technologies are utilized for proactive and predictive maintenance, and to schedule planned and corrective maintenance lubrica­ tion tasks. Lubrication test data is used to support RCA functions associated with the symptoms of failure and/or impending failure of the lubricant, lubri­ cation system, and/or lubricated component or machine. In general, lubricant analysis provides the organization with information about: a. Whether the most suitable lubricant has been selected for the machine application. b. Whether the selected lubricant was placed into service, or if the lubri­ cant is incorrect or an accidental mixture of various lubricants. c. The health and RUL of the lubricant with respect to its physical, chem­ ical, and performance properties. d. Failure indicators that support or refute root cause investigations such as: i. The concentration and nature of dust, water, chemical (e.g., corro­ sive agents, coolants, refrigerants, or process chemicals or gases), and other contaminants that reside in the lubricant. ii. The occurrence of excessive heat or exposure to radiological contamination. iii. Abnormal mechanical or operating conditions related to installa­ tion, pressure, speed, alignment, and balance. iv. Whether under-lubrication (starvation) conditions are occurring or have occurred. e. The health of the lubricated component or machine that is revealed by the lubricant. f. The performance of contamination control devices, such as the effec­ tiveness of breathers, filters, dehydrators, coolers, etc. Lubricant analysis is a compilation of data from multiple tests that are per­ formed on the lubricant sample. To assure the effective execution of lubricant analysis, the organization should:

5.7 Condition Monitoring and Lubricant Analysis 49

a. Determine which lubricated components/machines and the specific lubricant(s) used by the components/machines will receive lubricant analysis. This may be accomplished by considering asset criticality analysis, FMEA, FRACAS, RCA, and other appropriate methods and engineering analysis as specified in the organization’s physical asset management plan. b. Determine the combination of lubricant analysis tests required to pro­ vide adequate information about the target conditions for the lubricant and/or the lubricated component or machine. Consideration of machine failure modes that the tests are capable of monitoring should also be considered [1]. c. Determine the appropriate interval for sampling and analysis of lubri­ cants by considering: i. The P–F interval for the lubricant and/or the lubricated component or machine. ii. The machine criticality rating based upon a combination of safety, financial, and the MRO cost risk profile. iii. The failure risk profile for the lubricant and/or lubricated compo­ nent or machine, as a function of runtime, miles-kilometers, cycles, etc., for the lubricant, and the lubricated component or machine by employing reliability engineering analytics (e.g., MTTF, MTBF, Weibull Analysis, etc.) iv. The availability of data to support runtime/miles-kilometers/cycles and/or condition-based task interval decisions. v. Insurance or other regulatory requirements. d. Determine the appropriate sampling location(s) to extract the lubricant sample. This location should require a repeatable and useful machine condition to obtain consistent sample material. e. Consider the use of labels where samples will be extracted. f. Determine the required hardware and modifications to the lubricated component or machine to enable nonintrusive or minimally intru­ sive lubricant sampling. An ideal oil sample is from a turbulent fluid obtained while the lubricated component or machine is operating under typical load and speed conditions. g. Ensure that obtaining the sample will not place the machine in jeopardy. h. Determine optimum cautionary and critical limits (alarms) or targets for all reportable, routine lubricant analysis test results. Targets are typ­ ically used for root causes (abnormal viscosity, particle contamination, water contamination, glycol contamination, etc.) The required testing and limits/targets may vary by machine type and application.

50 Lubrication Management Plan(s) i. Trend or compare data from previous samples and limits/targets. Significant changes may signal incipient or impending failure condi­ tions and impaired machine reliability. j. Determine the lubricant analysis testing that may be conducted onsite by resident lubrication technicians and contractors. Portable or nearby bench-level instruments may be used to obtain quick results. Such onsite testing requires: i. The selection of test methods and instruments. ii. The selection of necessary ancillary hardware, materials, and workspace. iii. Trained and qualified technicians and/or analysts. iv. Standardized procedures. v. Instrument calibration and test standards to ensure instrument and method quality and accuracy. vi. Data collection and management methods. vii. Health and safety protection. viii. Waste disposal. k. Determine the lubricant analysis testing that should be conducted offsite by a qualified commercial lubricant analysis laboratory [2]. Some key lubricant condition monitoring tests are listed below: i. Viscosity ii. Water content iii. Neutralization (acid or base number) iv. Cleanliness (particle counting) v. Chemical composition and soot contamination (FTIR, Fourier Transform Infrared) vi. Elemental analysis of soluble and insoluble compounds vii. Microscopic particle identification and characterization viii. Oxidation stability ix. Air handling ability (air release/foam tendency) x. Flash point xi. Grease consistency l. Determine requirements for lubricant analysis tests and machine loca­ tions (if any) that require continuous analysis by embedded machine sensors (e.g., for monitoring viscosity, particle counts, wear debris, gases, moisture contamination, etc.) m. Establish a lubricant analysis information management system to sup­ port trending and analysis of lubricant analysis data and information. This system should work in conjunction with the organization’s general condition monitoring information management system as well as its

