ICML 55.2 – Guideline for the Optimized Lubrication of Mechanical Physical Assets (River Publishers Series in Energy Engineering and Systems) [1 ed.] 8770040370, 9788770040372

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ICML 55.2 – Guideline for the Optimized Lubrication of Mechanical Physical Assets

ICML 55.2 – Guideline 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 Alsbjergvej 10, 9260 Gistrup, Denmark www.riverpublishers.com Distributed exclusively by Routledge

605 Third Avenue, New York, NY 10017, USA 4 Park Square, Milton Park, Abingdon, Oxon OX14 4RN

ICML 55.2 – Guideline 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 may be reproduced, stored in a retrieval systems, or transmitted in any form or by any means, mechanical, photocopying, recording or otherwise, without prior written permission of the publishers. Routledge is an imprint of the Taylor & Francis Group, an informa business ISBN 978-87-7004-037-2 (hardback) ISBN 978-10-0382-664-4 (online) ISBN 978-1-032-66351-7 (ebook master) While every effort is made to provide dependable information, the publisher, authors, and editors cannot be held responsible for any errors or omissions.

Contents

Foreword

xiii

Acknowledgments

xvii

List of Figures

xix

List of Tables

xxi

List of Abbreviations

xxiii

1 Job Task Skills, Training and Competency 1.1 Delivering Effective and Appropriate Training . . . . . . 1.2 Selecting a Training Partner . . . . . . . . . . . . . . . . 1.3 Strata and Content for Lubrication Technicians/Trainees . 1.4 Providing Content for Knowledge Development . . . . . 2 Machine Lubrication and Condition Monitoring Readiness 2.1 Machine Lubrication . . . . . . . . . . . . . . . . . . . 2.2 Condition Monitoring Readiness . . . . . . . . . . . . . 2.2.1 Preparing for and building a condition monitoring (CM) program . . . . . . . . . . . . . 2.2.2 Benefitting from your CM program . . . . . . . . 3 Lubrication System Design and Selection 3.1 Lubrication System Design . . . . . . . . . 3.1.1 Gauging machine health . . . . . . . 3.1.2 Correct oil sampling . . . . . . . . . 3.1.3 Facilitating inspection . . . . . . . . 3.1.4 Facilitating lubrication tasks . . . . 3.1.5 Facilitating condition monitoring . . 3.1.6 Designing for contamination control 3.1.7 Designing for reliabilty . . . . . . . v

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vi Contents

3.2

3.1.8 Lubricant fill quantity . . . . . . . . . . . . . . . . . 3.1.9 Storage and handling practice . . . . . . . . . . . . . 3.1.10 Facilitating routine lubrication . . . . . . . . . . . . 3.1.11 Identifying lubricants . . . . . . . . . . . . . . . . . 3.1.12 Facilitating lubricant identification . . . . . . . . . . 3.1.13 Real-time monitoring . . . . . . . . . . . . . . . . . 3.1.14 Leak prevention . . . . . . . . . . . . . . . . . . . . Supplier Selection . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 The range and quality of lubricants offered . . . . . . 3.2.2 Lubricant test capability offered, to include condition monitoring service . . . . . . . . . . . . . . . . . . . 3.2.3 The ability and willingness to provide certification of conformity . . . . . . . . . . . . . . . . . . . . . 3.2.4 Having up-to-date SDS or other safety information and providing this information in a timely manner when changes occur . . . . . . . . . . . . . . . . . . 3.2.5 Willingness or ability to concurrently supply other chemical or hydrocarbon fluids including fuel, heat transfer fluids, coolants, solvents, and pastes . . . . . 3.2.6 Bulk and package volume and related options . . . . 3.2.7 Availability to supply accessible and competent technical support. . . . . . . . . . . . . . . . . . . . 3.2.8 Provide timely information when lubricants are no longer manufactured . . . . . . . . . . . . . . . . . . 3.2.9 Capability to provide compatible replacement lubricants when obsolescence is identified . . . . . . 3.2.10 Geographic coverage or service area (especially important for multi-plant operations, linear assets, mobile equipment, etc.) . . . . . . . . . . . . . . . . 3.2.11 Willingness or ability to supply and deliver any specialty lubricants that are required but are marketed under another brand name . . . . . . . . . . . . . . . 3.2.12 Willingness to guarantee the performance of their lubricants . . . . . . . . . . . . . . . . . . . . . . . 3.2.13 Lubricant cost . . . . . . . . . . . . . . . . . . . . . 3.2.14 Lead time of lubricant deliveries and willingness to maintain an inventory of critical lubricants, in proximity, to minimize delay in emergency situations 3.2.15 Avoid selecting and procuring lubricants as a commodity item . . . . . . . . . . . . . . . . . . . .

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Contents vii

4 Planned and Corrective Maintenance Lubrication Tasks 4.1 Health and Safety . . . . . . . . . . . . . . . . . . . . 4.1.1 Safety regulations . . . . . . . . . . . . . . . . 4.1.2 North American environmental regulations . . . 4.1.3 European environmental regulations . . . . . . 4.2 Planned Maintenance Task Elements . . . . . . . . . . 4.3 Corrective Maintenance Task Elements . . . . . . . . . 4.3.1 Comparison of planned and corrective lubricant maintenance task elements . . . . . . . . . . . 4.3.2 Guidance for planned and corrective lubricant maintenance programs . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . .

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5 Lubrication Support Facilities and Tools 5.1 Lubricant and Lubrication Support Facilities and Infrastructure . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1 Lubrication room that provides sufficient space and control of ambient conditions to maintain the lubricant assets in optimal condition . . . . . . . . . 5.1.2 Management and dispensation of lubricants, lubrication tools, filters, breathers, and other lubrication accessories . . . . . . . . . . . . . . . . . 5.1.3 Restricted access to the population that can obtain lubricants, to reduce the risk of poor lubricant management . . . . . . . . . . . . . . . . . . . . . . 5.1.4 Satellite storage areas, which may be created for large facilities by placing smaller/additional storage areas throughout the facility. Satellite storage facilities include tanks, piping systems, and mobile units (mining, construction, etc.). Also, satellite facilities need to comply with the same requirements as the primary lubricant storage area . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.5 Lubricant containers that are properly sized and of acceptable quality to support program requirements . . . . . . . . . . . . . . . . . . . . . . 5.1.6 A staging area that allows for support of lubrication tasks . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.7 Clear identification of lubricant types on each permanent or portable lubricant container. . . . . . .

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viii Contents

5.2

5.1.8 Methods to receive and inspect new lubricants that minimize the risk of spillage and contaminant ingestion . . . . . . . . . . . . . . . . . . . . . . . . 5.1.9 Methods for lubricant stock rotation (e.g., first in, first out) . . . . . . . . . . . . . . . . . . . . . . . . 5.1.10 A process to ensure that lubricants are not stored for extended periods prior to use . . . . . . . . . . . . . 5.1.11 A process to determine if new lubricants meet specification requirements . . . . . . . . . . . . . . . 5.1.12 A process to decontaminate or reject lubricants deemed to be unacceptable upon receipt . . . . . . . 5.1.13 Sample points that provide for effective, efficient, and safe access for the sampling of stored lubricants . . . 5.1.14 A sampling process of stored lubricants that minimizes the risk of contaminant ingestion . . . . . 5.1.15 A process to manage lubricant samples for testing . . 5.1.16 Effective, efficient, and safe access to allow periodic filtration and/or conditioning when required . . . . . 5.1.17 Containment areas to collect incidentally spilled or leaked lubricants to avoid safety and/or environmental risks . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.18 Separation of new and used lubricants. When kept in near proximity, clearly marked containers for storing used oil to avoid reuse . . . . . . . . . . . . . . . . . 5.1.19 A disposal plan to ensure proper handling and management of waste per the organization’s safety and environmental compliance standards and requirements . . . . . . . . . . . . . . . . . . . . . . 5.1.20 Safety provisions such as appropriately positioned eyewash stations and ventilation. Ready access to SDS/MDS sheets . . . . . . . . . . . . . . . . . . . 5.1.21 Local and national environmental regulations available for use. . . . . . . . . . . . . . . . . . . . . Tools, Instrumentation (Automation), and Consumables . . .

6 Machine and Lubricant Inspection 6.1 Inspection Plan . . . . . . . . . . . . . . . . . . 6.1.1 Multiple disciplines . . . . . . . . . . . . 6.1.2 Common goals . . . . . . . . . . . . . . . 6.1.3 Alignment with ranked failure modes . . . 6.1.4 Inspecting across the five operating states.

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Contents ix

6.2

6.1.5 Machine inspection ownership . . . . . . . 6.1.6 Inspection points. . . . . . . . . . . . . . . 6.1.7 Inspection tasks and methods . . . . . . . . 6.1.8 Inspector skills, training, and qualifications . 6.1.9 Tools and machine modifications needed . . 6.1.10 Inspection findings and data collection . . . 6.1.11 Inspection routes. . . . . . . . . . . . . . . 6.1.12 Health and safety issues . . . . . . . . . . . 6.1.13 Metrics and compliance . . . . . . . . . . . 6.1.14 Audits of the inspection plan . . . . . . . . Practical Implementation of the Inspection Plan . .

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7 Condition Monitoring and Lubricant Analysis 7.1 Lubricant Analysis Information . . . . . . . . . . . . 7.1.1 Lubricant baseline signature data . . . . . . . 7.1.2 Lubricant remaining useful life . . . . . . . . 7.1.3 Failure indicators . . . . . . . . . . . . . . . 7.1.4 Wear metal analysis . . . . . . . . . . . . . . 7.1.5 Contamination control device failure . . . . . 7.2 Assuring Effective Execution of Lubricant Analysis . 7.2.1 Test slate example for compressors . . . . . . 7.2.2 Test slate example for pumps . . . . . . . . . 7.3 Analytical Ferrography . . . . . . . . . . . . . . . . 7.3.1 Test slate example for gearboxes . . . . . . . 7.3.2 Test slate example for hydraulic systems . . . 7.3.3 Test slate example for bearings . . . . . . . . 7.3.4 The P-F interval . . . . . . . . . . . . . . . . 7.3.5 Machine criticality . . . . . . . . . . . . . . . 7.3.6 Failure risk profile and analytics . . . . . . . 7.3.7 Regulatory and insurance requirements . . . . 7.4 Lubricant Sampling . . . . . . . . . . . . . . . . . . 7.4.1 Sampling frequency . . . . . . . . . . . . . . 7.4.2 Optimize data density . . . . . . . . . . . . . 7.4.3 Sample bottles . . . . . . . . . . . . . . . . . 7.4.4 Sampling tools and retrofitting . . . . . . . . 7.4.5 Sample bottle labeling . . . . . . . . . . . . . 7.4.6 Setting alarm limits – determining optimal, cautionary, and critical limits . . . . . . . . . 7.4.7 Using cause failure analysis to set alarms . . . 7.4.8 Variation between machines and applications . 7.4.9 Data trending techniques . . . . . . . . . . .

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x Contents 7.4.10 7.4.11 7.4.12 7.4.13 7.4.14 7.4.15 7.4.16 7.4.17 7.4.18 7.4.19 7.4.20 7.4.21 7.4.22 7.4.23 7.4.24 7.4.25 7.4.26 7.4.27 7.4.28 7.4.29

Instrumentation . . . . . . . . . . . . . . . Selection of test methods . . . . . . . . . . Typical internal test slate . . . . . . . . . . Hardware, materials, and workspace . . . . Training . . . . . . . . . . . . . . . . . . . Standardized procedures: ASTM, ISO, and internal SOPs . . . . . . . . . . . . . . . . Instrument calibration/maintenance . . . . . Data collection and management methods . Health and safety precautions . . . . . . . . Waste disposal . . . . . . . . . . . . . . . . Selecting the right laboratory . . . . . . . . Test selection . . . . . . . . . . . . . . . . Offsite testing capabilities . . . . . . . . . . Wear testing . . . . . . . . . . . . . . . . . Ferrous debris . . . . . . . . . . . . . . . . Elemental analysis . . . . . . . . . . . . . . Microscopic analysis . . . . . . . . . . . . Contamination testing . . . . . . . . . . . . Physical properties testing . . . . . . . . . . Grease analysis . . . . . . . . . . . . . . .

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8 Fault/Failure Troubleshooting and Root Cause Analysis 8.1 Fault Analysis . . . . . . . . . . . . . . . . . . . . . . . . 8.1.1 Implementing a fault analysis system . . . . . . . . 8.1.2 Failure analysis process . . . . . . . . . . . . . . . 8.1.3 Output of failure analysis and risk mitigation . . . . 8.1.4 Measurement performance and effectiveness of the failure analysis system. . . . . . . . . . . . . . . . 8.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 8.2.1 The troubleshooting plan . . . . . . . . . . . . . . 8.2.2 The criteria and properties of the troubleshooting plan . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.3 Objective of the troubleshooting process . . . . . . 8.2.4 The troubleshooting process . . . . . . . . . . . . . 8.2.5 The review process of the troubleshooting plan . . . 8.3 Root Cause Analysis (RCA) . . . . . . . . . . . . . . . . . 8.3.1 Objective(s) of the RCA process . . . . . . . . . . 8.3.2 Benefits of performing RCA . . . . . . . . . . . .

Contents xi

8.3.3 Selection methodology for faults and defects investigated using RCA . . . . . . . . . . . . . . . . 8.3.4 The five-step RCA process . . . . . . . . . . . . . . 8.3.5 Root cause analysis methodology . . . . . . . . . . . 9 Lubricant Waste Handling and Management 9.1 Lubricant Specifications . . . . . . . . . . . 9.2 Waste Management Consumables . . . . . . 9.3 Waste Reduction Strategy . . . . . . . . . . 9.4 What Constitutes Waste Oil . . . . . . . . . 9.5 Classifying and Managing Waste Oil . . . . 9.6 Managing Used and Waste Oils . . . . . . . References . . . . . . . . . . . . . . . . . . . . .

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10 Energy Conservation and Environmental Impact 10.1 Energy Conservation . . . . . . . . . . . . . . . . . . 10.1.1 Choosing the right lubricant . . . . . . . . . . . 10.1.2 Contamination control . . . . . . . . . . . . . . 10.1.3 Fluid volume. . . . . . . . . . . . . . . . . . . 10.1.4 Measuring lubricant health . . . . . . . . . . . 10.1.5 Energy reduction measurement . . . . . . . . . 10.2 Environmental Impact . . . . . . . . . . . . . . . . . . 10.2.1 Choosing a more environment-friendly lubricant (EFL) . . . . . . . . . . . . . . . . . 10.2.2 Ensuring your environmentally friendly product stays that way in service . . . . . . . . . . . . . 10.2.3 Calculating the environmental carbon footprint effect of improved lubrication practice . . . . . Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Oil Reclamation and System Decontamination 11.1 Oil Reclamation . . . . . . . . . . . . . . . 11.1.1 Additive reconstruction . . . . . . . 11.2 System Decontamination . . . . . . . . . . 11.2.1 Dehydration . . . . . . . . . . . . . 11.2.2 De-varnishing . . . . . . . . . . . . 11.2.3 Acid scavenging . . . . . . . . . . . 11.3 Optimized Consumption of Greases. . . . .

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xii Contents 12 Program Management and Metrics 12.1 Structure, Authority, and Responsibility . . . . . 12.1.1 Executive management (program sponsor) 12.1.2 Stakeholder(s) . . . . . . . . . . . . . . . 12.1.3 Document alignment . . . . . . . . . . . 12.1.4 Risk analysis . . . . . . . . . . . . . . . . 12.1.5 Program viability checks . . . . . . . . . 12.1.6 Resource allocation . . . . . . . . . . . . 12.1.7 Succession planning . . . . . . . . . . . . 12.1.8 Communication . . . . . . . . . . . . . . 12.2 Management Outsourcing . . . . . . . . . . . . . 12.3 Program Documentation. . . . . . . . . . . . . . 12.3.1 Lubrication policy . . . . . . . . . . . . . 12.3.2 Lubrication strategy . . . . . . . . . . . . 12.3.3 Lubrication manual . . . . . . . . . . . . 12.3.4 Lubrication management plan . . . . . . . 12.4 Information Management . . . . . . . . . . . . . 12.5 Communication, Participation, and Outsourcing . 12.5.1 Stakeholder communication . . . . . . . . 12.6 Change Management . . . . . . . . . . . . . . . 12.6.1 Staffing changes . . . . . . . . . . . . . . 12.6.2 Program updates/changes . . . . . . . . . 12.6.3 Equipment changes . . . . . . . . . . . . 12.6.4 Outsource resource changes . . . . . . . . 12.7 Metrics . . . . . . . . . . . . . . . . . . . . . . . 12.7.1 Setting time intervals . . . . . . . . . . . 12.7.2 Setting threshold alarms . . . . . . . . . . 12.7.3 Developing SOPs . . . . . . . . . . . . . 12.7.4 Reporting processes . . . . . . . . . . . . 12.8 Improvement Actions . . . . . . . . . . . . . . . 12.9 Contingency Planning . . . . . . . . . . . . . . . Index

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Foreword

Certification to the ICML 55.1:2019 Standard – Requirements for the Optimized Lubrication of Mechanical Physical Assets, signals to the organization at large, its investors, clients, customers, and competitors that the maintenance department truly understands the value, profitability, and sustainability that an optimized and certified best-practice lubrication program can deliver, and that the maintenance department is, in fact, operating such a program. The intent of ICML 55.2:2023 is to provide the reader/organization with a practical implementation guideline for an optimized lubrication program for its mechanical physical assets. ICML 55.2 combines the knowledge and experience of twelve of the world’s best lubrication subject matter experts to deliver an easy-to-understand, best-practice implementation manual designed to augment the ICML 55.1 Standard. ICML 55.2 focuses on the twelve interrelated areas that make up an organization’s lubrication program plan as depicted in Figure F1. These interrelated areas represent the twelve distinct, auditable elements defined in the ICML 55.1 Standard to demonstrate compliance for certification purposes. ICML 55.2 is designed to illustrate the value of each element (the Why?) and to provide the reader with many examples (the How?) Included are many punch lists of typical elements an auditor may look for to prove compliance readiness for certification purposes. Even if certification of the program is not the goal, ICML 55.2 can still be used as a practical go-to manual for implementing a world-class lubrication management program. Any trade name used in ICML 55.2:2023 is for information purposes only and does not constitute an endorsement by ICML. The International Council for Machinery Lubrication (ICML) is a vendor-neutral, not-for-profit organization founded in 2001 to serve the global industry as the world-class authority on machinery lubrication that advances the optimization of asset reliability, utilization, and costs. ICML is an independent organization consisting of both paid professional staff and volunteer committees. It is a CERTIFICATION body, xiii

xiv

Foreword

Figure F1

ICML 55.1: twelve auditable elements.

serving both corporations utilizing lubrication assets and industrial lubrication and oil analysis practitioners worldwide; a technical AWARDS body recognizing companies and individuals that excel in the field of lubrication; a MEMBERSHIP body; and is the developer of ICML 55® STANDARDS for lubricated asset management. Established in part to address a clear need for specific standards in all areas of lubrication management that include lubricant selection, application, training and certification, ICML has always supported such activities at

Foreword xv

ASTM, ISO and other organizations. Following publication of the ISO 55000 – Asset Management standard in 2014, ICML marshalled its own worldwide team of forty-five technical experts to develop a highly tactical, lubrication-specific standard to supplement the more general ISO document. The result is collectively known as ICML 55, an international lubrication standard that spells out the requirements and guidelines to establish, implement, maintain, and improve consistent lubrication management systems and activities. The ICML thanks you for purchasing this copy of the ICML 55.2:2023 Standard.