5.8 Fault/Failure Troubleshooting and Root Cause Analysis 51

enterprise asset management (EAM) and/or through the availability of procedures/events within a well managed CMMS, and as specified in the organization’s physical asset management plan. n. Specify the required knowledge, skills, and qualifications required to carry out the various lubricant analysis tasks assigned. Note 1: Some lubricant analysis tests are conducted routinely. Others may be conducted periodically or only on condition (or on exception) as required. Note 2: The laboratory must have suitable accreditation and certifica­ tion credentials such as ISO 17025 and ASTM D6259. General Note: Complex circulating systems may require sampling from multiple locations to properly assess the condition of the lubricant and/or the lubricated component or machine and/or to serve the needs of various investigations. Such additional locations may be used for troubleshooting and can be instrumental in isolating problems to indi­ vidual components.

5.8 Fault/Failure Troubleshooting and Root Cause Analysis The lubrication program management plan shall have a fault/failure trouble­ shooting and root cause element. This element shall support and be aligned with the lubrication management plan. 5.8.1 Fault analysis The organization shall implement, document, and maintain processes and/or procedures for the handling and investigation of lubricant and/or lubrication-related failures, incidents, near misses, and/or nonconformities associated with lubricated components and machines where a failure of the lubrication management system is believed or suspected to be the causal fac­ tor and/or a contributing causal factor. Some elements to consider should include: a. A predetermined process to determine the level of effort or appropriate resource allocation that is most suitable to the failure investigation. b. A process to determine the relative importance of the lubrication-related assets. This evaluation may be a subset of the physical asset manage­ ment program. c. The level of involvement of management in these evaluations. d. A process to implement corrective action findings.

52 Lubrication Management Plan(s) e. A process to document corrective action findings and conclusions. f. A process that will allow retrieval of documented findings for use in determining whether the issue being addressed is reoccurring for this or similar machines. g. A process or metric to measure the effectiveness of the evaluations and actions taken. 5.8.2 Troubleshooting Effective troubleshooting requires the use of a graded approach that extends effort commensurate with the consequence of the failure in terms of the safety of personnel, machine repair costs, and the risk posed to operation or produc­ tion. The following elements support an effective troubleshooting plan: a. b. c. d.

Documentation of the troubleshooting steps. Predetermination of the level of management involvement. Preservation of evidence to allow determination of the cause. A review process for the troubleshooting game plan or evaluation rec­ ommendations [1]. Note 1: When the recovery approach is to begin immediately, with a series of previously used fixes, this approach may potentially cause new deficiencies, or—if successful—it may mask the underlying cause of the condition and obscure the corrective action that produced the fix.

5.8.3 Root cause analysis Preventing the recurrence of a failure requires specific knowledge of the root cause and the contributing causes that produced the fault or failure. General lubricant specification and handling practices are often root causes that lead to widespread machine reliability reduction, followed by reduced machine life. Generating corrective actions from a single failure can often have a mul­ tiplicative effect on other components and systems within a facility. Failure analysis strategies may include the following: a. Determining which failure(s) are of sufficient impact to designate it/ them for RCA. b. Determination of the scope of the failure or possible failure for machines in similar service or of similar design. c. Using a step-stage RCA process such as outlined below:

5.9 Lubricant Waste Handling and Management 53

i. Data collection (discovery of relevant facts, evidence, and data related to the failure and its causes). ii. Assessment related to determining all possible causes starting with immediately preceding causes and working backward to the termi­ nal root cause(s). Major root cause or contributing cause categories related to lubricated mechanical machinery include: 1. Machine/component design/manufacturing defect. 2. Mounting or installation defect. 3. Wrong selection of lubricant. 4. Wrong application of lubricant. 5. Contamination of lubricant. 6. Negligence or deferred maintenance. 7. Lubricant starvation (numerous). 8. Training deficiency. 9. Wrong or unavailable maintenance procedure. 10. Inadequate budget for tools and resources. 11. Lack of management awareness or support. iii. Perform corrective actions to bring the machine or component to a full operating state and remediate the discovered root cause(s). iv. Inform and document the event and RCA findings. v. Follow up to confirm that remediation was successful and sustained.

5.9 Lubricant Waste Handling and Management The lubrication program management plan shall have a lubricant waste han­ dling and management element. This element shall support and be aligned with the lubrication management plan. All lubricant and lubrication system-related methodologies pertaining to lubrication waste handling and management should support the organi­ zation’s physical asset management plan. Elements of waste handling and management should include: a. Specifying and acquiring lubricants, lubrication systems, and lubricant condition control systems in accordance with lubricant specifications. b. Obtaining consumables appropriate for waste management. c. Management of lubricants and consumables to reduce waste. d. Documents and procedures for the handling, disposal, and/or reclama­ tion of lubricants, lubrication systems, lubricant condition control sys­ tems, and consumables required for lubrication management.

54 Lubrication Management Plan(s) e. Inspection and analysis plan(s) to support documents, tasks, procedures, and regulatory or site environmental requirements. These may include: i. Specific technical instructions to achieve the objectives set for lubrication management over the entire lubrication life cycle. ii. SDS information for all lubricants and applicable materials.

5.10 Energy Conservation and Environmental Impact The lubrication program management plan shall have an optimum energy conservation and environmental impact element. Effective and optimum management of the elements of the lubrication program seeks to reduce main­ tenance costs and increase machine reliability, while also having a marked influence on energy consumption and the environment. For instance, optimum lubricant selection can reduce wear, extend machine service life, and reduce friction. Both reduced wear and friction have a positive impact on energy conservation and the environment. Further, many factors involved with lubricant application have an equally favorable impact on energy conservation and the environment. 5.10.1 Energy conservation A critical aspect of lubrication management is the reduction of fluid friction and the friction generated at the lubricated surface. Reduced fluid friction reduces the portion of the machine energy that is allocated (or needed) for the lubricant to perform at optimum design speeds and loads. Reducing fluid friction occurs when the most appropriate lubricant is selected for an applica­ tion. Reducing fluid friction must be balanced against mechanical interfacial friction and wear [1]. The organization shall consider the following energy management fac­ tors pertaining to its lubrication management plans: a. Lubricant selection to include an evaluation of the physical and chemi­ cal properties that minimize mechanical friction and fluid friction, and reduce energy consumption [1]. b. Lubricant selection (initial fill) in terms of manufactured product qual­ ity that minimizes friction and energy consumption [1]. c. Contamination control of lubricants, systems, and subsystems to min­ imize the presence of foreign or internally generated particles that can be expected to increase friction. d. Sizing and design of lubricant pumping systems and piping to minimize turbulent flow and fluid friction.

5.10 Energy Conservation and Environmental Impact 55

e. Fluid volume (grease and oil) to minimize churning, turbulence, and fluid friction. f. A monitoring program that regularly measures and trends lubricant health. g. A process that measures and verifies claims of energy reduction and then compares these claims to targeted savings (e.g., current consump­ tion, power index, temperature, fuel consumption in engines, etc.) Note 1: Energy conservation decisions should consider all potential consequences, including maintenance costs, machine reliability, and safety. General Note: the organization should consider aligning its lubrica­ tion energy management practices with ISO 50001, as amended, and its subparts. 5.10.2 Environmental impact Reduced demand for nonrenewable fossil fuels means cleaner air, reduced greenhouse gas emissions, and a healthier environment. When fuels are not consumed, there is no waste stream (smoke stack, tailpipe, etc.) nor the risk of pollutants from emissions such as nitrogen oxides (the principal compo­ nent of smog), sulfates, or CO2. Unburned hydrocarbons are reduced, as well. Hence, when there is a better economy in the consumption of both petroleum fuels and mineral-based lubricants, there is reduced dependence and con­ sumption of nonrenewable fuels. A significant and overarching benefit is a reduced carbon footprint related to plant or fleet operation. Lubricants and lubrication methods that reduce energy consumption will normally reduce heat and wear debris generation (with some exceptions). When heat and wear debris are reduced, less stress is imposed on additives and the base oil contained in formulated lubricants. The result will be longer ther­ mal and oxidative stability, lower oil consumption, and lower ancillary costs associated with oil changes. Furthermore, a well-designed and implemented lubricant analysis program can optimize lubricant change intervals and signifi­ cantly reduce consumption. When lubricant consumption is reduced, there is reduced disposal of the environment-polluting waste oil, and certain suspended contaminants—some of which may be hazardous and toxic. These benefits also lead to a significant and overarching reduction of carbon footprint. The selection, handling, and storage of lubricants shall meet regulatory and site requirements. These might include: a. Lubricants that are less toxic and more biodegradable. b. Lubricants that are food safe.