Acknowledgments

Whenever a book, article, or paper is published, it is done so through the efforts of many different people assisting and guiding the author(s) through the entire conception-to-publication journey. ICML 55.2 is no different, and ICML thanks the following for their patience, dedication, and hard work in making ICML 55.2 a reality. The ICML acknowledges and thanks all individuals who contributed suggestions, ideas, and criticisms concerning this ICML 55.2 element of the ICML 55® Standard series. The ICML thanks all individuals and corporations who have graciously granted permission for the use of their copyrighted materials that include charts, diagrams, and photographs used to accompany the ICML 55.2 text. The ICML also extends thanks to its dedicated staff members who have assisted in developing the ICML 55 series and to the hard-working staff at River Publishers who helped make this book a reality. Furthermore, the ICML particularly acknowledges and extends special thanks to the following lubrication subject matter experts (SME)/authors for their individual chapter contributions to this ICML 55.2 text: Senior Editor: Bannister, Kenneth E. Author—Chapter 1: Holloway, Michael Author—Chapter 2: Wenzel, Rendela Author—Chapter 3: Wright, Jeremy Author—Chapter 4: Moon, Mary Author—Chapter 5: Majka, Wojciech Author—Chapter 6: Fitch, James C. Author—Chapter 7: Williams, Lisa Author—Chapter 8: Soliman, Mina Author—Chapter 9: Bannister, Kenneth E. Author—Chapter 10: Bannister, Kenneth E. Author—Chapter 11: Livingstone, Greg; Soto, Cristian Author—Chapter 12: Bannister, Kenneth E. Peer Reviewer: Fitch, James C. and Wurzbach, Richard N. xvii

List of Figures

Figure F1 Figure 4.1 Figure 4.2 Figure 4.3 Figure 5.1 Figure 7.1 Figure 7.2 Figure 7.3 Figure 7.4 Figure 7.5 Figure 7.6 Figure 7.7 Figure 7.8 Figure 8.1 Figure 9.1 Figure 11.1

Figure 11.2

ICML 55.1: twelve auditable elements. . . . . . . . . xiv Routine maintenance work cycle. . . . . . . . . . . . 41 How RCM integrates both continuous improvement and condition monitoring.. . . . . . . . . . . . . . . 42 Maintenance strategy relationship. . . . . . . . . . . 54 Typical bulk lubricant storage tote system complete with moisture control breathers, dedicated fast fill fittings, and dedicated outlet filters.. . . . . . . . . . 71 Typical laboratory lubricant (oil) analysis report. . . 110 Typical laboratory ISO 4406 based oil analysis report. . . . . . . . . . . . . . . . . . . . . . . . . . 113 Compressor types and their lubricated components. . 117 Pump types and their lubricated components. . . . . 119 Typical P-F interval diagram. . . . . . . . . . . . . . 125 Primary and secondary oil sample point locations. . . . . . . . . . . . . . . . . . . . . . . . 129 Typical oil analysis label with QR code. . . . . . . . 133 ICML certification designations for oil analysis. . . . 143 Typical fault tree analysis diagram. . . . . . . . . . . 164 How not to manage lubricant waste. . . . . . . . . . 180 Industrial machinery oil formulations contain a small amount of additives. Reconstructing these additives allows the oil to be used longer at a lower cost than changing the oil. . . . . . . . . . . . . . . . . . . . 203 An example of an Additive Reconstitution Test Slate for In-Service Turbine Oil Qualification. It is essential that the post-aging analysis reveal no adverse impacts when adding the additive concentrate. In turbine oils, additive reconstructing shall also demonstrate a positive response in oxidation stability to avoid anti-synergism reactions between various antioxidants. . . . . . . . 207

xix

xx List of Figures Figure 11.3 Figure 11.4 Figure 11.5 Figure 11.6 Figure 11.7 Figure 11.8 Figure 11.9 Figure 12.1 Figure 12.2

Varnish deposits are commonly found on bearings. Image Source: Fluitec International. . . . . . . . . . Varnish deposit classifications based on chemistry and source. . . . . . . . . . . . . . . . . . . . . . . Visual representations of soft contaminants going into the solution as the oil is heated. . . . . . . . . . An example of several patches produced from the membrane patch colorimetry test with different varnish potential ratings. . . . . . . . . . . . . . . . Depth media filters are capable of adsorbing polar degradation products that are in suspension. . . . . . Electrostatic oil cleaners are capable of removing submicron particles, many of which contribute to varnish and deposits. . . . . . . . . . . . . . . . . . Resin media filtration absorbs contaminants both in suspension and in solution. . . . . . . . . . . . . . . Lubricant consolidation chart example. . . . . . . . . Key elements of a lubrication management system. .

215 217 218 219 220 221 222 233 235

List of Tables

Table 1.1 Table 6.1 Table 7.1 Table 7.2 Table 7.3 Table 7.4 Table 7.5 Table 8.1 Table 8.2 Table 11.1 Table 11.2

Sample guide for ICML training matrix. . . . . . . Leading and lagging indicators . . . . . . . . . . . Commonly recommended oil sample frequencies . Oil sampling do’s and don’ts . . . . . . . . . . . . Types of data trend analysis . . . . . . . . . . . . . Typical onsite oil tests. . . . . . . . . . . . . . . . Typical screening/hybrid onsite oil tests . . . . . . Example list of failure modes (LOFM) table . . . . Typical RCM criticality table . . . . . . . . . . . . Risks of additive reconstruction based on additive component. . . . . . . . . . . . . . . . . . . . . . Overview of system decontamination technologies.

xxi

. . . . . . . . .

10 107 128 131 136 140 142 160 161

. .

205 212

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 xxiii

xxiv 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 xxv

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

1

Job Task Skills, Training and Competency

Auditable Section 55.1.5.1: Job Task Skills,

Training and Competency

Preface Chapter 1 is a process map directive of how to establish and maintain a job task skills, training and competency development program. The organization pursuing certification is required to demonstrate ICML 55.1 compliance through an auditing process. Throughout this chapter you will be prompted to be able to provide proof of compliance with the ICML 55.1 Standard Section 5.1 of regarding job task skills, training and competency. After each topic, the instruction Typical Examples Used to Demonstrate Compliance will indicate typical requirement(s) sought by an auditor to prove understanding and application of the ICML 55.1 Standard requirement. To facilitate the audit process, it is recommended the organiza­ tion assemble documentation relating to the given examples. Developing a job task skills, training and competency program must include the reliability directive of the company. Organizations are classified as end-users, service providers, or both. The lubrication training structure 1

2 Job Task Skills, Training and Competency should reflect the lubrication policy, strategy, plans, and objectives of the organization. The positions that should be considered are focused on various activity levels within the organization that include:

• • • •

Daily activities of lubrication application and management Applied lubricant condition monitoring Laboratory lubricant testing, diagnosis, and management Lubrication engineering

Where applicable, the lubrication program development must primarily con­ sider the position requirements according to the ICML 55.1 (Lubrication Management Standard). If other relevant standard certifications are held within the organization, for example, ISO 55001 (Asset Management), ISO 14001 (Environmental Management), ISO 18436 (Condition Monitoring), and ISO 9001 (Document Management), their program structures can be lev­ eraged to facilitate the implementation of a lubrication job task skills, train­ ing and competency program.

1.1 Delivering Effective and Appropriate Training To deliver effective training, the training organization/department must seek to: Maintain effective communication: through engagement in active listening, provide constructive feedback, develop a trusting relationship, accommodate communication styles, pursue strategies to improve communication, and coordinate with other departments and training initiatives. Align expectations: to set clear expectations, align expectations, consider character differences, set attainable goals, and develop strategies to meet those goals. Assess understanding: assess instructor knowledge and estimate student ability. Foster independence: motivate students and build confidence, stimulate cre­ ativity, and acknowledge students’ contributions. Address diversity: account for biases and prejudices including different backgrounds of instructors and students. Promote professional development: help to effectively network and set career goals, help to establish a work/life balance, understand the impact of the role model, and help students acquire resources for continuous improvement.

1.1 Delivering Effective and Appropriate Training 3

To build a comprehensive program to develop skills and competency, the following seven-step program can be utilized to ensure all major elements are addressed: 1. 2.

3.

4.

5.

6.

7.

Establish the learning objective a. Align with corporate/maintenance organization vision and goal(s) Determine current level of experience and competence a. Individual’s training history b. Precourse questionnaires c. Knowledge requirements checklists (based on ICML body of knowledge) Establish the incentives a. Organization deliverables b. Individual deliverables c. Pay grade strata based on certification levels Develop and follow a lubrication training plan a. Determine who requires training b. Determine the type and level of training/certification based on a sup­ port or active lubrication role c. Develop a training timetable Provide the appropriate lubrication training resources a. Suitable training venue(s) b. Structured training materials based on knowledge requirements c. Qualified and experienced training organization/trainers Establishing competency through application of training and certifica­ tion examination a. Develop training that leads to recognized national/international certification b. Utilize licensed third-party examination Ensure certifications remain current and provide continuous improve­ ment opportunities a. Refresher training b. Plan to meet recertification requirements c. Certification upgrade plan(s)

It is imperative that individuals responsible for the management, supervi­ sion, and/or execution of the lubrication program training possess the requi­ site knowledge, skill set, and qualifications (e.g., training and certifications) to sustainably implement the program. The organization shall assure that individuals meet these objectives by obtaining adequate training and/or education to meet defined job functions. Success in meeting this objective

4

Job Task Skills, Training and Competency

is demonstrated through certification testing and continued competent job performance. The requirement of maintaining competent, certified person­ nel may be satisfied when using either local or outsourced labor. Proper and up-to-date knowledge and skills are foundational elements for achieving the objectives set forth by the organization’s lubrication management pol­ icy, strategy, and plans. Remediation of this resource shall be achieved in the areas identified as deficient. To achieve this objective, the organization shall: 1.

2.

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. a. Machinery Lubrication Engineer – MLE i. This is an engineering-level certification targeting reliability and asset management professionals with a strong emphasis on lubrication and lubricant analysis. The certification is ideal for those with daily activities associated with the development, implementation, and management of lubrication programs. It is intentionally structured for those with the responsibility to guide and facilitate organizations in a tactical step toward ISO 55001 certification. This is both an engineering and management level certification for those providing general engineering support to a user lubrication program including lubricant selection, lubri­ cation and sampling hardware selection and implementation, overall lubrication program design, procedure development, optimizing lubricant PMs and inspection program design, lubri­ cant analysis and troubleshooting, lubrication program metrics, training and skills remediation, and management/staff commu­ nications having 5+ years work experience. Shall be able to educate, train, and qualify personnel designated to exe­ cute routine lubrication tasks as defined in work procedures and job descriptions (task-based training) and to the bodies of knowledge set forth by ICML for the Machinery Lubrication Technician (MLT I, MLT II), Machine Lubricant Analyst (MLA I, MLA II, MLA III), Laboratory Lubricant Analyst (LLA I, LLA II) as well as ICML badge certifica­ tions, or equivalent. a. Machinery Lubrication Technician – MLT i. Level I – Targets in-plant technicians responsible for daily lubri­ cation tasks, including oil changes, top-ups, greasing bearings,

1.1 Delivering Effective and Appropriate Training 5

3.

lubricant receiving, and proper storage and care of lubricants and dispensing devices. ii. Level II – Targets in-plant technicians or engineers responsible for managing the lube team, selecting lubricants, troubleshoot­ ing abnormal lubricant performance, and supporting machine design activities. b. Machine Lubricant Analyst – MLA (ISO 18436-4) i. Level I – Targets in-plant technicians responsible for the daily activities associated with lubrication tasks and basic lubri­ cant analysis for machine condition monitoring, including oil changes, top-ups, greasing bearings, lubricant receiving and proper storage and care of lubricants and dispensing devices; and basic oil sampling, contamination control, and problem detection. ii. Level II – Targets in-plant technicians responsible for the daily activities associated with lubricant analysis for machine condi­ tion monitoring, including sampling, sample management, the performance of simple onsite tests, managing test results, and performing simple diagnostics. iii. Level III – Targets in-plant technicians and engineers responsi­ ble for managing the lubricant analysis function. Tasks include team management, test slate selection, setting alarms and lim­ its, sampling system design, instruments and software selection, and advanced diagnostics. c. Laboratory Lubricant Analyst – LLA (ISO 18436-5) i. Level I – Targets laboratory technicians performing daily activi­ ties, according to established ASTM procedures associated with the testing of lubricant samples. Tasks include receiving and handling lubricant samples, performing tests, reporting results, and inspecting data from individual test methods. ii. Level II – Targets senior laboratory technicians, laboratory managers, and diagnosticians responsible for the daily activ­ ities associated with producing lubricant analysis data for machine condition monitoring. Tasks include performing tests and analysis, diagnosing lubricant failure mechanism and modes instrument calibration, and SPC-based quality control. Provide appropriate lubrication training or equivalent ICML badge certifications for mechanical, electrical, and craftspeople, foremen,

6

4. 5.

6. 7.

Job Task Skills, Training and Competency

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 who are responsible for the design, specification, acquisition, and commissioning of lubricated components and/or machines. Provide summary education to senior plant and corporate manage­ ment to ensure alignment with the lubrication asset management plan as it supports the organization’s physical asset management objectives. Provide specialized training on relevant lubrication topics or equivalent ICML badge certifications as dictated by the operating and environ­ mental 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.

Typical examples used to demonstrate compliance Lubrication organization vision and goal statement(s) that align with maintenance and corporate vision and goals Process for assessing lubrication competence and experience Lubrication training requirement matrix Lubrication training plan Training resource requirements document Lubrication qualification requirement documentation by job title Job descriptions that show a lubrication certification requirement List of certified individuals in the organization Onsite library of resource materials (books) found in the ICML domain of knowledge Subscription to online resource material found in the ICML domain of knowledge

• • • • • • • • • •

1.2 Selecting a Training Partner An organization should select its training partner based on qualifications including industrial experience, statistical analysis, certifications held, independent publications, advanced education, competency assessment tools, and training materials built according to learning modalities. Training organizations should be staffed with proven professionals who have demonstrated commitment to the field of reliability and lubrica­ tion. A training organization should be recognized by the ICML. The

1.2 Selecting a Training Partner 7

following criteria can be used for the selection of a suitable training organization: 1.

2.

Experienced Instructors a. Instructors should have a minimum of 10 years of industrial experi­ ence in manufacturing, mining, construction, transportation, labora­ tory, or OEM setting b. Instructors’ experience should coincide with the lubrication tech­ nicians to whom they are providing instruction, i.e., maintenance, engineering, analysis, sales, or operations. c. Instructors, at a minimum, must be currently certified at the levels they are teaching, thus demonstrating competence in the relevant concepts of machine lubrication and condition monitoring. Training Materials a. A training organization should have materials built according to a lubrication technician’s certification requirements. b. A training organization should have materials that cover the required body of knowledge set forth by ICML. c. A training organization should not have any commercial references within their materials, and any images of products or services should be generic. d. To qualify as certification prerequisites, a training organization's courses must incorporate the required body of knowledge content and time frames according to the requirements put forth by ICML. For example: e. Machinery Lubrication Technician – MLT i. Level I – 16 class hours ii. Level II – 16 class hours f. Machine Lubricant Analyst – MLA (ISO 18436-4) i. Level I – 24 class hours ii. Level II – 24 class hours iii. Level III – 32 class hours g. Laboratory Lubricant Analyst – LLA (ISO 18436-5) i. Level I – 24 class hours ii. Level II – 24 class hours h. Machinery Lubrication Engineer – MLE i. MLE – Candidates must have at least 5 years’ education (post-secondary) or on-the-job training

Typical examples used to demonstrate compliance Process for choosing a lubrication training partner Training partner requirements document Copy of training materials

• • •

8

Job Task Skills, Training and Competency

1.3 Strata and Content for Lubrication Technicians/Trainees Lubrication application and management posi­ tion (Machinery Lubrication Technician – MLT) These individuals must demonstrate skills in the day-to-day activities associated with proper lubrication of machinery. There are two (2) desig­ nated MLT levels. MLT level I (MLT I) is oriented toward lubri­ cation basics and the proper application and storage of lubricant. MLT level II (MLT II) is directed toward an advanced understanding of lubrication fundamentals, lubricant selection, lubrication schedule, and program management. All MLT II designates must hold MLT I certification. Applied lubricant condition monitoring position (Machine Lubricant Analyst – MLA) These individuals must demonstrate skills in used lubricant analysis for machine condition mon­ itoring. There are three (3) designated MLA levels. MLA level I (MLA I) is oriented toward the basics of lubrication and sampling. MLA level II (MLA II) focuses on sampling, test selection, and fundamental data interpretation. All MLA II designates should hold MLA I certification. MLA level III (MLA III) is directed toward advanced diagnostics and troubleshooting, integration with other technologies, and program manage­ ment. All MLA III designates must hold MLA II certification. Laboratory lubricant testing, diagnosis, and management position (Laboratory Lubricant Analyst – LLA) These individuals must demonstrate skills in the performance of oil analysis activities typically required of a laboratory technician working in the used lubricant analysis field. There are two (2) des­ ignated LLA levels. LLA level I (LLA I) is oriented toward the basic aspects of performing common tests in the lab and assuring data quality.

1.4 Providing Content for Knowledge Development 9

LLA level II (LLA II) is directed toward advanced diagnostics, troubleshooting instrument errors, and managing lab processes, includ­ ing testing and service quality. All LLA II designates should hold LLA I certification. Lubrication engineering position (Machinery Lubrication Engineer – MLE) These individuals must demonstrate devel­ opment, implementation, and management skills associated with providing general engineering support to a user lubrication program at a typi­ cal industrial plant. This certification emphasizes the individual’s understanding of lubricant selec­ tion, lubrication, and sampling hardware selection and implementation, overall lubrication program design/machinery design/ inspection design, procedure development, key supplier relations, optimizing lubricant PMs, lubricant analysis and troubleshooting, lubrication program metrics, lubrication team management, training, and communications. This is an engineering-level certification targeting reliability and asset management professionals with a strong emphasis in lubrication and lubricant analysis A formal engineering degree is not required. The MLE body of knowledge is strategically mapped to ICML 55 Standard. Typical examples used to demonstrate compliance Evidence of how training assessments are based on the ICML body of knowledge (BoK) Demonstrate how lubrication technicians take concepts and provide practical application Evidence of ongoing assessment protocol by way of Key Performance Indicators (KPIs)

• • •

1.4 Providing Content for Knowledge Development Table 1.1 shows an example of how content is covered by training courses that prepare for various ICML certifications. The training organization should be able to provide a similar chart to demonstrate its own course content. For each certification level, the course must include, but not necessarily be lim­ ited to, the prescribed allocation of content from the ICML BoK.

10

Content Lubrication theory/fundamentals Machine reliability; basic elements

Sample guide for ICML training matrix.

MLA I X

MLA II X

X

X

Machine maintenance; basic elements

X

Maintenance strategies Condition-based maintenance (CBM)

X

Lubricant selection

X

Lubricant application

X

X

MLA III X

MLT I X

MLT II X

MLE* X

LLA I

LLA II X

X X

X

X

X

X

X

X X

X

X

X

X

X

X

X

X

Lubricant storage and management

X

X

X

X

Lubricant contaminant control

X

X

X

X

X

X

Oil sampling

X

X

X

X

X

X

X

X

Wear debris monitoring and analysis

X

X

X

X

X

X

X

X

Lubricant functionality

X

X

X

X

X

X

Lubricant health monitoring

X

X

X

X

X

X

Fundamentals of machine wear

X

X

X

X

X

X

X

Analyzing lubricant degradation

X

X

X

X

Oil analysis program development

X

X

X

X

X

X

X

X X

X

Job Task Skills, Training and Competency

Table 1.1

Data interpretation

X

X

X

X

X

X

X

X X

X X

X

X

X

X

X

X

X

Lubricant consumption reduction Lubricant manufacturing Grease Grease application

X

X

X

Grease testing

X

Sample preparation

X

X

X

X

Reagent management X

Quality control and statistics Instrument calibration ASTM testing specifications and procedures for contamination, oil condition, oil performance, wear debris

X

X

X

X

X

X X X

X

1.4 Providing Content for Knowledge Development 11

Grease performance Laboratory sampling

X

X X

Program logistics

12 Job Task Skills, Training and Competency *The MLE designation will also require this additional content: Asset management, ISO 55000 and ICML 55; basic elements Lubricant formulation for machine types to achieve optimum reliabil­ ity, energy consumption, safety, and environmental protection; basic elements Job- and task-based skills/training related to lubrication and reliability by user organizations Lubrication support facilities needed in plants and work sites Risk management for lubricated machines; basic elements Optimum machine modifications and features needed to achieve and sustain reliability goals Lubricant selection for optimum reliability, safety, energy consumption, and environmental protection based on machine type and application Lubrication-related planning, scheduling, and work processing Periodic lubrication maintenance tasks Inspection of lubricated machines for optimum reliability, safety, envi­ ronmental protection, and condition monitoring Lubricant analysis and condition monitoring for optimum reliability objectives Fault/failure troubleshooting, root cause analysis (RCA), and remediation Supplier compliance/alignment and procurement of services and products Waste and used lubricant management and environmental compliance Energy conservation and environmental protection Health and safety Oil reclamation, decontamination, de-varnishing, and additive reconstruction Lubrication during standby, storage, and commissioning Program metrics Continuous improvement

• • • • • • • • • • • • • • • • • • • •

Typical examples used to demonstrate compliance Provide evidence of coursework which contains the prescribed area requirements for each level

•

2

Machine Lubrication and Condition

Monitoring Readiness

Auditable Section 55.1.5.2: Machine Lubrication

and Condition Monitoring Readiness

Preface All best-practice lubrication programs retain machine lubrication and con­ dition monitoring program readiness elements designed to support and align with the corporate lubrication management plan. To the untrained, machine lubrication may appear relatively simple. In reality, it is a complex process that requires machine design, operating con­ ditions, and lubricant knowledge if it is to be performed in an efficient and effective manner. Lubricant choice and relevant service must be balanced against machine and lubricant reliability and cost. To determine if a lubricant is suitable and can continue to meet its minimum performance and economic requirements when in service will require diagnostic data and analysis collected from a condition monitoring process/program.

13

14 Machine Lubrication and Condition Monitoring Readiness Condition-based monitoring (CBM) programs take into account both predictive and preventive maintenance approaches primarily designed to reduce unscheduled downtime and increase asset reliability. Oil analysis, vibration analysis, thermal image analysis, and ultrasonic analysis are all CBM techniques that can be utilized in an engineered, best-practice lubrica­ tion management program

2.1 Machine Lubrication Many plants will already have an extended, mixed list of lubricants consist­ ing primarily of oils (hydraulic, automotive, gear, machine, and metal cut­ ting), greases, and waxes. Most of these lubricants will have been chosen and purchased at one time directly off a preferred lubricant list provided by the machine OEM. Keep in mind that these OEM decisions are based purely on the best guess, as in most cases the OEM has no information regarding the operating conditions to which their machinery will be subjected while in service. Over time, these inventories are added to or changed based on cost, with little or no consideration for the effect the machine design and operating conditions are having on the lubricant and machine life. When this is the case, an organization should seek to consolidate its lubricants based on its machinery operating conditions, operating context, and ambient operating conditions. Lubricants are engineered liquids, designed to operate in specific envi­ ronments under specific conditions and loads. Choosing the correct lubricant is as important as delivering the lubricant to the right place, at the right time, and in the right amount. When determining the correct lubricant for your machine and condi­ tions, both the physical and chemical properties of the lubricant must be considered. Lubricant selection will require specification of the key base oil alongside its physical, chemical, safety, and performance properties—all defined within a minimum and maximum specification limit guide that can be verified prior to lubricant use through oil analysis. Examples include:

• • • • • •

Base oil type and viscosity Grease thickener type Lubricant additives Lubricant compatibility with machine components (metals and plas­ tics), and seals materials Safety requirements, e.g., food safety, toxicity, flammability, volatility, and flash point Environmental protection, e.g., recyclability, aqueous toxicity, and bio­ degradability (see Chapter 10 for more details)

2.1 Machine Lubrication 15

Putting in place a lubricant consolidation program allows the maintenance department to gain intimate knowledge and understanding of its equipment and lubrication assets, and operating context. More importantly, it lays the foundation for a truly defined measurable method of understanding how the lubricant is performing and whether it can provide the required level of machine availability and reliability at an affordable cost. There are numerous benefits to implementing a lubricant consolidation program that can include:

• • • • • •

Minimized number of lubricants stored Minimized supplier base Standardized storage containment Standardized transfer equipment and methods Reduced lubricant waste Reduced risk of lubricant cross-contamination

Taking on a consolidation program will require the maintenance organi­ zation to perform some up-front classification work by mapping out each machine-lubricated point and lubrication system; this is then accompanied by the lubricant type currently used at each point. A list of stored lubricant inventories and their purchase cycle, amount, and cost, alongside their safety data sheets (SDS), is compiled in a database in preparation for a consolida­ tion audit. The maintenance department or a qualified lubricant management consultant can perform all preparatory work. In most cases, the current major lubricant supplier will take this com­ pany data and work with the maintenance department to put together a con­ solidation program based on an engineering assessment of your operating context. The lubricant supplier will usually involve the engineering staff of the lubricant manufacturer to assist in this effort. Often this is performed at little or no cost to the end-user in exchange for an exclusive purchase agree­ ment for a fixed amount of time. The purpose of any consolidation program is to minimize the number of different lubricants utilized and handled, balanced against providing the most effective lubricant for machine efficiency, reliability, and cost. In some cases, specialty lubricants may be required. Synthetic lubricants will only be employed where they add true benefit to the machine and organization. When making lubricant selection the consolidator must take into account the following:

• •

Operating condition range placed upon the lubricant, e.g., mechanical, electrical, chemical, radiation, thermal, and other stresses or exposures Machine-specific operation conditions, e.g., load, speed, pressure, and temperature

16 Machine Lubrication and Condition Monitoring Readiness

• • • • • • • • • • •

Usage pattern, e.g., runtime, standby, and intermittent use Environmental conditions, e.g., ambient temperature, humidity, localized radiant heat, airborne contamination, vibration, and radiological exposure Potential for contamination ingress, e.g., solid particulate, water, chemi­ cal, process material, and cross-mix contamination with other lubricants Machine reliability requirements as determined by criticality analysis, e.g., FMEA, FRACAS, or RCA as defined in the asset management strategy Optimal required lubricant service life (change interval) Accessibility and maintainability to perform lubrication tasks Environmental impact associated with the application and disposal of used and new lubricants Safety considerations for the use and storage of lubricant Energy policy requirements Lubricant availability, accessibility, or supply constraints Budget constraints

Typical examples used to demonstrate compliance Detailed lubricant list Machine mapping report Lubrication mapping diagrams by individual machine Lubricant change-out procedure Lubricant test procedure Dedicated lubricant storage and transfer equipment Lubricant consolidation report Lubricant purchase order records Current SDS catalog

• • • • • • • • •

2.2 Condition Monitoring Readiness Maintaining and controlling lubricants and lubrication systems can be achieved through condition monitoring and the implementation of proactive, planned activity alongside optimized use and location of sampling ports and/or methods. Condition monitoring (CM) is employed to help determine when cor­ rective actions are necessary to increase the reliability of lubricants and lubricated assets and to prevent equipment downtime. CM assumes that all equipment, regardless of service, will deteriorate over time and eventu­ ally fail. Interpretation of this data on a periodic basis establishes a base­ line of normal wear and equipment performance over time. This information can then be used proactively to determine when an asset is not performing

2.2 Condition Monitoring Readiness 17

according to its baseline, so that measures can be taken to minimize unsched­ uled downtime and subsequent loss of service. The reasons for implementing a CM program are many and include the following:

• •

• •

•

Reduction in unplanned outages, overtime, and repair costs – Periodic monitoring of the condition of rotating machinery reduces the number of catastrophic, unexpected lubricant and machine failures. Increased equipment longevity by minimizing intrusive maintenance – Utilize CM to perform baseline lubricated bearing vibration signatures. Perform oil analysis on virgin stock lubricants so a standard baseline can be achieved for all lubricants in use on the machine. Ultrasound and thermography can also be used to attain bearing fill signatures and tem­ perature baseline signatures. This data can be used to interpret overall machine health over the equipment life cycle. Time-based inspections and replacements can be implemented in conjunction with nonintrusive CM to pinpoint repairs and reduce operational disturbances. Reduction in spare part inventories – By implementing proper CM practices and applying them to the most critical machines, a targeted selection of the necessary spares can be implemented to save time and reduce overhead costs. Overall maintenance cost reductions – Maintenance costs are arguably the largest single controllable expenditure in most plants. Depending on the industry, costs can range from 10 to 40% of the overall cost of goods produced. Current thinking suggests one-third, or 33%, of total mainte­ nance cost is wasted due to poor or improperly executed maintenance. It is also widely understood that a correctly lubricated bearing can last up to three times longer in service. Product quality improvement – The quality of the product moving through a machine that fails less often increases when equipment health can be tracked and trended. By utilizing CM, the equipment can be better protected against failure and product contamination. These tech­ nologies combine to increase overall product quality.

2.2.1 Preparing for and building a condition monitoring (CM) program Implementing a CM program is essential to any maintenance organization, not only to understand how the equipment runs in a facility but also to be able to predict and prevent failures before they happen.

18 Machine Lubrication and Condition Monitoring Readiness When embarking on a CM program, much information needs to be gathered. There has to be an understanding of the organization, its culture, and its dynamics. You need to show that designing and implementing a CM program will positively affect the bottom line when relating potential sav­ ings against the potential cost of downtime and repair. Management may also need to see how your program matches up to similar businesses of relevant size and production methods. The first step in any project is to establish the leadership and obtain the necessary buy-in. Commence by meeting leadership with a sound proposal as to how you would like to structure the process, organization, what technolo­ gies are to be used, and who will be trained to use them. Discuss why there is a need for the program, why it is important, and what benefits can be attained. CM applies to all lubricated equipment. Numerous CM strategies can be simultaneously employed, the most obvious and important being oil anal­ ysis. Ancillary CM techniques will also come into play and may include ther­ mal (infrared) analysis, vibration analysis, and ultrasonic analysis. CM program – “Where to start?” In order to achieve success in any endeavor, one must begin by looking at the ways previous similar endeavors have failed. In the case of a CM program, the following are generally accepted as the common ways a CM program can fail: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Not first measuring where you are Not having a clear goal set Expectation of immediate results Trying to move too fast Innefective organization Not tying your effort to reliability Failure to look at the overall program Reluctance to change The perception that everything is okay Not using metrics to track the progress of your program Failure to communicate the results to the plant and to management sponsors 12. Not understanding that the program does not cost a lot of money to implement and sustain Commencing your CM program begins with determining what the effective overall CM program should look like compared to other organizations like yours. You must look at what your facility’s overall goal is for CM and design

2.2 Condition Monitoring Readiness 19

toward attaining that goal. A lubrication CM program should contain at least the following items: a. Lubricant audit a. Lubricant consolidation audit (see Section 55.1.5.2.1 for informa­ tion on implementing a lubricant consolidation program) b. Equipment audit a. Identify critical components b. Evaluate operating equipment c. Machine map all lubrication points d. Review the maintenance history of lubrication-related failures to identify and rank common failure modes. Condition monitoring must be aligned to these failure modes. c. Oil analysis a. Establish oil analysis tests to be performed i. Fluid properties and contamination levels ii. Current overall machine health iii. Oil baselines b. Inspection points (see Chapter 6 – Machine and Lubricant Inspection) c. Test frequency timetable d. Establish oil targets and alarms e. Establish test route(s) f. Establish sample port /valve locations based on sampling methods to be used and machine mapping g. Establish processes and procedures for taking samples, handling samples, and reading reports (see Chapter 7 – Condition Monitoring and Lubricant Analysis) d. Vibration analysis a. Secure access to vibration alarm and trend reports on lubricated machine bearings and surfaces i. Equipment set (i.e., pumps, agitators, hydraulic units, motors, etc.) b. Develop a process for correlated evaluation of oil analysis and vibra­ tion alarm reports e. Thermal analysis a. Establish bearing temperature set points under normal operations b. Develop a process for correlated evaluation of oil analysis and ther­ mal analysis alarm reports c. Establish temperature trends for like pieces of equipment

20

Machine Lubrication and Condition Monitoring Readiness

f. Ultrasonic analysis a. Establish acoustic limits established for route list equipment b. Develop a process for correlated evaluation of oil analysis and ultra­ sonic alarm reports g. Testing and evaluation of data a. Choose a suitable laboratory for oil analysis testing b. Establish process and procedure for acting on report findings h. Exception testing i. Data entry a. All data entered for each technology and housed in the same data­ base for ease of technology overlap j. Where applicable, always re-baseline after maintenance is performed k. Data analysis l. Reportable condition reports a. Use appropriate methods for each technology to detect and diagnose root causes, abnormal wear, etc. b. Develop technology reports for exceptions c. Communicate finding(s) d. Justify cost and expenditure e. Annual CM savings calculations m. Program evaluation a. Annual reassessment of critical equipment, routes, and overall pro­ gram health 2.2.2 Benefitting from your CM program Oil as a living history of a machine Oil that has been inside any rotating piece of equipment for prolonged periods of time will reflect its own unique equipment condition and start to exhibit the conditions within that machine. As a machine operates, it starts to shear particles that will invade the oil. The particles are smaller than the width of a human hair and remain in suspension. In this way, the oil itself becomes a working history of the machine. By identifying and measuring these impurities, you get an overall pic­ ture of the health of the machine. Oil analysis will also help to provide solu­ tions for removing the impurities in the oil, replenishing additives, etc. A typical oil analysis test is used to test for the presence of several dif­ ferent materials to determine sources of wear, find dirt and other contamina­ tion, and check for the use, health, and remaining useful life of the lubricants. Abrasive particles caused by ingression and normal wear and operation will

2.2 Condition Monitoring Readiness 21

mix with the oil. This includes any externally generated contamination due to the environment in which the equipment operates. By identifying and mea­ suring contaminates (number, size, composition, and appearance), the user is able to get an indication of the rate of wear of the equipment and/or the presence of abnormal solid contamination. Why is oil analysis important? Oil analysis is universally recognized as a “first line of defense” where lubri­ cated bearings, gears, and other frictional components are found. Early detec­ tion can assist an entire maintenance program and a corporate bottom line by reducing repair costs, decreasing the likelihood of catastrophic failures, and providing a reduction in unscheduled downtime. It can also dramatically increase machine life expectancy. Early detection advantages Early detection with oil analysis can allow for early corrective action such as realigning shafts in a gearbox or lubricant decontamination before major damage is allowed to occur. One of the major advantages of an oil analysis program is the ability to detect root causes and remediate problems before costly repairs and downtime occur. Industry data proves that over 70% of failures are lubricant-related. Professor Rabinowitz from MIT provided research on this concept. He also found that 6 to 7% of the Gross National Product (GNP) is required just to repair the damage caused by mechanical wear. History has shown that up to 80% of the oil samples taken from machines are perfectly fine and require no additional testing. In certain cases a simple, inexpensive, in-house screening test can be performed to lower the costs of sending samples outside the facility. The tests that should be performed on an oil sample vary considerably depending on the type of machine, lubricant in use, need for reliability, exposures, and operating conditions. Testing can also be performed on grease samples. Typical examples used to demonstrate compliance Oil sampling mapping and diagrams Oil sampling procedures CM oil analysis program implementation documentation Oil analysis reporting CM trending reports using thermal and vibration figures against oil analysis findings Policy and procedures for implementing and operating a lubrication CM program

• • • • • •

3

Lubrication System Design and Selection

Auditable Section 55.1.5.3: Lubrication System

Design and Selection

Preface Equipment reliability, operability, and maintainability are all major aspects of functionality affected by the lubrication system design. Proper selection and design decision-making should consider and reflect worker safety, stake­ holder needs, environmental protection, and regulatory requirements. Each section of ICML 55.1.5.3 provides a list of practical examples that an auditor might look for to demonstrate that the ICML 55.1 requirements have been met for this section of the standard. Note: these examples are typ­ ical in nature and are not exhaustive. They may need to be expanded upon depending on corporate structure, lubrication management plan require­ ments, and the nature of the business or operation type. Section 55.1.5.3 is divided into two subsections. The first deals with sys­ tem design and consists of fourteen key points that will guide the user to make proper decisions regarding best-practice system design. The second subsection will help the user understand how the proper selection of a lubricant supplier 23

24

Lubrication System Design and Supplier Selection

can become a critical factor in achieving effective lubrication and machinery reliability. This chapter addresses both subsections below.

3.1 Lubrication System Design When an asset with moving mechanical components is purchased, it is almost always delivered with a designed lubrication system or approach in place. The type of lubrication delivery system can be as complex as a high-end, inte­ grated, computer-controlled, automatic lubricant delivery system that sup­ plies each point with a measured amount of lubricant based on time, cycle, or condition. Or, if the design budget is constrained, new machinery could arrive with a simpler form of lubrication technology involving inexpensive grease nipples and/or oiling points, accompanied by the simplest of instructions in the operations and maintenance manual stating only to “lubricate as neces­ sary with a specified lubricant.” These examples represent the extremes in lubrication design and approach. Fortunately, from one extreme to the other, and in between, main­ tenance department personnel can tune lubrication system set-ups to improve/ optimize their particular lube program deliverables. The following standard elements represent recommendations to follow for better compliance with best practices, whether during the commissioning of a new asset or for the retrofit of an existing system. 3.1.1 Gauging machine health As a dedicated practice, machine inspection refers to scheduled, purpose­ ful, proactive equipment checks that are carefully designed to identify pos­ sible issues and forecast necessary maintenance needs. By gauging machine health at regular intervals, the facility is able to address potential issues more quickly, reduce unplanned maintenance events, and more effectively plan for inventory and MRO needs. The design must 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, instru­ ments, or aids are acceptable. Typical examples used to demonstrate compliance Visual-level inspection devices are installed on equipment Gauges are easily readable while the machine is in operation Ventilation is easy to reach and inspect Bottom sediment and water bowls are installed where needed

• • • •

3.1 Lubrication System Design 25

3.1.2 Correct oil sampling Coupled with the knowledge of how to take a proper oil sample, a lubrica­ tion specialist extracting a representative oil sample is only as good as his or her tools. Without these two things, a nonrepresentative oil sample will be the result. Using the wrong or inadequate oil sampling hardware, taking oil samples from unsuitable locations, collecting samples incorrectly, and even handling the samples improperly can all lead to samples that do not represent the true condition of the equipment. The system design must manage access in a manner to minimize risk at the machine and safe access for technicians to acquire samples for lubricant analysis. Typical examples used to demonstrate compliance Proper sample valves have been installed in the correct locations Proper sampling tools are being used to extract the samples Sampling extraction SOPs and training program in place

• • •

3.1.3 Facilitating inspection By gauging machine health at regular intervals, the facility is able to address potential issues more quickly, reduce unplanned maintenance events, and more effectively plan for inventory and MRO needs. The design must pro­ vide easy access for low-risk inspections at the machine and safe access for technicians performing the inspections to allow retrieval of system operating information. This can include flow rate, pressure, level, spray pattern, filter differential pressure, fluid property sensor readings, etc. Typical examples used to demonstrate compliance Gauges are installed for easy viewing while the machine is still operational Sensors report to remote locations that are safe for viewing Level gauges can easily be viewed from safe distances Inspection ports and windows allow for safe viewing of internal flows and sprays Inspection devices are not contained in a designated confined space area

• • • • •

3.1.4 Facilitating lubrication tasks For a lubrication program to be truly successful, a major component is mak­ ing sure the machinery is equipped with the proper accessories to allow

26 Lubrication System Design and Supplier Selection best-practice activities. The system design should 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. Typical examples used to demonstrate compliance Machines are modified with quick connects Machines are modified with proper valving to allow access to mainte­ nance points Components utilize proper grease fittings where needed Technicians have access to product-dedicated filter carts

• • • •

3.1.5 Facilitating condition monitoring Predictive maintenance (PdM), also known as condition-based maintenance, evaluates the condition of equipment by performing periodic or continuous (online) equipment condition monitoring. The goal of PdM is to perform maintenance at scheduled points in time when the maintenance activity is most cost-effective and before the equipment loses optimum performance. The design should provide access for low-risk activities at the machine and safe access for technicians performing planned condition monitoring tasks that supplement effective lubrication. These tasks may include surface and/ or airborne ultrasonic analysis, vibration analysis, thermometric and/or ther­ mographic analysis, etc. Typical examples used to demonstrate compliance Use of IoT sensors Sensors that require physical touch are installed in such a way that allows data collection while the machine is running in a safe manner Thermally transparent windows are installed where needed for data collection

• • •

3.1.6 Designing for contamination control Given contemporary advances in technology for excluding and removing contaminants, it could be said that a failure to control contamination is a failure of machine design rather than a failure of maintenance. The design should provide for effective, efficient, and safe-to-perform modifications that restrict contaminant ingress to, or remove contamination from, lubricants or headspace zones.

3.1 Lubrication System Design 27

Typical examples used to demonstrate compliance Machines should have proper headspace management Breathers that exclude moisture and particulate are installed Quick connect fittings are utilized on sumps large enough to utilize filter carts Proper filtration is used on circulating systems Separators are being used where appropriate SOPs are in place to manage contamination

• • • • • •

3.1.7 Designing for reliabilty Digital manufacturing tools frequently support decision-making in the design and operation of advanced multi-stage manufacturing machines. In order to be effective in their scope, such tools must be based on high-fidelity virtual representations of the real system. To achieve this goal, they are continuously fed with process and system data directly collected from the field. Once val­ idated, these digital tools can be used to evaluate and generate alternative system improvement actions and optimized re-designs of the system, based on scenario analysis. The designs should include machine reliability require­ ments as determined by asset criticality analysis; failure mode and effects analysis (FMEA) details; failure reporting, analysis, and corrective action system (FRACAS) information; and root cause analysis (RCA). Typical examples used to demonstrate compliance A process is in place to conduct RCA when a major failure occurs A system exists to track component failure An asset criticality assessment has been completed

• • •

3.1.8 Lubricant fill quantity The proper lubricant fill quantity is important to ensure that all contact sur­ faces are provided with a suitable lubricating film over the designed operat­ ing life. Over-lubrication can be as detrimental as under-lubrication. With over-lubrication, there is an increase in the internal friction of the component due to fluid friction as the excess lubricant is moved through the free space. This results in increased heat generation and, therefore, a shorter applica­ tion operating life. With under-lubrication, a boundary lubrication condition will occur, as all contact surfaces are not supplied with the proper quantity of lubricant. This condition may lead to wear and/or lubrication starvation resulting in shorter operating life.