56 c. d. e. f. g.

Lubrication Management Plan(s)

Lubricants that can be recycled. Lubricants with longer service life. Indoor climate-controlled storage. Requirements to mitigate and retain spills. Reporting spill or usage to appropriate regulatory bodies.

5.11 Oil Reclamation and System Decontamination The lubrication program management plan shall have an oil reclamation and system decontamination element. The organization shall establish, imple­ ment, and maintain documented processes and/or procedures to support oil reclamation and system decontamination in support of the lubrication man­ agement plan. 5.11.1 Oil reclamation In-service lubricating oils may be replaced or reconditioned when they approach their end of useful life. Reconditioning (or reclamation) includes testing of in-service oil to determine the properties that require decontamina­ tion and the degraded properties that require replenishment (e.g., additives). Once these are determined, there is a need to assess the potential effect on the design and function of the lubricant before reclamation is performed. This process is highly specific to the lubricant and can pose a reliability risk when not properly executed [1]. In certain cases, waste oils can be re-refined and reformulated for use as replacement oil. Re-refining is generally only performed by service orga­ nizations that possess the required equipment, tools, and skills. This process involves the removal of existing additive chemistries (as possible), the testing of the resulting base oil, and the reconstruction of the lubricant additives and certain base oil components. This can be a cost-effective approach to obtaining replacement lubricants for use in the organization’s lubrication plan. It may also carry a reliability risk when re-refining and reformulation are not properly implemented, or when the restored lubrication is installed in machinery. For this reason, re-refined and reformulated lubricants are often blended with new lubricants to mitigate risks. Note 1: Reclamation is usually only applicable to machines and sys­ tems that hold large volumes of oil (e.g., turbine generators, centrifugal compressors, hydraulic systems, etc.)

5.12 Program Management and Metrics 57

5.11.2 System decontamination System decontamination or flushing involves mechanical or chemical clean­ ing of the system’s internal surfaces, including low-lying zones where sludge and sediment can be trapped. It is not related to the cleaning of in-service lubricants. Removal of surface deposits (including varnish), sludge, sediment (including wear debris), bacteria, etc., can restore machines to a higher state of reliability and enable new lubricants to have a longer service life. The methods, chemicals, tools, and processes used for decontamination and flushing are extensive. The correct selection of the flushing protocol is an engineering process, and environmental constraints or special requirements may exist, especially when chemical cleaning is required. There are many standardized procedures that can be consulted, including those published by ISO, NFPA, AGMA, API, SAE, and ASTM. The use of knowledgeable ser­ vice providers with specialized skills and tools should be strongly considered. A proactive approach to mitigating the need for flushing is important and detailed throughout this ICML 55.1 Standard. This includes practices to reduce contamination, remove contamination, frequently inspect and monitor lubricant health/state, and train/certify lubrication personnel.

5.12 Program Management and Metrics The lubrication program management plan shall have a program manage­ ment and metrics element. This element shall support and be aligned with the lubrication management plan. The identification and implementation of necessary control measures are required throughout the life cycle of the lubricant and lubrication systems. The organization’s lubrication-related risk management policies and systems shall comply with the risk management policies and systems as spec­ ified in the organization’s physical asset management plan. 5.12.1 Structure, authority, and responsibility The organization shall establish and maintain an organizational structure of roles, responsibilities, and authority consistent with the objectives of its lubrication management policy, strategy, and objectives. The enabling roles and responsibilities, along with requisite authority, shall be defined, documented, and communicated to all relevant individuals and stakeholders.

58 Lubrication Management Plan(s) Top management shall provide evidence of its commitment to the devel­ opment and implementation of the lubrication management system, includ­ ing continuous improvement of its effectiveness, by: a. Appointing a member of top management who, irrespective of other responsibilities, shall sponsor and take responsibility for the design, maintenance, documentation, review, and improvement of the organi­ zation’s lubrication management system. b. Appointing member(s) of management with the requisite authority to ensure objectives are achieved. c. Identifying and monitoring the expectations and roles within the lubri­ cation management system for the organization’s stakeholders. d. Ensuring that the lubrication management policy and strategy are con­ sistent with the organization’s physical asset management plan. e. Considering the adverse impact that the lubrication management pol­ icy, strategy, objectives, and plan(s) may have on other aspects of the organization; conversely, considering also whether plans generated from other parts of the organization might have an adverse effect on the lubrication management plan. f. Ensuring the viability of the lubrication management policy, strategy, objectives, and plan(s). g. Ensuring that lubrication program-related risks (and their corresponding risks to the organization’s physical assets) are included in the organi­ zation’s overall maintenance strategy and risk assessment management framework. h. Ensuring the availability of required resources, such as materials, funds, manpower, etc. These resources should be considered in terms of their balance to performance, risk, and cost. i. Ensuring an up-to-date succession plan. j. Actively communicating to stakeholders the importance of compliance with all relevant lubrication management system requirements. These communications should include the alignment between the lubricant and physical asset management plans. 5.12.2 Management outsourcing When an organization chooses to outsource any aspect or portion of its lubri­ cation management plan, it introduces the possibility of an unexpected out­ come that may affect the conformity of the plan to the requirements set forth in Section 5.0 of this standard. The organization shall ensure proper controls are in place to ensure alignment with the plan when outsourcing.

5.12 Program Management and Metrics 59

The organization shall evaluate and document the outsourcing within its lubricant management plan. Documentation should clearly detail how control will be exercised and integrated into the organization’s lubrication manage­ ment system. All such aspects of plan implementation shall conform to the requirements of the physical asset management plan. 5.12.3 Program documentation The organization shall establish, implement, and maintain up-to-date docu­ mentation to ensure that its lubrication management system can be adequately understood, communicated, and operated. The lubrication management sys­ tem documentation shall comply with the organization’s physical asset man­ agement documentation system. The organization shall create, execute, and maintain a lubrication man­ ual that clearly specifies the aspects associated with the execution, manage­ ment, and continual improvement of the organization’s lubrication policy, strategy, objectives, and plan(s). The lubrication manual shall contain the following elements: a. A clear and concise definition of the lubrication program policy and its importance to achieving the objectives of the organization’s physical asset management plan. b. A clear and concise description of the organization’s lubrication man­ agement strategy and its relationship to the organization’s physical asset management plan. c. A clear and concise description of the organization’s objectives for lubrication management and its relationship to the organization’s phys­ ical asset management plan. d. A clear description of the organization’s lubrication management plan(s) and its relationship to the organization’s physical asset management plan. The organization shall provide a process that associates the part number or technical designation of the specific lubricant usage to specific and/or unique machinery. The organization should structure its lubrication management manual to enable periodic auditing of practices. The organization shall organize its lubrication manual to enable effec­ tive, continual improvement and management of change. The organization shall maintain strict version control in accordance with ISO 9000 to ensure that all internal and external stakeholders have access to the requisite information.