28

Lubrication System Design and Supplier Selection

The correct lubricant quantity is determined by the design, operating speeds, reservoir volume, and the extent of sealing or shielding found in the application. The objective of the lubricant fill quantity is to provide the con­ tact surfaces with a consistent lubricating film thick enough to prevent met­ al-to-metal contact and support full fluid film lubrication. The design should provide the appropriate or optimized quantity of the specified lubricant to the lubricated surfaces in the machine to assure proper and reliable operation in terms of friction, heat, corrosion, and wear. Typical examples used to demonstrate compliance Reservoirs clearly labeled with upper and lower fluid limits Components labeled with proper grease quantity and type Grease guns have been calibrated for volume Lubricant type and volume requirement are clearly specified on relevant work orders

• • • •

3.1.9 Storage and handling practice Good storage and handling practices can help deliver productivity, safety, and sustainability benefits for any industrial operation. These practices help ensure lubricants are in peak condition to properly protect equipment and keep it running with minimal unscheduled downtime while also helping to reduce potential lubricant waste. The program design should assure that the lubricant is delivered in optimum condition with respect to defined machine design and operating conditions and/or environmental constraints. Typical examples used to demonstrate compliance Decontamination of stored lubricants Clean, cool, dry storage conditions Dedicated, sealable, and refillable dispensing options are being used First in, first out (FIFO) practices are being used for inventory management Stored lubricants are properly identified and labeled

• • • • •

3.1.10 Facilitating routine lubrication Routine maintenance is defined as maintenance activities carried out regularly. These tasks can be performed daily, weekly, monthly, or annually. Routine maintenance typically includes regular inspections and machine servicing with the primary goal of identifying problems on an ongoing basis before they result in catastrophic equipment failure. The design should enable the

3.1 Lubrication System Design 29

effective, efficient, and safe execution of routine maintenance tasks. These may include oil top-offs and top-ups, re-greasing, inspections, monitoring, sampling, and other adjustments. Typical examples used to demonstrate compliance Frequent sensory inspections are being performed in a controlled man­ ner using work orders Quick corrective actions such as lubricant top-ups are easily executed

• •

3.1.11 Identifying lubricants There are multiple lubricants in a factory servicing hundreds, or even thou­ sands of lubrication points. The likelihood of cross-contamination is high. Introducing the wrong lubricant into an application leads to unplanned down­ time and costly repairs. Lubricant cross-contamination has been identified as one of the root causes affecting asset reliability. Proper lubricant identifi­ cation is one way to help solve the problem. The design should allow clear identification of lubricant types specified for use within the machine and/or defined lubrication points. Typical examples used to demonstrate compliance Proper lubricant labeling is used throughout the facility Lube points are identified, color-coded, and/or labeled with proper lubricant Every dedicated cart, tote, grease gun, oiler, etc., is labeled with the lubricant it contains

• • •

3.1.12 Facilitating lubricant identification Identifying lubricants in the field–from determining the method for identifi­ cation to the physical tasks of installing identifiers on the components–can be a daunting task. In addition, any identification system must be complex enough to individually identify lubricant requirements and ensure that incom­ patible or incorrect lubricants are not introduced into a component. The level of complexity depends on the number and types of lubricants onsite. The design should 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 following elements: I. Labels with codes of colors, shapes, and symbols related to: 1. Chemical/Safety 2. Lubricant product information

30 Lubrication System Design and Supplier Selection II. Asset identifiers III. Quantity requirements IV. Other local requirements Typical examples used to demonstrate compliance The lubricant identification system utilizes colors, shapes, and descrip­ tive coding The labels contain all pertinent information about the lube points The labels can be found on top-up containers, filter carts, grease guns, totes, pumps, and other similar products Training program on lubricant ID systems

• • • •

3.1.13 Real-time monitoring Real-time monitoring of the oil is possible with advancements in sensor tech­ nologies and IoT. It can help overcome some of the limitations of traditional lab analysis. The real-time system consists of a sensor or group of sensors monitoring key oil health parameters and/or detecting contaminants or wear metal. The real-time monitoring may not give detailed information on oil quality with quantification of different contamination or degradation parame­ ters, but it can help indicate that there is a problem. The design should include sensors 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 vis­ cosity, lubricant chemistry, the accumulation of machine wear particles in the oil, and other issues. Typical examples used to demonstrate compliance Sensors installed to measure wear particles Sensors installed to measure moisture in the lubricant Sensors installed to measure viscosity

• • •

3.1.14 Leak prevention Understanding the risks associated with an oil leak is important. While pre­ venting leaks altogether is desirable, it is often not achievable. Therefore, the leaks must be reduced to an acceptable level based on variables of risk. The design should provide for contingencies such as expected or unexpected loss of lubricant from the machine. Contingencies may include drip pans,

3.2 Supplier Selection 31

berms/containment areas, grease traps, oil spray/mist coalescing devices, spill containment cleanup kits, etc. Typical examples used to demonstrate compliance Drip pans are used to keep lubricant contained Lubricant cleanup kits are readily available A leak detection program is in place

• • •

3.2 Supplier Selection Lubricant is a critical engineered component (or consumable asset) within the machine. The proper selection of the lubricant supplier can become a critical factor in achieving effective lubrication and machine reliability. Selecting the right supplier capable of meeting unique business demands and application needs is a crucial process for any company. The types of suppliers today span a large spectrum of business models. Some offer products only, while others bundle in additional services and capabilities. Understanding exactly what products and services a business requires is critical to the supplier selection process. The selection of a lubricant supplier should, at minimum, take into consideration the following factors: 3.2.1 The range and quality of lubricants offered The suppliers best equipped to meet requirements for diverse lubricating solu­ tions offer a complete line of industrial lubricants. Fluids for high-volume appli­ cations include hydraulic, compressor and vacuum pump, gearbox and chain, and multipurpose oils. Specialized industrial compounds such as greases, pastes, anti-friction coatings, and dispersions must be contained in their catalog as well. In addition, a wide range of base stocks is essential. Synthetics provide excel­ lent resistance to emulsification and last longer to extend maintenance intervals. Ultra-high-purity mineral oils also resist emulsification and promote improved additive performance, which results in a longer life than conventional mineral oils. The full-line supplier must also be able to draw on functional additive tech­ nologies including antioxidant, antiwear, and extreme temperature additives. Typical examples used to demonstrate compliance Supplier can offer a full catalog of products (paper-based and online) Supplier has multiple solutions for lubricant selection based on quality and price Supplier is technically competent in assisting with proper selection

• • •

32 Lubrication System Design and Supplier Selection 3.2.2 Lubricant test capability offered, to include condition monitoring service Oil analysis services help monitor performance and identify issues and trends through consistent oil sampling programs. Some benefits of regular oil anal­ ysis (when applicable) include longer equipment life, reduced production downtime, and decreased maintenance/repair expenses. Typical examples used to demonstrate compliance The supplier offers a service to test new lubricant deliveries The supplier can test used lubricants to determine health The supplier can use lubricant test data to help schedule maintenance tasks The supplier can test lubricant compatibility

• • • •

3.2.3 The ability and willingness to provide certification of conformity Product qualification is the process of certifying that a certain product has passed performance tests and quality assurance tests to meet qualification criteria stipulated in contracts, regulations, or specifications (typically called “certification schemes” in the product certification industry). To protect cus­ tomer benefits and control product security, product certification is necessary. Typical examples used to demonstrate compliance Supplier can produce technical data sheets when requested Supplier can produce safety data sheets when requested Supplier can produce certificate of origin when requested Supplier can produce conformity testing when requested

• • • •

3.2.4 Having up-to-date SDS or other safety information and providing this information in a timely manner when changes occur Safety data sheets (SDS) are an important element of chemical law. They contain detailed information on regulation conformity as well as the charac­ teristics of substances. They also describe possible risks and provide guide­ lines for handling, storing, and transporting the substances as well as what to do in the event of a fire or leakage.

3.2 Supplier Selection 33

Typical examples used to demonstrate compliance There should be a designated area to find SDS on every lubricant being used The SDS list should be updated periodically, anytime new lubricants are introduced or eliminated from use (this can be managed through the work order system)

• •

3.2.5 Willingness or ability to concurrently supply other chemical or hydrocarbon fluids including fuel, heat transfer fluids, coolants, solvents, and pastes Many lubricant suppliers either directly stock or partner with other distrib­ utors to be able to offer products outside their basic lubricant lineup. Being able to consolidate suppliers makes inventory management easier. Typical examples used to demonstrate compliance Supplier can supply fuel Supplier can supply coolants Supplier can supply solvents

• • •

3.2.6 Bulk and package volume and related options In many cases buying in bulk can offer considerable cost savings and less packaging waste. Typical examples used to demonstrate compliance Supplier can offer bulk delivery Supplier can offer totes instead of gallon or drum quantities

• •

3.2.7 Availability to supply accessible and competent technical support Most suppliers offer a dedicated team with technical expertise and engineer­ ing support to help reduce maintenance downtime, provide cost savings, and proactively detect problems before they become catastrophic issues. Typical examples used to demonstrate compliance Supplier offers 24/7 technical support Supplier has access to engineers that can help when problems arise Supplier has an online database for frequent issues or questions

• • •

34

Lubrication System Design and Supplier Selection

3.2.8 Provide timely information when lubricants are no longer manufactured A major issue could arise when a lubricant is discontinued. Finding a replace­ ment can be a struggle. The supplier should have the technical expertise to be able to guide a user to find a suitable replacement. Typical examples used to demonstrate compliance Supplier SOP demonstrating immediate communication of supply line issues Supplier knows the machinery and environment well enough to be able to make recommendations on replacement lubricants should the need arise.

• •

3.2.9 Capability to provide compatible replacement lubricants when obsolescence is identified Before a lubricant manufacturer discontinues a product, there will usually be a suitable replacement identified, but this is not always the case. In the event that this happens, the supplier should have the technical expertise to be able to guide the user to find a replacement. Typical examples used to demonstrate compliance Supplier can perform lubricant compatibility testing

•

3.2.10 Geographic coverage or service area (especially important for multi-plant operations, linear assets, mobile equipment, etc.) The supplier should be properly sized to the account both geographically and from a volume standpoint. Typical examples used to demonstrate compliance The supplier should be able to get any needed lubricants to the site in a timely manner, backed up with a defined supply guarantee

•

3.2.11 Willingness or ability to supply and deliver any specialty lubricants that are required but are marketed under another brand name There will be occasional instances where a low-volume, specialty lubricant is needed. The supplier should be able to help procure these specialty lubricants.

3.2 Supplier Selection 35

Typical examples used to demonstrate compliance Supplier can demonstrate a network of partners that can easily provide specialty lubricants.

•

3.2.12 Willingness to guarantee the performance of their lubricants Most major lubricant manufacturers will guarantee their lubricants meet or exceed the stated specifications. They will guarantee them to be free from defects and some will even pay for parts and labor deemed reasonably necessary to repair damage to engines or other pieces of equipment if it can be demonstrated that the damage was caused solely and directly by a breach of this warranty. Typical examples used to demonstrate compliance Supplier can provide a performance warranty for all purchased products

•

3.2.13 Lubricant cost The amount spent on lubricant purchases typically is less than 1% to 2% of a plant’s maintenance budget. When most companies go through an exercise to determine the overall cost of lubrication, they are often shocked by the results. Most companies (particularly in heavy industries such as steel, base metals, pulp, and paper, etc.) realize that the losses due to poor lubrication practices can amount to 10% to 20% of their maintenance budget. Lubrication cost can vary depending on the quality of the base oils and additives used, but also built into that cost could be the level of support offered by the supplier. Typical examples used to demonstrate compliance Supplier offers oil analysis Supplier offers technical support Supplier offers machine surveys and consolidation program audits Supplier offers labeling and tagging Supplier offers bulk discounts and delivery

• • • • •

3.2.14 Lead time of lubricant deliveries and willingness to maintain an inventory of critical lubricants, in proximity, to minimize delay in emergency situations A lubricant supplier’s turnaround time should be a metric used to aid in determining the quantity of lubricants stored. If there is a short time interval

36 Lubrication System Design and Supplier Selection between deliveries, fewer lubricants can be stored onsite, but if there is a long time interval between deliveries, the quantity of lubricants stored onsite should account for this. Typical examples used to demonstrate compliance Supplier can have any critical lubricant onsite within an acceptable amount of time Supplier carries the proper volume on hand to replenish the site when needed

• •

3.2.15 Avoid selecting and procuring lubricants as a commodity item Lubricant performance can vary greatly between competing mineral-based and synthetic oils. Because these quality differences directly and signifi­ cantly impact the ultimate cost of operating and maintaining rotating equip­ ment, lubricant purchases cannot be managed the same way an organization manages its purchasing of commodity-type products. Lubricant excellence must always be the top priority, for even the most effective lubricant-manage­ ment practices cannot impart properties to a lubricant that it does not possess. Typical examples used to demonstrate compliance A strategy is in place to evaluate the total cost/benefit of selecting cer­ tain lubricants The cost of poor lubrication is often more than 10x the cost of the lubri­ cant; a program that tracks such cost would demonstrate meeting the requirement

• •

4

Planned and Corrective Maintenance

Lubrication Tasks

Auditable Section 55.1.5.4: Planned and Corrective

Maintenance Lubrication Tasks

Preface The lubrication program management plan shall have planned and corrective maintenance lubrication task elements. This element shall support and align with other elements of the lubrication management plan. Auditable element 55.1.5.4 consists of an introduction to maintenance in the context of lubrication programs and their management, including guidance on initiation and improving lubri­ cation management plans and the system(s) required for their implementation. A primary goal of maintenance shall be to reduce or eliminate failure of mechanical assets so that they continue to operate safely and economically. The occurrence of machine failure depends on the design, operating condi­ tions, and maintenance of machines as well as the selection and in-service condition of lubricants. Failures can be categorized as follows:

•

Random failures occur during the normal service life of a machine, often due to defective components, improper 37

38 Planned and Corrective Maintenance Lubrication Tasks

•

•

operation, inadequate maintenance, incorrect type or amount of lubricant, etc. Time-dependent failures occur near the end of the useful service life of a component, after hours of use, or during cycles of fatigue, tem­ perature change, or other stress. According to Toms, “Usage data in conjunction with condition data can be used to determine the need for component or fluid replacement in order to maximize utilization and prevent failure…. By tracking the accumulated usage and measuring the condition of individual parts of an equipment system, maintenance can be performed at properly scheduled intervals and utilize ‘just in time’ inventory.” [Toms] Condition-dependent failures are consequences of the gradual deteriora­ tion of machine components (e.g., wear) and fluids (e.g., contamination, degradation). This is the most common category of lubricant-related failure. It is possible to use routine oil analysis and machine monitoring techniques to detect these failure modes and schedule repairs.

Poley recounts a historical perspective on the value of oil analysis for condition-based lubrication maintenance. “...The late 1940s saw an advan­ tage to analyzing used lubricants for various metals found in specific compo­ nents of the engine. By observing changes in wear metals concentration from one sample to the next…mechanical maintenance could be anticipated and scheduled in advance of complete component failure and resulting excessive loss of productivity from the engine…. Having this additional information on engine wear allowed the railroads to schedule teardowns on the basis of need rather than arbitrary hours of operation. The addition of a spectrometric metals analysis gave birth to ‘predictive maintenance,’ a vast improvement over preventive maintenance. Today virtually every segment of the American military...and most of the private industry sector employs this technique to at least a cursory extent.” Mechanical asset maintenance and management evolved in response to increasing complexity, operating speed, and use of mechanical assets and understanding of failure mechanisms. At present, there are several general approaches to mechanical asset management and maintenance, listed below in order of historical development and increasing sophistication: [Toms]

• •

Run-to-failure (RTF) followed by repair or replacement of assets Planned (also referred to as preventive) maintenance (PM), which con­ sists of tasks scheduled and performed at defined regular intervals, which may correspond to the statistical end of the usable life of assets, intended to reduce the probability of failure

Preface 39

•

Condition-based maintenance (CBM), sometimes described as predic­ tive or proactive maintenance, which consists of tasks scheduled and performed in a manner intended to identify, monitor the development, and predict the progression of failure modes.

Run-to-failure and condition-based maintenance are both categorized as forms of corrective maintenance. Corrective maintenance tasks are measures undertaken in response to condition-based information about emerging fail­ ure, predictions of failure, or actual failure of assets. Planned maintenance tasks are preventive measures performed on a recurring schedule or basis such as calendar time or asset time in service. Lubrication maintenance tasks include inspection, repair, and/or replacement of lubricants, other consumables such as filters, and machinery components (parts). A specific maintenance task may be performed as an element of planned and/or corrective maintenance. For example, replacement of in-service lubricant may:

• • •

Be scheduled during annual plant shut-down (planned maintenance) Be based on data and trends from oil analysis tests, data from mon­ itoring vibrations, temperature, energy consumption, and other oper­ ating parameters of machines, and predictions about the progression of lubricant or machine failure modes (condition-based corrective maintenance) Take place after lubricant or machine failure (run-to-failure corrective maintenance)

Run-to-failure is the oldest and simplest approach to mechanical asset man­ agement. In-service lubricants, components, and machines are repaired or replaced reactively, after they stop functioning properly, degrade, or break down. [Toms] In contrast, planned maintenance tasks are performed on a routine, pre­ dictable schedule. For example, a planned maintenance program may specify that gear oil shall be replaced in every gearbox in a manufacturing facility every six months. [Toms] Another planned maintenance program may specify a schedule for the evaluation of fluids, components, and/or machines, followed by reviews of results and decisions about additional maintenance tasks. For example, a planned maintenance program may specify that samples of an in-service gear oil are collected from every gearbox for analysis of viscosity and wear metal levels every six months. If test results are abnormal (e.g., outside of alarm limits), then corresponding gear oils shall be replaced. When test results are

40 Planned and Corrective Maintenance Lubrication Tasks normal, gear oils shall be kept in service and re-evaluated during the next planned maintenance task in six months. Condition-based maintenance uses a more flexible approach to lubri­ cation maintenance. Condition-based maintenance is a well-defined, ongo­ ing program in which personnel monitor the utilization and condition of in-service fluids, lubricated components, and machines, and apply this infor­ mation to optimize the scheduling and performance of maintenance tasks. This approach is intrinsically more dynamic than planned maintenance at predetermined, fixed intervals. [Toms] For example, a condition-based maintenance program may specify that on the first day of each month, a sample of in-service gear oil shall be col­ lected from each gearbox, and its hours of service recorded. Samples shall be sent to a designated laboratory for analysis of viscosity and wear metal levels. Test results shall be added to a designated database (e.g., part of a computerized maintenance management system or CMMS) and compared with alarm limits. Trends shall be analyzed and abnormal results reported to designated personnel. Follow-up tasks by designated personnel may include:

• • • • • • • • •

Inspecting gearboxes Checking the operating parameters of gearboxes Repeating tests or performing additional tests on gear oil samples Collecting more samples of gear oil for analysis Allowing gear oils to remain in service for a specific period of time before collecting more samples of oil for testing Performing “bleed-and-feed,” supplying an additive package, or using filtration or other means to treat in-service gear oil Replacing gear oils Decreasing the interval for subsequent collection and analysis of gear oil samples Adjusting the alarm levels used to define abnormal test results

Of these three general approaches–RTF, PM, and CBM–condition-based maintenance offers the most natural alignment with the plan-do-check-act and continuous improvement management programs. According to Toms, “A properly designed CBM program allows flexibility and leeway to establish PM intervals and uses measurement data from condition and usage monitoring to set the final PM timing. …CBM operates as a closed-loop sys­ tem wherein the routine work cycle is constantly adapted to actual machinery conditions and production requirements. Instead of a preplanned schedule, work planning is ongoing, conditionally changing with the analysis results from periodic condition and usage data.” [Toms, p. 51].

4.1 Health and Safety 41 Plan work according to machinery condition, etc.

Schedule work around production, staff, etc.

Analyze CBM data and update records

Perform CBM tasks

Figure 4.1 Routine maintenance work cycle.

Figure 4.1 illustrates a routine work cycle as discussed by Toms [Toms, Figure 2.28, p. 51]. Reliability-centered maintenance (RCM) is a variation of condition-based maintenance. Reliability is defined as the likelihood that a machine will oper­ ate in a predetermined manner for a specified period of time. RCM employs a logical approach to determine the required maintenance and lubrication tac­ tics to ensure an asset (machine/component) will perform at a level required by the user, and within its current design specification. A detailed FMECA analysis of each component is undertaken to understand how a component may fail in service; the safety, environment, throughput, quality, and cost consequence of its partial or complete failure; and the appropriate manner or approach by which the component must be maintained to minimize risk to persons and the organization. This information is incorporated into the organization’s FMECA or Failure Mode Effects and Criticality Analysis (discussed below). An RCM program adds a feedback loop for continuous improvement to a CBM pro­ gram. The result is the improvement of the global (organization-wide) main­ tenance program. [Toms] Figure 4.2 illustrates an RCM program that combines a continuous improvement cycle (left) and a condition monitoring cycle (right) discussed by Toms [Toms, Figure 2.31, p. 56]. The analyses of the results from CBM contribute to both cycles and link them.

4.1 Health and Safety Compliance with all organizational and government regulations, policies, processes, and procedures associated with health, environment, and safety, and related to the creation and execution of all lubrication tasks is required.

42

Planned and Corrective Maintenance Lubrication Tasks FMEC

Plan work

Continuous Improvement Cycle

Analyze results Figure 4.2

Schedule work

Condition Monitoring Cycle

CBM

How RCM integrates both continuous improvement and condition monitoring.

Together, health (H), environment (E), and safety (S) comprise HES, the part of an organization that manages practical aspects of worker health, environmental protection, and safety in the workplace. Health is a broad umbrella that covers the development and implemen­ tation of processes, practices, and systemic activities that prevent or reduce the risk of harm to workers. Environment refers to a systematic approach to complying with envi­ ronmental regulations, from minimizing the risk of uncontrolled release of chemicals, managing waste, and using environmentally advantaged materials to reducing the company’s energy consumption and carbon footprint. Safety includes organized efforts and procedures for identifying work­ place hazards, reducing accidents, and limiting the exposure of workers to harmful situations and substances. Training workers in accident prevention, use of personal protective equipment, etc. are also components of safety. All documents, processes, and activities, including preparation of TSEA (Task Safety and Environmental Analysis), related to every planned and cor­ rective lubrication maintenance program and task shall take into account fac­ tors relevant to health and safety including the following (at minimum):

• • •

Minimum personal protective equipment (PPE) Safety Data Sheet (SDS) guidance including hazards (health, reactivity, flammability, toxicity, etc.) of lubricants and other chemicals present in the workplace Proper disposal and waste management of lubricants and lubrication management-related consumables, including spill kits and other mate­ rials used for cleanup activities

4.1 Health and Safety 43

• • • •

Slip, trip, and fall hazards, especially the effects of lubricants on floors Hazards associated with microbes, mists, powders, gases, and other inhalable substances Hazards related to pressurized fluids and fluid injection through the skin and into the bloodstream Confined spaces, limited visibility, and other conditions related to fire, combustion, electrocution, and general mechanical hazards

Lubrication programs should also align with an organization’s plans and pro­ grams for response to emergencies that may entail unplanned shutdown of machines and/or other disruptions:

• • • • • •

Loss of electrical power as a consequence of lightning, high winds, tor­ nadoes, hurricanes, and other weather conditions Loss of public water and sewer utilities through flooding and other conditions Uncontrolled release of bulk chemicals through spills or accidents that damage tank trucks, railroad cars, storage tanks, etc. Fires that burn lubricants and bulk chemicals and release smoke, gases, particulates, and any contaminants into the atmosphere Acts of terrorism and other crimes that may damage facilities for the storage, transport, or utilization of chemicals and other potentially haz­ ardous materials and create abnormal risks for their release Epidemics, pandemics, disruption of roads and other transportation facilities, and other circumstances that may curtail the availability of skilled or trained operators, mechanics, maintenance specialists, and other personnel

Each organization relies upon qualified specialists to develop policies and execute procedures regarding HES as well as emergency response and related matters, compliance, and regulations. An organization shall engage HES per­ sonnel in all aspects of the development and implementation of their lubrica­ tion maintenance program in order to align with HES policies, procedures, regulations, and other relevant considerations. Several of the broadest bases for HES policies and practices that have implications for lubrication maintenance include the following: 4.1.1 Safety regulations The Occupational Safety and Health Administration (OSHA) was created by the US Congress to ensure safe and healthful working conditions for working

44 Planned and Corrective Maintenance Lubrication Tasks men and women by setting and enforcing standards and by providing train­ ing, outreach, education, and assistance. OSHA is part of the US Department of Labor. The scope of OSHA is broad and includes workers’ compensation, workplace violence, sanitation, and other general concerns. OSHA covers most private sector employers and their workers, in addition to some public sector employers and workers in the fifty states and certain territories and jurisdictions under federal authority. (www.osha.gov) Half of the states (PA, TX, OH, FL, DE, etc.) are “federal OSHA states” and under direct federal OSHA jurisdiction. Other states have individual OSHAapproved State Plans that cover private and state/local government work­ places (VA, WA, OR, etc.) or only state/local government workers (NY, NJ, CT, MN, and IL). (www.osha/stateplans). The examples cited above cover the USA only; other countries will have their own safety regulatory bodies. When safety can be an issue, always refer to your local and national safety regulations. OSHA regulations relevant to lubrication maintenance cover Hazardous chemicals, requirements for Safety Data Sheets (SDS), and Communications Standards under the Global Harmonized System (GHS), including Hazard and Precautionary Statements The General Duty Clause, which requires employers to provide workers with a safe workplace that does not have any known hazards that cause or are likely to cause death or serious injury Requirements for personal protective equipment (PPE) to protect work­ ers from job-related injuries, illnesses, and fatalities, including hard hats, gloves, goggles, safety shoes, safety glasses, chemical protective equipment, and fall protection equipment See https://www.osha.gov/SLTC/personalprotectiveequipment/index.html

• • • •

4.1.2 North American environmental regulations The Environmental Protection Agency (EPA) is an independent agency of the US federal government for environmental protection. EPA’s pur­ poses include ensuring that all Americans are protected from significant risks to human health, and that federal laws protecting human health and the environment are enforced fairly and effectively. EPA is responsible for issuing regulations and maintaining and enforcing national standards under environmental laws passed by Congress. The EPA delegates some permitting, monitoring, and enforcement activities to the states. (www. epa.gov)

4.1 Health and Safety 45

Relevant examples of EPA actions include EPA supports and enforces the Clean Water Act. EPA regulations for­ bid oil discharges from polluting navigable waters and shorelines and require containment of oil discharges in the event of a spill. For exam­ ple, in July 2019, U.S. Lubricants Inc. (Los Angeles, CA) agreed to pay a US $196,314 penalty for violating EPA regulations by failing to: ○ Inspect oil storage tanks ○ Perform tank integrity testing ○ Provide spill containment around tanks ○ Develop and implement a facility response plan (FRP) to respond to major oil spills, and ○ Develop a spill prevention, control, and countermeasure plan (SPCC) certified by a professional engineer EPA defined and put into practice vessel general permit (VGP) regulations on all commercial vessels longer than seventy-nine feet and imposed strict limits on incidental discharges (including lubricants) for vessels operating within three nautical miles of US coastlines and in the Great Lakes. EPA administers regulations based on the Toxic Substances Control Act (TSCA or TOSCA), which is a US federal law that regulates the intro­ duction of new or already existing chemicals. The main objectives of TSCA are to assess and regulate new commercial chemicals before they enter the market, and to regulate the use of existing chemicals that pose an “unreasonable risk to health or to the environment.”

•

• •

For example, EPA regulates the use of PCBs (polychlorinated bi-phenols, formerly used in electrical transformers), lead, mercury, radon, dioxin, chlo­ rofluorocarbons, and hexavalent chromium, and stringently governs the removal and disposal of asbestos. Additionally, TSCA prohibits the manu­ facture or importation of chemicals that are not on the TSCA Inventory or subject to an exemption. Always refer to your local and national environmen­ tal regulations 4.1.3 European environmental regulations REACH (Registration, Evaluation, Authorisation, and Restriction of Chemicals) is a European Union regulation that addresses the production and use of chemi­ cals and their potential impacts on human health and the environment. REACH is comprehensive, and it affects industries worldwide. REACH applies to all chemicals imported or produced in the EU. Some countries outside the EU are considering the adoption of REACH or similar regulations.

46 Planned and Corrective Maintenance Lubrication Tasks REACH requires all companies manufacturing or importing chemical substances into the European Union in quantities of one ton or more per year to register these substances with the European Chemicals Agency (ECHA). Since REACH applies to substances that are contained in objects, any com­ pany transferring goods into Europe may be affected. REACH also addresses the continued use of chemical substances of very high concern (SVHC), including carcinogens, mutagens, and reproduc­ tive toxins, because of their potential negative impacts on human health or the environment. The ECHA must be notified of the presence of SVHCs in objects if the total quantity used is more than one ton per year and the SVHC is present at more than 0.1% of the mass of the object. One implication for lubrication maintenance may be the discontinua­ tion of commercial availability of certain chemical additives and fully formu­ lated lubricants in the EU and, as a consequence, in the US and elsewhere. Typical examples used to demonstrate compliance Formal Task Safety and Environmental Analysis (TSEA) program/ documentation Maintenance department health and safety representative Safety Data Sheet (SDS) management/deployment program PPE requirements detailed on every work order Confined space program Available safety training records for all maintainers Breathing apparatus stations and training program Defibrillator stations and training program Fire drill schedule Posted fire equipment location and safety routes/muster points Lubricant waste disposal program Policies and procedures for Emergency Response situations Demonstrated use and compliance with ISO 45001 Demonstrated use and compliance with ISO 14001

• • • • • • • • • • • • • •

4.2 Planned Maintenance Task Elements Planned lubrication maintenance tasks may be organized, scheduled, and performed in a manner that complies with the organization’s physical asset management plan. Planned lubrication maintenance tasks shall be designed to achieve one or more objectives such as:

•

Provide safe work practices

4.2 Planned Maintenance Task Elements 47

• • • • • • • •

Preserve and optimize the reliability and safety of lubricated com­ ponents, machines, or systems, including those in storage or out of service Improve or maintain the integrity, composition, cleanliness, and/or per­ formance of in-service lubricants Prevent or control the ingress of particles, moisture, chemicals, and other contaminants into in-service lubricants and machines Prolong the service life of in-service lubricants and/or machine components Prevent or control loss of in-service lubricant due to leakage, etc. Satisfy operational needs such as the availability of machines, compo­ nents, and devices Improve energy conservation Minimize environmental impact

Typical examples of planned lubrication maintenance tasks include:

• • • •

• • •

Replacement of in-service lubricants, filters, and other consumables Replacement of in-service bearings, gears, pumps, and other lubricated components Monitoring the performance of machines and/or lubricated components by measuring temperature, fluid pressure, energy consumption, vibra­ tions, and other operational parameters Collecting samples of in-service lubricant in order to: ○ Measure concentrations of lubricant additives and assess the possible need to adjust the composition (e.g., with additive concentrates) and/ or replace lubricants ○ Identify the presence of dust, fibers, moisture, chemicals, and other contaminants in lubricants and evaluate possible necessity of control measures ○ Check for the presence of lubricant degradation by-products and determine possible steps for lubricant remediation, replacement, etc. ○ Collect particles generated by mechanical wear and assess mecha­ nisms of wear and possible steps to control wear Install or replace desiccants, breathers, filters, and other equipment and devices that are designed to prevent contamination or remove contaminants Flush equipment (including lines and sumps) to clean and remove lubri­ cant, degradation by-products (sludge, varnish, etc.), and other residues prior to installing new (same or different) lubricant Add or remove lubricant in order to provide the correct lubricant level in machines, components, sumps, reservoirs, bottle oilers, oil mist sys­ tems, single-point lubricators, auto-lubricators, centralized lubrication

48 Planned and Corrective Maintenance Lubrication Tasks

• •

systems, total loss lubricant devices, etc. Filter in-service lubricants to remove contaminants using a deep cleansing filtration system Purge sediment and water from a sump or reservoir Clean sumps, reservoirs, piping, supply lines, etc.

A planned lubrication maintenance task may include steps such as:

• • • • •

Move containers of lubricants from storage to workplace areas Open containers and transfer lubricants from containers into dispens­ ing devices, sumps, reservoirs, and/or lubricated components and/or machines Inspect lubricants, lubricant dispensing or application devices, lubricant condition control devices, lubricated components or machines, and/or areas around lubricated components or machines Collect “alarm” data from pressure gauges, temperature gauges, and other devices, and use this data to trigger condition-based maintenance activity and trend the machine condition Disassemble, modify, replace, and reassemble machines and components

Planned lubrication maintenance tasks may be scheduled on the basis of the criteria:

• • • • • • •

Estimates of P-F intervals for common failure modes of lubricants, components, and/or machines Risk profiles for failure of lubricants, components, and/ or machines Requirements for data to support planning and scheduling maintenance on the basis of machine and/or component runtime, miles-kilometers, cycles, etc. Availability of machines, lubricants, personnel, and other resources Operating histories of components and/or machines at the site Operational constraints, e.g., production schedules Collect condition-based data required for calculations, modeling, statis­ tical determination of alarms, etc.

Design of a planned lubrication maintenance tasks may take into account input such as:

• • •

Recommendations from suppliers of components, machines, and lubricants Vendor warranty requirements Inductive engineering analysis methods utilizing FMEA, which may include an RCM initiative or other engineering analysis methods

4.2 Planned Maintenance Task Elements 49

• • •

Engineering analysis methods utilizing Failure Reporting, Analysis, and Corrective Action System (FRACAS), which may include application Apparent Cause Analysis (ACA) and/or Root Cause Analysis (RCA) Access to the task location by the personnel designated to perform the task Required operating state (runtime or downtime) of machines

Documentation for a planned lubrication maintenance task shall be worded clearly and provide sufficient detail to assure that the task can be completed correctly, consistently, and with appropriate accuracy and precision. Documented procedures, such as work instructions for planned lubrica­ tion tasks, should include:

• • • • • • • • • • • • • • • • •

Task name, description, purpose, objectives, and summary Components and/or machines that are the subject of the task Health and safety requirements Lubricant products and/or lubricant product properties, e.g., viscosity grade, that shall or should be used in specific lubricated components and/ or machines Relevant contact information and machine access requirements Required knowledge, skills, and/or qualifications of personnel desig­ nated to perform the task Estimate of time to complete the task Tools, parts, and consumables required to perform the task Preparations including safety and briefing requirements Required authorizations to commence work Prework preparation, including scaffolding, staging of materials, etc. Work permits or other site requirements Clear, objective, and detailed work instructions including pictures, drawings, and other visual aids Definition of all specifications, tolerance, quantity, and quality details (e.g., lubricant type, max/min lubricant volume, max/min dispense rate, etc.) Requirements to comply with site safety measures such as a summary of relevant TSEA, jobsite observations, and inspections to assure safety and environmental compliance Sequence(s) of mandatory and optional steps or activities that comprise the task Details such as maximum and/or minimum lubricant volume in specific components and/or machines, maximum and/or minimum dispensing rates for transfer of lubricant, etc.

50 Planned and Corrective Maintenance Lubrication Tasks

• • •

Required documentation with entry fields for personnel to record obser­ vations and data, during task performance and/or after task completion, for continuous improvement programs, company records, etc. Cleanup requirements including disposal of lubricants, components, materials from cleanup actions, etc., and preparation of components and/or machines for service Requirements and directions for post-task inspections and follow-up reporting.

Typical examples used to demonstrate compliance Planned lubrication work order template Processes and procedures for the development of lubrication work orders Lubrication PM / PdM Job Task Library PPE master list Risk management strategy/process Access to plant machinery operating history files Machine warranty status list In place reliability-centered maintenance program Accessible lubrication work order record archive Lubrication route mapping Training program for work order development Planning and scheduling processes and procedures Corporate physical asset management plan

• • • • • • • • • • • • •

4.3 Corrective Maintenance Task Elements Corrective maintenance tasks may be performed in response to the results of planned maintenance such as inspections, machine monitoring, and/or analysis of samples of in-service oils, as well as operator alerts, discovery of impending or actual machine failure, artificial intelligence elements of CMMS, alerts from online sensors and other monitoring devices, etc. Corrective lubrication maintenance tasks shall be performed in a man­ ner that complies with the organization’s physical asset management plan. Appropriately qualified lubrication technicians, maintenance mechanics, or operators shall execute corrective lubrication maintenance tasks. Corrective lubrication maintenance tasks shall be designed to achieve one or more of the following objectives:

•

Prevention of predicted or emerging failure of a lubricant, lubricated component, and/or machine

4.3 Corrective Maintenance Task Elements 51

• • •

Control or reduction of damage and other adverse effects of predicted or emerging failure of a lubricant, lubricated component, and/or machine Recovery or restoration following the failure of a lubricant, lubricated component, and/or machine Remediation or correction of the root cause of the fault or failure con­ dition (failure mode)

Examples of corrective lubrication maintenance tasks may include the fol­ lowing, as well as tasks listed in the above section for planned lubrication maintenance:

• • • • • •

Redesign, replace, and/or rebuild lubricant application devices, lubri­ cant condition control devices, lubricant monitoring devices, or other components or systems necessary to assure the proper lubrication of components and machines After a rebuild or overhaul of a lubricated component or machine, flush the lubrication system as part of the process to re-commission and restore the equipment to service Use varnish removal (de-varnishing), water removal (dehydrating), gas extraction (degassing), or other processes to improve the condition of the in-service lubricant Perform detailed inspections of lubricated components and/or machines Obtain samples of in-service lubricant for troubleshooting and/or testing Restore the composition of in-service lubricant with additive concen­ trates, “bleed-and-feed,” or other methods

Corrective lubrication maintenance tasks may include the following steps or elements, as well as those listed in the above section for planned lubrication maintenance tasks:

• • • • • • • •

Emergency shutdown of machines, electric power, other utilities, etc. Remove in-service lubricant from lubricated components and/or machines Save/preserve portions of in-service lubricant for subsequent failure analysis Photograph machine condition prior to commencing repair/replace work for use in subsequent failure analysis Replace lubricated components and/or machines. Save components and/or machines for subsequent failure analysis Cleanup in-service lubricant and other chemicals that leaked from machines Ventilate the work area to dilute or remove smoke, vapors, by-products of burning, and degradation of lubricants, elastomers, chemicals, etc.

52 Planned and Corrective Maintenance Lubrication Tasks

• • • • • •

Disconnect electric power and other utilities Provide special lighting, e.g., mobile floodlights Take machines out of service using a LOTO (lock out-tag out) procedure Cleanup spills of water, lubricants, and other materials Replace and restock PPE, spill kits, fire extinguishers, and other con­ sumables used by personnel during the corrective maintenance task Check and reset sensors, alarms, etc.

Corrective lubrication maintenance tasks do not follow a recurring interval schedule. Instead, they are performed in response to nonconforming condi­ tions that may be scheduled on the following basis of criteria:

• • • • • •

Follow-up or consequences of planned maintenance tasks Nonconformance, including observations during inspections, monitor­ ing of operating parameters such as temperature, fluid pressure, vibra­ tions, etc., condition-based lubricant analysis and test data, etc. An impending or actual catastrophic event such as smoke, fire, electro­ static discharge, explosion, etc. An incident or accident that affects the health and/or safety of personnel or the environment An automatic response from a CMMS based on data, alarms, and other criteria, artificial intelligence, neural networks, etc. An automatic signal from an online sensor, pressure gauge, thermocou­ ple, or other warning device

In addition to the input for planned lubrication maintenance tasks, input for the design of corrective lubrication maintenance tasks shall take into account the following:

• • • • • • •

Urgency and possible consequences of nonconformance, predictions, emerging failure, etc. Possible needs to evacuate personnel, shut down equipment, shut off utilities, etc. Input from emergency responders, environmental experts, etc. Guidance from chemical suppliers regarding the release of chemicals into the atmosphere, possible reactions with other materials, appropri­ ate fire-fighting precautions and equipment, etc. Access and/or accessibility to the task location point and the required operating state (runtime or downtime) of machines Availability of parts, lubricants, other consumables, and substitute machines Availability of designated personnel, PPE, etc.