60 Lubrication Management Plan(s) 5.12.4 Information management The organization shall identify the lubrication management information nec­ essary to meet the requirements of all phases of the lubricant management plan and the lubrication system life cycle. The information shall be of a qual­ ity appropriate to the lubrication management system and the activities it supports. The organization’s lubrication information management system shall comply with the information management policies and systems as specified by the organization’s physical asset management plan. 5.12.5 Communication, participation, and outsourcing The organization shall ensure that pertinent lubrication management infor­ mation is effectively communicated to and from employees and stakeholders, including contracted service providers. The organization shall ensure consultation with stakeholders that are relevant and appropriate to their involvement in: a. The development of the lubrication management strategy, objectives, and plan(s). b. The development of functional policies, engineering standards, pro­ cesses, and/or procedures. c. Risk assessments and determination of controls. d. Incident investigation. e. The continual improvement of the lubrication management system in support of the organization’s physical asset management system. 5.12.6 Change management When existing arrangements (equipment modifications) are revised, or when new arrangements (e.g., outsourcing) are introduced, this could have an impact on lubrication management activities. The organization shall assess the associated risks before the new or revised arrangements are implemented. The new or revised arrangements to be considered include: a. Revisions to the organizational structure, roles, responsibilities, or authorities. b. Revisions to lubrication management policy, strategy, objectives, or plan(s). c. Revisions to processes and/or procedures in support of lubrication man­ agement activities.

5.12 Program Management and Metrics 61

d. The introduction of new lubricated components, machinery, or lubrica­ tion systems, or of new technology being applied to the same. e. The introduction of new contractors or suppliers. 5.12.7 Metrics The organization shall develop metrics that will monitor the effectiveness of all twelve lubrication program elements as described in Section 5.0. The design and deployment of the metrics will enable awareness and documen­ tation of any element(s) trending toward an unsatisfactory state relative to the defined program element. The metrics shall include predetermined action plans when shortfalls are identified. A process will be developed to require the periodic review and reporting of metrics. The review process should include: a. b. c. d. e.

A time interval. A threshold to increase the interval of review and reporting. An action threshold. A documentation process. A reporting process to include management and other defined program stakeholders.

Areas that should be considered for inclusion within the metrics program include (this list is not conclusive but rather suggests areas for consideration): a. b. c. d. e. f.

Overall lubrication program performance compliance. Performance compliance of each element. Compliance metrics for the twelve elements along with action triggers. Lubricant and system contamination control. Manpower resource utilization ratios. Lubricant usage and consumption ratios.

Metrics that relate specifically to asset management, reliability engineer­ ing, quality, environmental protection, and various aspects of maintenance management (e.g., work management metrics) are outside the scope of this standard. The many existing standards that relate to these topics should be consulted and followed as appropriate. 5.12.8 Improvement actions The organization shall establish and maintain the processes and procedures for instigating a corrective action program that is designed to correct conditions

62 Lubrication Management Plan(s) or deficiencies (or exceptions) identified by the metrics. The program should be capable of assigning an action to avoid recurrence. The corrective action program should be designed to: a. Eliminate the cause of poor lubricant and/or lubrication performance. b. Eliminate nonconformities identified from investigations, evaluations of compliance, and audits. c. Create preventive action(s) to eliminate the potential causes of noncon­ formities or poor lubricant and/or lubrication performance. Any corrective or preventive action(s) taken and their associated timing for implementation shall be balanced against the possible encountered risk(s). The organization shall create and maintain records of corrective and preventive actions taken, including the time interval from the identification of each deficiency to its correction. 5.12.9 Contingency planning The organization shall establish, implement, and maintain plan(s) and proce­ dure(s) for identifying and responding to incidents and emergency situations, and to maintain the continuity of the critical lubrication management activ­ ities in compliance with the organization’s physical asset management plan.

6

Additional Requirements

Support and execution of the lubrication program plan may require additional resource allocation. These resources may come from outside the organization or from outside the direct sphere of influence of the lubrication program.

6.1 Legal Requirements The organization shall establish, implement, and maintain processes and/or procedures to identify and implement legal, regulatory, statutory, environ­ mental, and other applicable lubrication program management requirements. The organization’s lubrication management-related policies and sys­ tems for complying with legal and other regulatory requirements shall comply with the organizational policies and systems. The organization’s lubrication management-related policies and systems shall comply with legal and other regulatory requirements as specified in the organization’s physical asset man­ agement plan.

6.2 Audits The organization shall ensure that audits of the lubrication management sys­ tem are conducted to: a. b. c. d.

Verify that the lubrication management plan(s) is being performed. Verify conformance to lubrication management plans. Verify that the plan documentation is being properly maintained. Verify that the organization’s lubrication management policy, strat­ egy, and objectives effectively meet the organization’s objectives as described in its physical asset management plan. e. Verify that necessary information is being provided to management.

Auditing program(s) used to assess the elements of the lubrication man­ agement plan shall be defined, established, planned, implemented, and then maintained by the organization based upon the results of risk assessments 63

64 Additional Requirements in accordance with the organization’s lubrication management activities. Previous audit findings shall be used to determine the effectiveness of actions taken to address deficiencies. Audit processes and/or procedures shall address: a. The roles and responsibilities, competencies, and requirements for the planning and coordination required to conduct audits, report results, and retain associated records. b. The determination of audit criteria, scope, and methods that are com­ mensurate with the business significance of the managed risks. The selection of auditors and the performance of audits shall ensure objec­ tivity and impartiality of the audit process. Personnel that is independent [1] of direct responsibility for the activity shall conduct and examine the audits and audit processes. Note 1: The term “independent” does not necessarily suggest that the auditor must be external to the organization, although in most cases this is the preferred auditing scheme. General Note: Auditors should have a comprehensive knowledge and understanding of the lubrication management activities as specified in Section 5.0 of this ICML standard. Those who obtain the designation of certified Machinery Lubrication Engineer (MLE)® by the ICML are qualified. General knowledge of asset management as defined in ISO 55000 is also required. Auditors should conform to the guidelines out­ lined in ISO 19011 and ICML 55.3 (the Practice and Policies Manual for Auditors of ICML 55.1). Finally, all questions related to audits, auditors, and ICML 55.1 certification should be directed to the respon­ sible person at the ICML.

6.3 Records The organization shall create and maintain records as necessary to demon­ strate conformance to the requirements of its lubrication management system as set forth per this ICML standard. Records shall be legible, documented, and traceable. The records shall be maintained in accordance with the requirements of this ICML standard.

7

Program Oversight and Management

Review

Top management program sponsors shall, at appropriate intervals, and as defined within the organization’s lubrication management plan, review met­ rics, KPIs, and the outcomes of identified corrective actions to ensure pro­ gram sustainability, adequacy, and effectiveness. These reviews may include changes made to the lubrication management plan as it relates to the physical asset management plan and management policy, strategies, and objectives. Input to management reviews may include: a. Results of internal compliance audits and evaluations with applicable legal requirements, or with other requirements to which the organiza­ tion subscribes. b. The results of communication, participation, and consultation with employees and other stakeholders. c. Relevant communication(s) from external stakeholders, including complaints. d. Records or reports related to the organization’s performance in the lubrication management plan. This review may be accomplished using metrics. e. Financial return or program performance such as ROI. f. Organizational performance in addressing incident investigations, and corrective and preventive actions. g. Follow-up actions from previous management reviews. h. The performance of outsourced elements of the lubrication manage­ ment plan using tools such as KPIs. Feedback from management reviews, which are relevant to the organizational physical asset management plan, shall be documented for later retrieval and use. Records of management reviews shall be retained, and information rele­ vant to specific employees, contracted service providers, or other stakehold­ ers shall be made available for communication purposes. Adverse findings 65

66 Program Oversight and Management Review of the management review shall be addressed through the corrective action program. ICML 55, ICML 55.0, ICML 55.1, ICML 55.2, and ICML 55.3 are trade­ marks of the International Council for Machinery Lubrication. Machinery Lubrication Engineer (MLE) is a registered trademark of ICML.

Index

C Change management 60

Condition monitoring 2, 6–7,

10–11, 24–26, 28–29, 31, 35,

43–45, 47–48, 50

Corrective Maintenance 2, 32,

36–40, 43, 48

M Machine lubrication 2, 26, 28

Metrics 3, 12, 46, 57, 61–62, 65

O Oil reclamation 3, 56

P Program management 3, 22, 26,

28, 32, 40, 43, 47, 51, 53–54,

56–57, 63

E Energy conservation 3, 27, 33,

54–55

Environmental impact 3, 8, 21, 27,

34, 54–55

R Root cause analysis 12, 51–52

H Health and safety 32–33, 46, 50

S Supplier selection 30

Support facilities 2, 40–41

System design 2, 28–29

I Information management 50, 60

J Job task skills 22, 25

T Training 2, 22–26, 45, 53

Troubleshooting 3, 35, 38, 51–52

L Lubricant analysis 2, 24, 29, 35, 43,

47–51, 55

67