4.3 Corrective Maintenance Task Elements 53

•

Whether the task documentation has sufficient content and clarity to assure that the task can be completed correctly with an appropriate degree of precision

Documentation for a corrective lubrication maintenance task shall be worded clearly and provide sufficient detail to assure that the task can be completed correctly, consistently, and with appropriate accuracy and precision.Work instructions should include sufficient detail, especially for relatively rare conditions, circumstances, and tasks that may be unfamiliar to maintenance personnel and other personnel with limited experience. For each corrective lubrication maintenance task, documentation should include:

• • •

Items listed above for planned lubrication maintenance tasks A detailed Task Safety and Environmental Analysis (TSEA) for the task and required jobsite observations to assure safety and environmental compliance. A TSEA should include confined space and required permits/risk evaluations as appropriate Documents that may be needed by emergency responders, e.g., SDS, inventories of chemicals and other materials, diagrams of electrical and water utilities, evacuation records, etc.

Typical examples used to demonstrate compliance Corrective lubrication work order template Processes and procedures for the development of corrective lubrication work orders Lubrication PM / PdM Job Task Library PPE master list Risk management strategy/process Access to plant machinery operating history files Accessible lubrication work order record archive Training program for work order development Planning and scheduling processes and procedures Emergency response plan Emergency response training program Corporate physical asset management plan

• • • • • • • • • • • •

4.3.1 Comparison of planned and corrective lubricant maintenance task elements Long-term financial savings are among the leading considerations for an organization. [Bloch/Bannister, Toms]. Organizations realize their greatest

54

Planned and Corrective Maintenance Lubrication Tasks

Fault/Failure

Root Cause

Savings

Triage

Breakdow Figure 4.3

Preventive/Predictive

Proactive

Maintenance strategy relationship.

overall long-term savings by using condition-based maintenance to avoid failure. Proactive maintenance tasks and root cause detection and correction or remediation of developing or emerging failure modes are essential compo­ nents for achieving this goal. [Bloch/Bannister] Savings can be significant when organizations use planned maintenance to detect abnormalities such as machine and component wear, in-service lubricant degradation or contamination, and other subnormal conditions. Detection and correction are more effective for dealing with emerging faults than impending failure. Overall costs typically increase with the size of deviations from normal conditions, i.e., closeness to catastrophic fail­ ure. Condition-based maintenance task elements often complement planned maintenance programs for this reason. Run-to-failure (RTF) is generally the most expensive approach for maintenance. “Breakdown maintenance” is an oxymoron. Triage repairs rep­ resent a failure on the part of an organization to take advantage of cost sav­ ings inherent in planned and condition-based maintenance programs. RTF is only advantageous when equipment is not maintainable using a planned or condition-based strategy. If this is the case, a reliable spare part/asset replace­ ment strategy must be employed to minimize downtime. According to Bloch/Bannister, the savings associated with maintenance increase from RTF to predictive maintenance, to proactive maintenance. This relationship is illustrated clearly in Figure 4.3. Although these generalizations appear compelling, each organization should consider its own specific circumstances. There is no easy panacea that

4.3 Corrective Maintenance Task Elements 55

assures optimum financial savings for every organization. Inputs from HES, finance, purchasing, production, IT, and other departments contribute to suc­ cessful lubrication program management. [Toms] Run-to-failure maintenance, also known as reactive or breakdown main­ tenance, calls for the repair or replacement of in-service lubricants, compo­ nents, and machines after they stop functioning properly, degrade, or break down. Run-to-failure maintenance is most useful for applications where reli­ ability is inherently high while safety issues, downtime costs, and capital costs are low, e.g., power tools and many consumer goods. Run-to-failure maintenance advantages include:

• • • •

Program details and tasks typically are straightforward and readily understood by maintenance personnel and operators Involves limited documentation and personnel training Uses a relatively small inventory (only replacement fluids and components) Is a useful planned maintenance approach (see RCM) when an asset is non-maintainable

Run-to-failure maintenance disadvantages:

• • • • • •

Long-term costs of run-to-failure often exceed the costs of planned and condition-based maintenance Run-to-failure is ineffective for industries that require orderly shutdown of complex machines, e.g., power generation equipment Failure of a relatively minor component, such as a single bearing or a gear tooth, can disable a much more valuable machine or system Shutdowns for unplanned maintenance disrupt production schedules Some companies may struggle to finance unexpected capital expenses such as the replacement of machinery Delays for delivery and installation of new machinery

Organizations should weigh these aspects of run-to-failure against the challenges, pros, and cons of planned and/or condition-based lubrication maintenance. Planned maintenance (PM), also referred to as preventive maintenance, uses a predetermined, systematic, predictable plan to schedule and perform maintenance of lubricants, lubricated components, and machines. Typical advantages of planned maintenance programs include:

• •

The ability to anticipate failures, thereby reducing unscheduled down­ time and unanticipated repairs Greater operational safety and equipment availability versus run-to-failure

56 Planned and Corrective Maintenance Lubrication Tasks

• • • •

Long-term cost-effectiveness that facilitates budgeting for replacement components, consumables, and machines Inspection records, reports, and data may be useful for continuous improvement programs They may extend the service life of lubricants and machinery Inspections, observations, and test data from planned maintenance often can be used to modify in-service fluid composition, re-alignment of shafts, and make other operational adjustments that improve energy efficiency and provide other benefits

Planned maintenance programs are not without potential disadvantages:

• • • • • • •

Planned maintenance programs entail an initial investment in skilled personnel, statistical studies, forecasts, computer hardware and soft­ ware, monitoring equipment, etc., that are necessary to set up and implement the program Operational data for initial analysis and statistics may be required to develop maintenance plans Documentation and personnel training for the execution of planned maintenance programs typically are more extensive than for run-to-fail­ ure maintenance Organization-wide planning and cooperation of multiple departments are required to put a planned maintenance program into practice A planned maintenance program may have uniform plans for multi­ ple machines and/or lubricants that actually operate under different conditions and consequently have somewhat different maintenance needs A planned maintenance program may lead to the replacement of lubri­ cants, components, and consumables before their actual or statistical end of service life, thus generating more waste than run-to-failure maintenance Some planned maintenance programs do not include machine monitor­ ing, testing samples of in-service fluids, and record-keeping that add utility and value in condition-based maintenance programs

Planned maintenance programs satisfy the needs of some organizations. They may provide a feasible stepping-stone for other organizations that seek to advance from run-to-failure to eventual condition-based maintenance. Condition-based maintenance, also referred to as predictive mainte­ nance, uses a well-defined program to monitor the utilization and condition

4.3 Corrective Maintenance Task Elements 57

of in-service lubricants, lubricated components, and machines to optimize the scheduling and performance of maintenance of lubricants and equipment. The advantages of condition-based maintenance are numerous:

• •

• • • • •

Condition-based maintenance offers all of the advantages of planned maintenance (above) Decision-making and maintenance tasks are based on a framework of inspections, historical observations, test results for samples of in-ser­ vice fluids, and machine monitoring data. This collection of infor­ mation provides a multi-dimensional perspective that may facilitate effective maintenance, efficiently prevent failure, improve operational performance, and better control long-term costs Condition-based maintenance often leads to less expense, downtime, and waste than other methodologies Condition-based maintenance may be specific to individual components and machines, and thus be more effective than planned maintenance programs where common maintenance schedules and tasks are applied uniformly to lubricants, components, and/or machines with varied oper­ ating conditions A condition-based maintenance program may include means to use monitoring data, test results, etc., as feedback to improve and optimize scheduling, performance, efficiency, and cost-effectiveness of mainte­ nance tasks Routine data collected during normal operations may be less expensive and more effective than diagnostic trials as a means to identify develop­ ing failure modes and other abnormal conditions Condition-based monitoring may detect early stages of abnormal per­ formance when remediation is relatively more straightforward, rapid, and inexpensive compared to the latter stages of failure

These advantages notwithstanding, condition-based maintenance has several inherent disadvantages:

• • •

CBM shares several disadvantages with planned maintenance (above) Investments in specialized equipment, testing, training, documentation, and record-keeping for condition-based maintenance programs typi­ cally exceed those for planned maintenance programs Some companies are subject to government regulations and industry-specific planned maintenance programs that must take prece­ dence over internal condition-based maintenance programs

58 Planned and Corrective Maintenance Lubrication Tasks

• •

Warranties, insurance policies, and other considerations may require planned maintenance separate from or in addition to condition-based maintenance programs Budgeting may be easier with planned maintenance than with more dynamic condition-based maintenance

4.3.2 Guidance for planned and corrective lubricant maintenance programs Many considerations come into play when an organization begins a new lubri­ cation maintenance program or modifies an existing program. Toms describes a number of steps that are equally applicable for oil analysis, machine moni­ toring, and other elements of lubrication maintenance. First, an organization shall set goals, for example:

• •

Detect and avoid problems that can lead to failure such as contamina­ tion, degradation, abnormal wear, etc. Report conditions and prescribe appropriate maintenance tasks in order to prevent unnecessary maintenance

Second, each organization shall put together a framework to enable the orga­ nization to attain its goals:

• •

•

Establish a mandate or general rules for how an organization shall con­ duct its lubrication maintenance program. This may include compliance with government and industry-specific regulations, safety factors, and machine availability to meet production requirements Specify the use of appropriate lubricants that meet OEM and other relevant specifications. This may entail quality control testing of new as-supplied lubricants, maintaining records of certificates of analysis and other documents, and maintenance procedures covering the stor­ age, transport, and transfer of lubricants to protect them from contam­ ination and degradation. The use of expired lubricants (after their shelf life) shall be avoided Collect representative samples of in-service lubricants on an appro­ priate schedule. This may entail the specification of designated per­ sonnel, appropriate sample collection equipment, sample bottles, etc., procedures for flushing sample ports, and storage of retained samples. Additionally, samples should be collected under consistent machine operating parameters and environmental conditions, to minimize sam­ ple variations that are unrelated to actual lubricant conditions

4.3 Corrective Maintenance Task Elements 59

•

•

Properly perform all lubricant tests by qualified, designated in-house personnel and/or outside analytical test laboratories. This should include specifications for the use of standard test methods from ASTM, ISO, etc. When possible, a specific test should be carried out using the same laboratory, using the same procedure, instruments, and person­ nel, to minimize variations in data that are unrelated to actual sample conditions Treat all data consistently, using reliable record-keeping, identification of trends, diagnosis of failure modes, and recommendations of cor­ rective maintenance tasks. Additionally, an organization may perform statistical data analyses, define and set alarms, develop artificial intel­ ligence or neural networks for automated decision-making, apply data for continuous improvement programs, etc.

Third, an organization should analyze financial and general management considerations. Does the lubrication maintenance program scope make sense from a financial perspective? Does the program strategically align with an organization’s asset management plan, budget, and existing processes and practices across its departments?

• • •

•

An organization shall establish guidelines for estimating the benefits of lubrication maintenance tasks An organization shall calculate realistic benefits for comparison with measured costs associated with maintenance An organization should describe the benefits of lubrication manage­ ment maintenance in terms of: ○ Cost avoidance, defined as expenses that are avoided as a result of “a timely maintenance action initiated by the assessment of an oil sample” [Toms], machine monitoring, or other maintenance tasks ○ Cost savings, or “real earnings resulting from a reduction in consum­ able labor and materials” [Toms] An organization may not have adequate records of data, costs, machine availability, etc., before and after the implementation of lubrication maintenance tasks. Thus, it may not be possible for an organization to accurately calculate the actual effects of lubrication maintenance tasks on operational and maintenance costs. Toms suggests that estimates may be based on the experience of other operators, recommendations from OEMs, and relevant analyses such as: ○ Cost of equipment failures ○ Cost incurred from lost production, penalties for delayed delivery of products, repercussions of contractual obligations, etc.

60 Planned and Corrective Maintenance Lubrication Tasks ○ Savings realized by using information from lubrication mainte­ nance tasks as a basis for decisions to defer unnecessary scheduled maintenance ○ Detailed projections of costs associated with specific lubrication management tasks Fourth, an organization shall select specific tasks and parameters such as:

• • • • •

Intervals and methods for collecting samples of in-service oil and per­ forming specific oil analysis tests, including the sample volume required for specific slates or sets of tests Intermittent machine monitoring methods and intervals for making measurements Continuous machine monitoring methods and intervals for examining data Methods for measuring machine operating parameters and utilization in parallel with oil analysis and machine monitoring methods Criteria for defining alarms and their consequences. and other means for analyzing data, assessing failure modes, recommending additional (corrective) maintenance tasks, etc.

References Bloch, H. P., Bannister K.E. (2017) Practical Lubrication for Industrial Facilities, 3rd Edition, River Publishers, CRC Taylor & Francis Ltd. Johnson, M. (2006) Lubrication Program Development and Scheduling, in Handbook of Tribology and Lubrication, Vol. 1 Application and Maintenance, 2nd Edition, George E. Totten, Editor, CRC Taylor & Francis Ltd. Kauffman, R.E. (1994) Rapid Determination of Remaining Useful Lubricant Life, in CRC Handbook of Lubrication and Tribology, Volume III Monitoring, Materials, Synthetic Lubricants, and Applications, E. Richard Booser, Editor, CRC Taylor & Francis Ltd. Marscher, W.D. (1994) Rotating Machinery Vibration Testing, Condition Monitoring, and Predictive Maintenance, in CRC Handbook of Lubrication and Tribology, Volume III Monitoring, Materials, Synthetic Lubricants, and Applications, E. Richard Booser, Editor, CRC Taylor & Francis Ltd. Poley, J. (1994) Diesel Engine Lube Analysis, in CRC Handbook of Lubrication and Tribology, Volume III Monitoring, Materials, Synthetic

References 61

Lubricants, and Applications, E. Richard Booser, Editor, CRC Taylor & Francis Ltd. Toms, L. A., Toms, A. M. (2008) Machinery Oil Analysis – Methods, Automation and Benefits, 3rd Edition, Society of Tribologists & Lubrication Engineers (STLE) Venalainen, E. (1994) CRC Handbook of Lubrication and Tribology, Volume III Monitoring, Materials, Synthetic Lubricants, and Applications, E. Richard Booser, Editor, CRC Taylor & Francis Ltd.

5

Lubrication Support Facilities and Tools

Auditable Section 55.1.5.5: Lubrication Support

Facilities and Tools

Preface Section 5.5 of the ICML 55.1 Standard details the lubrication program man­ agement plan elements related to the organizational facilities and tools used to support lubrication. Appropriately organized, designed and maintained, these lubrication support facilities and tools are key elements used to enable effective plant lubrication operations. It is the organization’s responsibility to ensure all lubrication-related tools, facilities, and equipment are properly designed, maintained, calibrated, renewed, or replaced. In doing so, the organization shall establish and maintain processes and procedures to control these maintenance and calibration activities. Corporate structure, nature of the business, and specifics of the plant lubrication management plan (LMP) impact the complexity of the applied technical and organizational measures. Therefore, well-maintained and cali­ brated tools, facilities, and equipment are essential for: a. The implementation of the lubrication management plan(s) 63

64 Lubrication Support Facilities and Tools 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

5.1 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 in the lubrication man­ agement plan. The proper storage of lubricants, lubrication systems, lubrica­ tion parts, and lubrication-related consumables is essential for the effective, efficient, and safe execution of lubricant tasks. Investment in the necessary infrastructure is required to support lubricant storage and its management. Lubricant support facilities and infrastructure should include: 5.1.1 Lubrication room that provides sufficient space and control of ambient conditions to maintain the lubricant assets in optimal condition When designing and building a controlled lubrication room/facility, it is important that the facility and its rooms/separated areas are properly access controlled and appropriately marked and labeled. The lubrication room (also called the lube room) shall be a dedicated facility designed to allow for the following activities:

• • •

Supervision over lube room operations and lubrication technician activ­ ity, e.g., people management, computer station(s), documentation stor­ age, etc. Stations or designated areas designed specifically for receiving, storage, and dispensing of lubricants and associated consumables. Lubricants will include both oils and greases in bulk form or pre-packaged in drums, pails, cartridges, etc. Consumables can include cleaning materi­ als, filter elements, gaskets, hoses, grease fittings, etc. A designated area for in-house lubricant care/conditioning operations, e.g., filtration, de-hydration, varnish removal, degassing, etc., where applicable

5.1 Lubricant and Lubrication Support Facilities and Infrastructure 65

• •

A designated area for the collection, separation, and temporary storage of used/waste lubricant products and by-products, e.g., used oils, used filter elements, empty packaging and containers, used cleaners, used cleaning cloths, etc. If space permits, a designated area for performing workshop services related to the maintenance of lubrication equipment, tools, and instru­ mentation. These include activities such as basic maintenance checks and controls of lubrication-related equipment; preparation of the equip­ ment for use onsite (e.g., working tests, exchanging of filter elements, configuring of hoses and manifolds, preparation of electrical extend­ ers, etc.); after-use cleaning and decontamination of equipment such as pumping and filtration carts, oil dispensers and oil containers; charging batteries of portable equipment; executing lubricant quality control tasks (sampling of lubricants being handled in the facility, testing of samples taken onsite and/or taken in the lube room)

The facility shall be designed for air exchange and ambient control and utilize BAT (best available technologies) that meet all applicable local and national health and safety requirements. Typical design aspects can include:

• • • •

Building construction design (including floor/deck load carrying capac­ ity evaluation). Flooring must be designed to limit slippage of persons and transportation tools/vehicles due to oil/grease spills designed with the appropriate berms, and collection system to prevent and mitigate environmental spills Fire hazard risks evaluation and applicable requirements that include evacuation routes, type and amount of stored materials for fire extin­ guishing, fireproof cabinets and waste containers, etc. Safety requirements that include Safety Data Sheet (SDS) access, wash station(s), eyewash station(s), breathing apparatus, gloves, eyewear, etc. Personal work conditions and restrictions. These include room tem­ peratures, air quality, lighting quality, height fall prevention, confined space management, bathroom access, etc. A good practice is to: ○ Perform air exchange through air filters ○ Insulate building walls and roofs to meet applicable energy con­ sumption standards ○ In extremely hot or cold climates, heating and/or cooling will be required to meet local working condition requirements and facilitate the pumping of lubricants in low temperatures

66 Lubrication Support Facilities and Tools

•

○ In case the facility is located outside, sun and rain protection (roof) is highly recommended. Note: if possible, it is recommended to store new lubricants (and other sensitive equipment) inside, not outside Required electrical, water, sewage, heating/cooling, and spill preven­ tion installations

Typical examples used to demonstrate compliance Lubrication facility design specification Lubrication facility plans and drawings Lubrication facility building control documents Lubrication room material take off Lubrication facility operational and related processes and procedures

• • • • •

5.1.2 Management and dispensation of lubricants, lubrication tools, filters, breathers, and other lubrication accessories The lubrication facility is primarily designed to combine the functions of stor­ age and dispensation of lubricants and consumables such as filters, breathers, etc., and lubrication tools and equipment. Both categories require a specific and dedicated approach. Effective management of lubricants is a key factor in lubrication man­ agement. The kind and the amount of lubricants (and consumables) used are determined from the lubrication management plan and are derivatives of:

• •

Specified lubricant type(s) (derived from the lubricant assessment audit) and lubricant consumption forecast (operational quantities for expected typical use and strategic surplus levels in case of defined emergency plans) Purchase options and lead time

Typically, the use of dedicated IT tools (software and hardware) for storage and dispensation management of lubricants, consumables, and tools is rec­ ommended. At each stage of lubricant use cycle (request, purchase, delivery, storage, dispensation, consumption, unused lubricant return, generation of used/waste oils and other waste) all transactions are to be tracked, recorded and made available for audit purposes. It is also recommended that similar records be available for the use of equipment and tools. Bulk storage requires a means to measure the quantity of lubricants being received and dispensed in the storage facility. Typically, these are scales and volumetric flowmeters. For precise records, however, certified and calibrated scales are always recommended.

5.1 Lubricant and Lubrication Support Facilities and Infrastructure 67

To ensure the lubricant is always fresh and never reaches its expiration date, a FIFO stock control method must be adopted. This requires adequate coding and labeling of every type of stored lubricant and other materials. Note: there is no universal life for any lubricants; every producer specifies a shelf life (few lubricants have more than a one year shelf life). After reach­ ing that time, if not used, testing of properties is recommended prior to use. (Always consult with the lubricant provider for recommendations). Most modern lubrication management plans now support the use of lubrication management software to deliver management functional­ ity in the storage and dispensation of lubricants. Modern digitalization tools can be used to support handling operations in the lubrication room; onsite operations where required; and for warehouse inventory audits when required (typically once per year) to comply with legal requirements from a fiscal perspective and also to verify the real state of inventory and stock rotation. Typical examples used to demonstrate compliance Proof of the use of certified and calibrated scales (e.g., periodic cali­ bration certificate) Proof of use of the software for storage management Detailed usage reports of lubricants and other inventory supplies (e.g., daily, monthly, annually) Documents related to quality control of supplies, e.g., supplier prod­ uct quality certificates, and quality control certificates (oil/grease analysis) performed by (or on behalf of) the organization for new deliveries Dispensing records for specific lubrication operations (showing what, how much, when, for what purpose, and by whom) Records of lubricant quantities remaining and returned from lubrica­ tion operations (showing what, how much, when, for what purpose, and by whom) Inventory list of storage facility equipment and warehouse lubricant handling tools (tanks, containers, transportation equipment – such as forklifts and carriers, etc.) Consumption records/reports for lubricated equipment (usage proto­ cols) compared to overall lubricants dispensed SDS and TDS of lubricants or other supplies that are in use by an organization Used oil records/reports (what, from what machinery, when) and its product codes

• • • • • • • • • •

68 Lubrication Support Facilities and Tools 5.1.3 Restricted access to the population that can obtain lubricants, to reduce the risk of poor lubricant management Access to a lubrication facility shall be controlled so as to allow only des­ ignated staff to enter the lubrication room. Designated staff will have taken and passed all training requirements before being allowed access to enter and perform functions in the lubrication room. A lubrication facility may warehouse a large value of stored lubricants, equipment, tools, and documentation. It is crucial that employees are trained and well acquainted with the rules for receiving, handling, and dispensing of goods to avoid potentially costly mistakes resulting from the inappropriate type and quality of handled and dispensed (and returned) lubricants. Specialization of individuals promotes efficiency and quality of the pro­ cess. Typical skills of individuals authorized for work as lubricant storage personnel include and require (but are not limited to):

• • • • • • • •

Knowledge of IT software for warehouse management Knowledge of warehouse organization, logistics, and inventory man­ agement (control) Knowledge of quantity evaluation (weighing, volume dispensing, label­ ing, etc.) Knowledge of quality chain management and quality evaluation, e.g., understanding of quality and safety documents, sampling for quality control, cleanliness rules for packaging and handling equipment Knowledge of methods of transportation and storage rules, e.g., where to locate specific goods, how to transport lubricants in packages or in bulk quantities, etc. Permits such as driving licenses for cars, trucks, forklift trucks, etc. Knowledge of general rules of lubricant handling and use of associated equipment Knowledge of oils reclamation and conditioning methods

The practice of restricting access to the lubrication facilities, especially stor­ age and dispensation space, enables better control over lubricants and consum­ ables distribution and its associated quality. It also mitigates possible use of the wrong type of lubricant (risk of accidental lubricants mixing while introduced to machinery) while encouraging expected quality (including cleanliness). Typical examples used to demonstrate compliamce Job description for lubrication personnel identifying training require­ ments for entry into lubrication facility

•

5.1 Lubricant and Lubrication Support Facilities and Infrastructure 69

• • •

Lubrication facility access requirement list document HR roster of approved lubrication facility persons Access control to log into lubrication facility (e.g., doors/gates with locks, electronic access locks, etc.)

5.1.4 Satellite storage areas, which may be created for large facilities by placing smaller/additional storage areas throughout the facility. Satellite storage facilities include tanks, piping systems, and mobile units (mining, construction, etc.). Also, satellite facilities need to comply with the same requirements as the primary lubricant storage area In general, most facilities limit the number of lubrication areas/facilities to one only; however, in some very specific cases, satellite facilities are some­ times necessary. Additional storage areas are usually unofficial and often are not subjects of official lubrication plans. As a result, such areas are often sources of common mistakes and errors resulting from a lack of access con­ trol and management. If a satellite lubrication facility is used due to the size of the organiza­ tion facility(ies), it shall be an inherent part of the lubrication management organization supervised by skilled, responsible individuals. General require­ ments for these facilities shall be no different from the main lubrication facility. Since satellite storage areas may often be in remote locations and may not be supervised daily, it is important for controlled access to be in place along with the use of defined processes and procedures for the management and dispensation of lubricants. The best practice is updating the informa­ tion directly within IT systems (e.g., local computer station or on a remote tablet-type device); however, if this is not possible, paper records can be utilized and introduced into the IT systems on a frequent (daily minimum) basis. Mobile dispensing units are, de facto, a specialized class of “satellite” storage equipment that also must comply with the processes and procedures set in place for lubricant storage and dispensation. 5.1.5 Lubricant containers that are properly sized and of acceptable quality to support program requirements The type and size of containers and other storage packaging (drums, pails, totes, cans, cisterns, etc., whether permanent/stationary or single-use) shall

70 Lubrication Support Facilities and Tools be chosen and adapted to the program needs. The sizing of containers is related to:

• • • • • • • • •

Type of lubricants stored and dispensed Amount of lubricants required to be in stock (typically, the more fre­ quent and greater consumption and emergency stock required, the big­ ger volumes stored and bigger containers accordingly) Storage area capacity (floor area, building cubature) Operations with use of the containers (frequency of incoming supplies, frequency and size of dispensation, means of transportation to-site and onsite handling, required mobility) Safety and environmental hazards and ergonomic measures Multiple/single-use type of containers Permanent identification tags of portable multi-use containers such as intermediate bulk containers (IBC) or totes Cleaning feasibility Disposal procedures

See Figure 5.1 showing typical bulk lubricant storage tote complete with moisture control breathers in place and fast fill fittings. Typical examples used to demonstrate compliance Container specification document for purchasing requirements Container inventory list (includes tagging numbers for each container) Lubricant consumption report showing historic and forecasted (future) lubricants consumption (e.g., annual, monthly, daily, etc.) and lubricant turnover (purchasing cycles) Reports from periodic technical inspections/condition reviews of sta­ tionary tanks (especially when infrastructure is a subject of mandatory third-party technical inspection) and portable containers

• • • •

5.1.6 A staging area that allows for support of lubrication tasks Designated staging area(s) shall be available in the lubrication facility, whether inside or outside the building. Depending on the kind of tasks per­ formed, specific requirements may require: Ergonomic space allocation for safe and comfortable work execution If outdoors, shade from sun and rain Temperature controlled environment Required services, e.g., water, compressed air, and electrical power

• • • •

5.1 Lubricant and Lubrication Support Facilities and Infrastructure 71

Figure 5.1 Typical bulk lubricant storage tote system complete with moisture control breath­ ers, dedicated fast fill fittings, and dedicated outlet filters. Courtesy Des-Case Corporation.

•

Appropriate lifting and moving equipment

Typical examples used to demonstrate compliance Lubrication facility drawings and plans Onsite verification to demonstrate the area is reasonably fulfilling the needs

• •

72 Lubrication Support Facilities and Tools 5.1.7 Clear identification of lubricant types on each permanent or portable lubricant container Any containers (permanent or portable) of lubricant products used in the facility must be clearly marked and an identification means shall be applied. There are many ways of achieving this goal, starting from simple tagging (labeling) attached to the container, to more advanced ID systems using color/ shape identification, QR/bar code/RFID tagging, etc. Identification shall be intuitive and minimize the risk of misidentification while in use. A good practice is to identify more than just the name and make of the lubricant and its viscosity grade. More advanced ID systems can incorpo­ rate additional data such as suppliers’/receivers’ batch number and date or additional information such as if the oil has elevated purity (prefiltered) or as-in-delivery standard condition, etc.; or whether the lubricant was trans­ ferred from a large bulk container to smaller container, with fill date clearly visible. Of course, these additional identification practices require diligence if they are to stay up-to-date and reliable. Since many lubricants are not compatible with other lubricants and chemicals, it is crucial that both transfer equipment and portable con­ tainer systems be dedicated and labeled with the appropriate color or sign identification. Typical examples used to demonstrate compliance Procedures/instructions describing color/shape/pictogram/QR code/ RFID labeling (tagging) system in use Use of containers with appropriate labeling/tagging (applies also to grease dispensing guns) Designated area for periodic cleaning and dispensing of containers Proof that the given lubricant is really contained inside the container, especially when nonoriginal containers are in use and re-filled by technicians (such as low-volume cans, grease guns, mobile tanks, etc.)

• • • •

5.1.8 Methods to receive and inspect new lubricants that minimize the risk of spillage and contaminant ingestion Safety measures are always an important part of any operation. Lubricant spillage (new, used, or waste) can present as a potential major hazard while handling lubricants. To mitigate spills the following common sense rules can be applied:

•

Use only containers certified for use with lubricants

5.1 Lubricant and Lubrication Support Facilities and Infrastructure 73

• • • •

Transport lubricant containers in an approved manner, e.g., drum hold­ ers, pallets, forklift trucks, and other lifting systems Utilize proper/approved storage systems, e.g., anti-spill trays, racks, and shelves Utilize approved/recognized best-practice lubricant transfer systems, e.g., flexible hoses equipped with reliable connectors protected by cov­ ers or plugs, appropriate pumps, filtration skids, anti-spill trays Use of dedicated transfer equipment for each and every lubricant

Clear marking of the allowed storage zone is important. Any operations that may cause an increased (unacceptable) risk of spillage to an unprotected environment will require continual supervision. Contaminant ingestion may occur whenever lubricants have contact with the environment (typically with surrounding air or direct contact with water and dust) or with dirt (contaminants) from interiors of containers, transfer hoses, pumps, housings, filters, etc. To control this, it is always rec­ ommended to keep lubricants in tightly sealed containers, stored in a clean, controlled environment. If inside storage is not possible, outside storage must provide protection against the elements especially for container openings that can have contact with water and dust. In this case, the use of protective covers for drums and totes stored in an upright manner is essential. Proper positioning (horizon­ tal) of steel drums in a specially designed drum rack can be implemented as a way of reducing contact with liquid water and dirt around the drum openings (bungs). The condition of the seal in the drum and totes, plugs, and lids is import­ ant and must be checked on a regular basis using the PM work order system. Dispensing of lubricants from larger containers to smaller contain­ ers (decantering) must be performed in a dust- and moisture-free environ­ ment (preferably indoors) or in a portable shelter. The use of breather filters attached to both full and empty containers, and the use of filtering/pumping units, are recommended in order to prevent contamination ingress. In permanent containers (storage and dispensing tanks of larger vol­ umes), use of breather filters is strongly recommended due to the intensive natural air exchange between the inside and outside of the tank. Typical examples used to demonstrate compliance Procedures/work orders that state how to store or protect the container Procedures/work orders that instruct how to check container lid tight­ ness and/or condition of breathers on containers Training materials that emphasize how to manage spill control

• • •

74 Lubrication Support Facilities and Tools 5.1.9 Methods for lubricant stock rotation (e.g., first in, first out) Stock rotation is important especially for products that have a limited life span. Lubricants (oils, greases) age over time, and awareness of their con­ dition is required. The best way of limiting the risk of using degraded “new” lubricants is to use the FIFO stock rotation method (first in, first out). This is achieved by appropriately labeling incoming containers with the date of receipt and batch code, enabling employees to verify in the storage software when any particular container was received at the warehouse. Storage software shall allow introduction of the expiration date of the products (typically defined by the manufacturer). Combining that with the number of containers will help identify which particular stock is reaching its expiration date. Labeling containers with expiration dates allows personnel quick and natural identification of which stock is older or newer. If applicable, physically arrange incoming supplies in a way that new stock is always placed at the end of the line. Typical examples used to demonstrate compliance Stock rotation procedure Stock rotation report (from warehouse management software) confirm­ ing dates of deliveries and consumption

• •

5.1.10 A process to ensure that lubricants are not stored for extended periods prior to use Precise planning of lubricant consumption over time is essential for any successful lubrication plan. Whenever possible (and safe for the process), attempt to supply lubricants on a just-in-time (JIT) basis, which eliminates excessive inventory and creates a natural pace of delivery and consump­ tion. This balance is the result of detailed planning and good coopera­ tion with lubricant (and other consumables) suppliers. Any JIT approach should take into account all considerations such as risks associated with running out of lubricant, versus the cost of frequent deliveries, versus general market conditions such as availability, price stability, etc. At all times, minimum stock limits shall be maintained. These can be calculated from lubrication schedules and can also be based on minimum volumes for emergency situations.

5.1 Lubricant and Lubrication Support Facilities and Infrastructure 75

Typical examples used to demonstrate compliance Report showing all “best before” dates for delivered products Verification report showing that production dates provided on container labels are within the expiration dates provided by the manufacturer Laboratory reports of samples tested shortly before the expiration date and renewal of the new expiration date

• • •

5.1.11 A process to determine if new lubricants meet specification requirements Quality control of new lubricants in delivery is essential. Every delivery shall include the actual batch number and a quality report from the supplier con­ firming actual batch parameters vs. the technical datasheet of the product. A good practice is to establish a quality control plan based on sampling and measuring specified parameters. The control plan is used to determine:

• • • • •

Scope of general delivery control (delivery completeness versus order type, amount, packaging, etc.), documents verification and control, packages and containers control (tightness, seal verification) What lubricants need to be tested (usually for oil cleanliness rating) Scope of onsite and laboratory testing Sampling procedure (sampling points, sampling methods, sampling witnessing by receiver and supplier, etc.) Sampling frequency in the case of multiple-container delivery (which packaging shall be sampled, and whether the sample shall be drawn from different packaging, etc.)

A critical element of the plan is cooperation with a professional oil analysis laboratory (internal or external) – best if working according to the ISO 17025 accreditation that allows access to independent, reliable, and quick lubricants analysis. Typical examples used to demonstrate compliance Quality control procedures/instructions Quality control documents for incoming delivery (e.g., batch laboratory tests by vendor, delivery completeness report, weigh report, etc.) Quality control results performed at delivery (testing for chosen param­ eters and comparing to declaration by vendor)

• • •

76

Lubrication Support Facilities and Tools

5.1.12 A process to decontaminate or reject lubricants deemed to be unacceptable upon receipt The use of a quality control process shall determine what is the real condition of received lubricants. If evaluated properties vary from specifications warranted by the supplier, a next step decision must be taken. Usually, only cleanliness and water content can be a subject of improvement after receiving (filtration and dehydration process). Based on the process, the batch is accepted or denied. If the batch does not meet accepted level requirements, a process must be in place for the next steps that can include the supplier’s filtering and/or dehydrating the lubricant onsite or taking it away to be replaced with an acceptable product. Typical examples used to demonstrate compliance Process and procedure for accepting deliveries of quality product Decontamination action reports Supplier quality control agreement

• • •

5.1.13 Sample points that provide for effective, efficient, and safe access for the sampling of stored lubricants The organization shall determine methods of sampling the lubricants during receipt from suppliers and also that of its stored lubricants. There are many methods of sampling available. It is important to understand the impact of the sampling place and method on the sample quality and homogeneity (espe­ cially important for particle contamination). Usually in the case of stored lubricants, sampling occurs from nonflowing lubricants directly from con­ tainers through open lids or plugs (e.g., by suction devices or pipettes). In case lubricants are sampled from larger tanks (truck cisterns, large storage tanks, etc.) that allow high liquid head pressure (or are equipped with pump­ ing systems), samples may be obtained from permanent sampling points located in outlet ports (if available) or downstream at the pump. Awareness of oil sedimentation particles on the bottom section of con­ tainers is important for sampling procedures and quality evaluation. Samples taken directly from the bottom outlets can reach worse cleanliness than those from the middle of the containers. In most cases, the same applies to free water (for lubricants of specific gravity lower than water). For further infor­ mation see Chapter 7 – Condition Monitoring and Lubricant Analysis. Safety measures shall be maintained all the time. Typical risks during sampling are related to falls from heights, slippery floors, splashing to

5.1 Lubricant and Lubrication Support Facilities and Infrastructure 77

eyes, lubrican contact with bare skin, spillage, etc. Samples shall always be precisely labeled and stored in dry, dark, room temperature conditions. Based on the scope of testing, the appropriate size and type of sample bot­ tles shall be chosen. Never use previously used sample bottles or bottles, jars, etc., after food or other products. If the samples are a subject of quality dispute between vendor and receiver, a procedure of committee sampling shall be developed. Typical examples used to demonstrate compliance Written procedures/instructions including standards (e.g., ASTM, ISO, etc.) or industry recommendations for taking samples Evidence of sampling equipment Oil analysis reports from previous deliveries Map of existing sampling points Copy of a typical sampling procedure

• • • • •

5.1.14 A sampling process of stored lubricants that minimizes the risk of contaminant ingestion Sampling personnel must always be cognizant of whether the environment is clean enough to attain a representative oil sample. This requires them to ensure the sampling environment is free of any surrounding dust, dirt, or water (rain) while sampling is taking place. A standardized sampling pro­ cedure designed to ensure cleanliness at all times during the procedure is required for the work order description and for training purposes. Typical examples used to demonstrate compliance Representative sampling procedure text Oil sampling training document

• •

5.1.15 A process to manage lubricant samples for testing Once a sampling procedure is in place there must also be a procedure for managing the sample to ensure it does not become contaminated, is labeled correctly, and is sent to the laboratory for testing within a specific time period. This can be for bulk sampling and/or single samples. Typical examples used to demonstrate compliance Representative sample management procedure

•

78 Lubrication Support Facilities and Tools 5.1.16 Effective, efficient, and safe access to allow periodic filtration and/or conditioning when required Particulate contamination and excess moisture in lubricants are major causes of premature wear (and corrosion) of lubricated machine components. Water is also a critical factor in lubricant and lubricated component degradation. Therefore, lubricants transferred into machine reservoirs must be clean and free of water contamination prior to the transfer taking place. Achieving this can require filtration (the most common procedure in use) and corrective dehydration (in case of excessive water content). Oils in the storage area can be filtered directly in their original con­ tainers with the use of dedicated filter carts comprised of a dedicated set of pumps, filter housing, and flexible hoses (one cart per oil type). For large storage totes and tanks, a permanent stationary filtration system dedicated to each storage tank is both practical and efficient. These systems allow for peri­ odic and effortless filtration of oils. Filtration systems can also be equipped with online particle counters (and water sensors). Whenever in use, temporary purification systems shall ensure the required level of safety and spill control (tight reliable connections, emer­ gency switch-off button, cut-off valves on the outlet from tanks, etc.). Antispill precautions must also be present (oil absorbents, clothes, etc.). Typical examples used to demonstrate compliance Evidence of storage area and available hardware used for contamina­ tion control (filter carts, connectors, hoses, sampling equipment, clean­ liness evaluating instruments, etc.) Process for filtering lubricants using external filtration equipment

• •

5.1.17 Containment areas to collect incidentally spilled or leaked lubricants to avoid safety and/or environmental risks See Chapter 9 – Lubricant Waste Handling and Management. 5.1.18 Separation of new and used lubricants. When kept in near proximity, clearly marked containers for storing used oil to avoid reuse New and used lubricants shall be properly separated. Whenever possible, separate areas for housing and managing new and used lubricants are cru­ cial if the used oils are not to contaminate the new oils. Used lubricants

5.1 Lubricant and Lubrication Support Facilities and Infrastructure 79

shall be clearly marked and labeled. In most countries and jurisdictions, used lubricants are classified as hazardous materials, and required codes and pictograms must be used in their management and identification. Additional requirements may also apply for storage areas dedicated to waste oils (additional access control, additional anti-spill trays, additional ventilation, etc.). You will need to refer to your local authorities for direc­ tion in this regard. Typical examples used to demonstrate compliance Evidence of storage area and available containers with associated antispill protection and their labels Reports identifying the amount (and type) of used oils Copy of local regulations regarding the storage and movement of used and waste oils

• • •

5.1.19 A disposal plan to ensure proper handling and management of waste per the organization’s safety and environmental compliance standards and requirements A disposal plan of waste shall be in compliance with the local environmental and safety standards and requirements and shall follow a responsible and sus­ tainable approach. In addition, practices must also align with any corporate sustainability program and commitments. Proper handling and management of wastes (including waste oils and lubrication-related wastes) is one of the most restrictive and important areas of the company’s operations and is thoroughly supervised by independent state organizations. Most integrated management systems such as ISO 14000 series (or similar) require a dedicated waste management plan and investi­ gation of all related aspects. Legal requirements may strongly vary between countries. For more detailed information, refer to Chapter 9 – Lubricant Waste Handling and Management. Typical examples used to demonstrate compliance Copy of identified corporate legal requirements (access to applicable law acts, standards, etc.) Copy of corporate sustainability program Lubricant disposal plan and associated documents (what is produced, how much, from which lubricated equipment, what is a waste code , etc.) Copies of actual waste disposal documents (waste sales and receipt report from the waste receiver, invoices, etc.)

• • • •

80 Lubrication Support Facilities and Tools 5.1.20 Safety provisions such as appropriately positioned eyewash stations and ventilation. Ready access to SDS/MDS sheets Handling open lubricants, new or used, requires the use of gloves and masks to ensure the skin and eyes are always protected against accidental contact with chemicals and lubricants stored in the lube room. If skin contact with the lubricant does occur, most SDS sheets will demand that the affected area be washed immediately. This requires the installation of a wash facility either in or nearby the lube room. For contact with the eyes, the lube room will need to have in place a certified eyewash station. These can be permanently plumbed in place or can be a portable design used in smaller lubrication facilities. For eyewash and ventilation requirements the company safety officer can be an excellent resource in determining local and national codes, regula­ tions, and safety requirements. In addition, the lubricant SDS sheet will provide relevant product safety information regarding fume inhalation, skin and eye contact. 5.1.21 Local and national environmental regulations available for use. Refer to Chapter 10 – Energy Conservation and Environmental Impact.

5.2 Tools, Instrumentation (Automation), and Consumables Tools (equipment, instruments, etc.) for use in lubrication management oper­ ations are an important part of the process and lubrication plan. These tools are necessary to support the lubrication function and, as such, they must be specified correctly and maintained to the highest order. This will require the following:

• • • •

Tools must comply with recognized performance and quality standards Tools must be stored and managed to assure availability, accessibility, and defined operational performance Tools must be individually identified and tagged and tracked in the asset management system As required, tools must be calibrated to recognized standards. Calibration certificates must be current and made available to mainte­ nance and engineering at all times

5.2 Tools, Instrumentation (Automation), and Consumables 81

•

Tools must be evaluated and tested for expected performance before being accepted for use

There are certain common groups of tools and instrumentation typically used in lubrication service activity, which can include:

• • • • • • •

Storage and handling equipment: containers, lift trucks (hand and motorized), cranes, dedicated transfer vehicles (electric and gas-fueled), transfer pumps, associated hoses, contaminant exclusion breathers and filters Oil purification equipment: pumps, filtration units, dehydration units, degassing units, varnish mitigation units, etc., whether used onsite or offsite Greasing tools: grease guns, automatic lubricators, grease dispensing pumps, etc. Onsite/offsite condition monitoring and control equipment/instruments: sampling devices, sample containers, sampling ports and valves, parti­ cle counters and cleanliness monitors, water content sensors, scales, flow meters, pressure gauges, thermometers, ultrasound sensors, etc. Safety and environmental protection hardware and consumables: por­ table lighting units, housekeeping tools, work wear and personal safety equipment, cloths, oil absorbents, anti-spill barriers (for open waters). breathing apparatus, portable eyewash stations Technology tools/IT systems: computer, software, printers, labelers, infrared thermometers, infrared cameras for lubrication management Test instruments: portable oil analysis test equipment, gauges

The type and amount of equipment employed shall be adjusted to the scale (type and number) of operations executed during lubrication maintenance. Planning shall take into consideration the use of tools, and they should be identified on the lubrication work order. This will take into consideration the following:

• • • • •

Type, size, and specificity of the plant (area and vertical dimensions) and ease of installation access Type of lubricants in service Type and size of oil/grease systems in service Cleanliness requirements (particle contamination, water contamination, varnish, and other contaminants such as dissolved flammable gases in compressor oils, etc.) Schedule of planned tasks (frequency, shifting policy (1/2/3 shifts on duty), the number of workers executing tasks, etc.)

82 Lubrication Support Facilities and Tools

• • •

How many tasks will be performed simultaneously Required redundancy of service equipment Availability and lead times of spare parts, consumables, and service of equipment

Above shall result from a properly designed lubrication management plan, know-how, and understanding of the jobs to be performed. Typical examples used to demonstrate compliance Tools and instrument equipment list showing unique identification numbers (UIN) for all assets, thus enabling proper tracking and asset management Service manuals for tools in use Current calibration certificates for tools and instruments, e.g., periodic electrical inspections, leak control tests, harnesses, slings, and ropes certificates, etc. Available equipment PM service plans (service schedule, testing, etc.) Proof of performance evaluation, especially regarding control and measurement instruments, with use of inter-laboratory (or OEM) test­ ing and calibration Proof of safety evaluation in regard to flexible rubber hoses (periodic visual inspection and pressure testing)

• • • • • •

6

Machine and Lubricant Inspection

Auditable Section 55.1.5.6: Machine and Lubricant

Inspection

Preface Condition monitoring and inspection should never be limited to a single technology or method. Instead, it should combine and integrate an optimum selection of purposeful tools and tasks. Condition monitoring can be largely technology-based but can also be based on observation or inspection. Most machines share condition monitoring and inspection needs with many other types of equipment. This is because they have components and operating conditions in common, e.g., motors, bearings, seals, lubricants, couplings, etc. At the same time, their operating conditions and applications may demand unique inspection requirements. These influence failure modes and machine criticality. Inspection should be viewed with the same serious intent as other con­ dition monitoring practices. In fact, a world-class inspection program should produce more “saves” than all other condition monitoring activities com­ bined. It is not an alternative to technology-based condition monitoring but rather a strategic and powerful companion. 83

84 Machine and Lubricant Inspection The technologies of infrared thermography, analytical ferrography, vibra­ tion, motor current, and acoustic emissions are generally used to detect active faults and abnormal wear. Conversely, a well-conceived inspection program should largely focus on root causes and incipient (very early-stage) failure con­ ditions. Detection of advanced wear and impending failure is secondary. Inspection is the most fundamental and arguably the most effective form of machine condition monitoring. It entails not just looking at a bearing, seal, coupling, or pump, but rather examining these components in a probing, intense and purposeful manner. It seeks early-stage detection of abnormal conditions that can be remediated before irreversible harm is done. A successful and effective inspection program requires a comprehen­ sive understanding of the machinery, the manner in which failures can occur, and how humans can intervene to impede the progress to sustain a reliable state of operation. This invariably involves an engineering process, starting with an inspection plan customized to the plant’s mechanical assets, need for reliability, and available inspection resources (people, tools, budget, etc.) that can be deployed. Inspection presents some benefits and advantages that are difficult, if not impossible, to duplicate with other condition monitoring options. These include:

• • •

• •

Simple and inexpensive: There are no large capital acquisitions or need to get bogged down with learning and operating complex technol­ ogy and software. This is not to say that training is not required, but the know-how needed is more intuitive and similar to craft skills. Abstract, theoretical, and scientific concepts are not required. Operator-driven: Operators often accept ownership of machine reli­ ability through inspection. This is very similar to Total Productive Maintenance (TPM), which stresses that maintenance and reliability are everyone’s responsibility. Examination skills: Condition-based Maintenance (CBM) requires continuous awareness of the meaningful conditions made known by the machine. It does not care how these conditions become known or understood. Hence, there is a basic need for condition awareness regardless of how this information is discovered, i.e., by inspection or technology-based methods. The power of frequency: It is far better to know a critical condition sooner than later. Inspections are often performed daily. Root cause oriented: A root cause is not a disease, but it leads to a dis­ ease. Once machine wear has been allowed to occur, we cannot reverse

6.1 Inspection Plan 85

• •

the loss (wear metal, for instance). Inspection has the potential to be very proactive and less reactive. Fault bubble oriented: Contrary to what the name implies, sudden death failures do emit subtle symptoms that, if detected, could reduce the damage and consequences of failure. This requires inspection fre­ quency, certainly, but also the ability to detect and respond to the weak­ est of failure symptoms. Lasting deployment: Inspection at a high level is culture-driven. Once solidly in place, it has inertia and sustainability.

The activities of inspection are extensive and wide-ranging. This chapter of ICML 55.2 primarily focuses on lubricants and lubrication in the context of mechanical reliability.

6.1 Inspection Plan Like most business plans and strategies, an inspection plan should be built top-down. It should begin with a clear statement of corporate goals and objec­ tives related to asset management. This approach is addressed in ISO 55001 on asset management. ICML 55 focuses on the optimized management of lubricated assets and is aligned with ISO 55001 guidelines. An inspection plan should be a detailed and comprehensive document to ensure that key features and functional elements are not overlooked. From there, it can be abridged or streamlined for quick readable review by techni­ cians, operators, and other stakeholders. The unabridged version of the plan can also serve as a rough curriculum for training and competency testing for both current and aspiring new inspectors. A well-constructed inspection plan serves as a framework for enhanc­ ing the likelihood and magnitude of successful and sustained deployment. The subsections that follow are intended to help codify the structure of the inspection plan, similar to an engineering specification, including the tasks and main features that should be incorporated. Modern reliability and asset management programs expect documented, procedure-based work plans that reduce the risk of variability, uncertainty, and drift over time. The plan is best if it is consensus-based and certainly should be continually improved. Before considering the input of stakehold­ ers in writing the inspection plan, it is best to get everyone on the same page through training or self-study on the fundamental elements of inspection and condition-based maintenance. Consensus-based inspection plans tap into the knowledge base and experience of skilled practitioners and others with valuable craft skills. This

86 Machine and Lubricant Inspection provides a helpful foundation related to the machine’s operating conditions, critical inspection points, reliability history, and known failure modes. It also establishes buy-in or ownership among operators, mechanics, technicians, and other stakeholders who will be asked to both execute and respond to the plan. Furthermore, a well-constructed inspection plan communicates the seriousness of effort and purpose. It documents what is different or unique from more conventional inspection practices of the past. It also documents that these differences are necessary to achieve the optimized level of machine reliability established by the asset owner. 6.1.1 Multiple disciplines For many organizations, typical inspections will include lubrication, mechan­ ical maintenance, electrical, safety, and machine operation. If a plant has different maintenance planners for different maintenance functions (lubrication, mechanical, electrical, process/production, etc.), the inspection must be viewed from the standpoint of skill sets, tools, inspection intervals, and other factors. The role of the inspector and the integration of multiple disciplines must be viewed from that context to achieve the most efficient and effective outcome. Typical examples used to demonstrate compliance Inspection points and tasks are examined based on objectives, skills, and tools needed Inspection frequency or interval is viewed across the inspection disciplines

• •

6.1.2 Common goals Inspection should be purposeful. It should gather routine answers to import­ ant questions about the health and conditions of the machine overall, as well as individual components that the machine depends on such as the lubricant. Inspection is a vital condition monitoring method that requires unification with other companion methods, including remote control room surveillance. All condition monitoring activities and technologies should conform to or align with corporate goals and business objectives, particularly related to asset management and machine reliability. As mentioned, it should start at the top and become increasingly gran­ ular and prescriptive as it works down into the specific tasks of condition

6.1 Inspection Plan 87

monitoring and inspection. For instance, if the corporate goal is to increase earnings-per-share, then inspection must directly and indirectly be aligned toward achieving that goal. This might come from increased worker safety, reduced maintenance costs, increased asset utilization (productivity), and reduced energy consumption – all achievable through an engineered lubri­ cation program. Typical examples used to demonstrate compliance A top-down approach is applied to ensure the plan is aligned to broader organizational policy and strategy objectives/goals Cross-functional stakeholders are engaged to establish the goals of the plan across relevant operating units and functional activities Inspection plans are recognized as an integral part of the broader main­ tenance initiative and part of a reliable asset management business structure

• • •

6.1.3 Alignment with ranked failure modes Ranking failure modes helps customize and optimize the condition monitor­ ing approach. Failure modes and failure root causes are closely associated and in some cases are the same. For instance, abrasive wear may be the failure mode, but particle contamination is the root cause. Ignorance, culture, insuf­ ficient maintenance, and poor machine design are all possible pre-existing conditions that individually or collectively lead to contamination. Because you can always search for deeper levels of “cause,” for the sake of simplicity the terms “failure mode” and “root cause” are used interchangeably. It is best not only to list failure causes but also to rank them in terms of probability and severity. This helps allocate resources by priority. From lubricant to machine, failure has specific consequences, and these conse­ quences are mutually exclusive. Lubricant failure consequences include oil replacement costs, downtime during the oil change, labor to change the oil, and flushing costs. Machine failure consequences relate to safety, spare parts, labor to repair, and downtime (e.g., production losses). Identification and ranking of failure modes are often performed during a formal study commonly called Failure Mode and Effects Analysis (FMEA) – see Chapter 8. Experience is generally considered to be the best source of information on failure modes. Service histories, condition monitoring data, and statistical analysis can also be instrumental, as well as the compiled records from root cause analysis studies. FMEA should be done for process critical machine assemblies, individual machines, and/or machine components.

88 Machine and Lubricant Inspection Once a reliable ranking of failure modes is known, the process of con­ structing an inspection plan for early and reliable detection and troubleshoot­ ing can be conducted. Highly ranked failure modes merit the inspection and condition monitoring methods. In many cases, there may be a need to modify the machine, e.g., to add a sight glass, or to include a special instrument or tool in the inspection procedure. Typical examples used to demonstrate compliance List of machines meeting the definition of process critical (at minimum) identified for Failure Mode and Effects Analysis Demostrated use of FMEA or similar methodology, with failure modes of the process-critical machines ranked according to the likelihood and severity of potential failure An inspection and condition monitoring program designed to ensure early and reliable detection of failure modes well in advance of func­ tional failure

• • •

6.1.4 Inspecting across the five operating states Inspection is not used solely for running machines, such as when making daily rounds. True, this type of on-the-run inspection is critical to machine condition monitoring, but other types of inspections are equally important. At its best, inspection should seek and find the “precursors” to failure, also known as root causes. Next, the inspection must look for incipient failure conditions (the earliest detectable state). The time horizon for inspection should span cradle-to-grave. A well-de­ signed inspection program performs checks across multiple states. 6.1.4.1 Inspection of spares, storage, and standby (SSS) equipment Keeping spares and standby machinery in a prime, healthy state can be dif­ ficult. Often machines and critical spare parts must be stored for years in a “ready for operation” state. It is important to sustain a state of readiness. A common enemy for this type of equipment is water that condenses, settles, puddles, and corrodes. Therefore, from the standpoint of inspection, looking for water entry points and the presence of invasive water is a priority. The ability of a lubricant’s additives to suppress corrosion is largely neutral­ ized when additives are unable to circulate. For numerous reasons, water is the enemy of stored and idle machines and spare parts.

6.1 Inspection Plan 89

Many types of machines are internally flooded with oil during storage to minimize air movement between the headspace and the atmosphere. This also keeps internal surfaces oil wet, which would otherwise be exposed to condensation and other atmospheric contaminants. In gearboxes, these surfaces would include all bearings, internal shafts, and gears. Because of hydrostatic forces, these flooded machines are prone to leakage over time, often through gaskets and lip seals. All evidence of leakage, from dampness to oil puddles, should be examined by inspectors. Typical examples used to demonstrate compliance The SSS inspection plan should confirm All shafts and couplings have protective coatings still in place Lube lines and components are tightly sealed (caps, plugs, etc.), and hatches and covers are battened down Reservoirs and sumps are clean and free of water and sludge Shafts are rotated frequently Dirt and other debris have not accumulated on exterior surfaces Parts and small assemblies are sealed (e.g., plastic sheets/bags) and oriented correctly (i.e., vertical versus horizontal), including hydraulic cylinders, bearings, gearboxes, pumps, etc. Storage areas do not expose spare parts, assemblies, and stored machines to vibration Parts and small assemblies are used in a First In, First Out (FIFO) manner to prevent the excessive storage time of common spare parts such as bearings Proper positioning of safety equipment such as guards, gates, or other barriers Labeling or other process to communicate particular details of the storage condition that would not otherwise be obvious to the inspec­ tor, e.g., a “full vapor phase inhibitor” with application date or dated sign-offs that demonstrate the performance of storage requirements such as periodic shaft rotations

• • • • • • • • • •

6.1.4.2 Start-up inspection It is frequently stated that the time a machine is most prone to failure is just after commissioning, major repairs, or teardown. These episodes are critical states of change, and change presents a risk from the standpoint of machine reliability.

90 Machine and Lubricant Inspection There is also the human element. When operators, lubrication techni­ cians, mechanics, and maintenance workers alter a machine, it is often dif­ ficult to precisely return it to the previous operating state. Any form of an intrusive event presents a danger. A good countermeasure to avoid start-up risk is thorough and continu­ ous inspection. Respect all potential areas of danger. Inspect as many of these hazards as possible until operational stability is restored. Typical examples used to demonstrate compliance The start-up inspection plan should include Temperature (all critical zones, components, and surfaces) Vibration Balance and alignment Gauge readings (temperature, pressure, vacuum, flow, speed, proximity, etc.) Differential filter pressure Magnetic plug collections Oil level, color, and clarity at all sight glasses Fluid cleanliness Wear debris analysis Leak zones

• • • • • • • • • •

Do not overlook the need to pull samples frequently and run onsite checks for cleanliness levels and wear debris. Often there is no need for a laboratory to perform these checks. Many different field methods do an adequate job, including patch testing and blotter spot testing. 6.1.4.3 Run inspection An enhanced state of reliability demands an enhanced state of operator involvement. It is not just about looking at a machine, but rather examining the machine frequently and intensely with a skilled, probing eye. For all “bad actor” machines under the operator’s care, there is a need for inspection vigilance. These are the machines that are pushed beyond their design limits. They are most responsible for business interruption and lost production, as well as for 80 percent of the costs of downtime and repair. Typical examples used to demonstrate compliance The run inspection plan should include Inspections customized to the machine conditions/environment

•

and

operating

6.1 Inspection Plan 91

• • • •

Inspection methods, tools, and frequency tailored to operating conditions Documented inspection alerts/limits Data records used for trending and statistical analysis Use of electronic data collection devices with routing tools for running inspections

6.1.4.4 Stop inspection Stop inspections allow access to those hard-to-reach machine conditions and frictional surfaces. However, one should avoid all unnecessary invasions that can introduce a root cause for failure. That said, an inspector can often safely gain access to gear teeth, sump walls, couplings, shaft seals, bottom sediment and water (BS&W) bowls, magnetic plugs, bearing clearances, etc., for a brief look at their condition. Cameras, including borescopes, inspection mirrors, etc., may be used to facilitate the inspection process. Typical examples used to demonstrate compliance The stop inspection plan should include A protocol for inspecting hard-to-reach machine conditions and fric­ tional surfaces The frequency or conditions that justify the need and potential risk of performing such inspections The methodology and tools to mitigate risk

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6.1.4.5 Repair inspection Repair and rebuild inspections present a valuable opportunity. This not only involves what failed and why it failed, but also what else you can observe while the investigator is performing the autopsy. Rebuild shops can teach us about the causes of failed electric motors, cylinders, gearboxes, pumps, etc. Confirm that inspection reports from these rebuild shops document observations and all findings. Do they give you guid­ ance on prevention? Note how this knowledge (feedback) can be used to improve maintenance practices. Once the operation has been restored to a process or machine, do not fail to investigate the cause of the failure. Inspect other wear zones and machine surfaces. Other important inspection zones or components include used fil­ ters, strainers, sump floors, seal conditions, corrosion, journal bearings, etc. It is important to know who has been assigned responsibilities for fail­ ure reporting, analysis, and corrective action system (FRACAS) activities.

92 Machine and Lubricant Inspection One of the problems with repair inspections and failure investigations is that the people assigned to the task are often the same people who are directly or indirectly targets for blame. Asking a maintenance organization to find fault with itself is fraught with challenges for which there is no easy solution. Typical examples used to demonstrate compliance The repair inspection plan should include Protocols for inspecting and reporting findings by rebuild shops Protocols for performing root cause failure analysis of failed machines or components Procedures for performing inspections related to ancillary zones and surfaces, i.e., not directly related to the point of failure but might exhibit distress or contributing factors Protocols for failure reporting including FRACAS

• • • •

6.1.5 Machine inspection ownership There are five inspection-operating states that influence inspection owner­ ship. Take machine parts, for instance. They are often staged in warehouses or on shelves and pallets near operating machines and other active work areas. These components sooner or later become an integral part of the machines or machine trains where they are intended to be used and will be relied upon. Inspection is cradle-to-grave, including all of the parts that build a complete and functioning machine or power train. Whatever impaired state or condition any part sustains or is exposed to, that impairment eventually is transferred to the operating machine. Even the smallest components that are infected with issues can metastasize and impart hazards and destruction to operating process lines and beyond. It is not the cost of the repair but rather the cost of lost production that matters, often at many multiples of the repair cost. Still, due to the potential consequences of failure, inspection requires responsibility and accountability. For this reason, an inspection plan should outline the role and skills of the inspector. The tasks of inspectors are broad and, in some cases, also difficult. Each task, as defined in the inspection plan, requires a corresponding inspector skill set. The skills must match the tasks, not generally, but rather specifically. Each inspector should qualify his actual inventory of skills to the required skills defined by the tasks (and procedures). Gaps in these skills must be closed by training or perhaps by means of staff­ ing change.

6.1 Inspection Plan 93

6.1.5.1 Operator-driven inspection In some organizations, the best choice for many routine inspections is the machine operator. This is the person who works physically close to the machines and is sometimes in front of machines eight to twelve hours a day. Because of this, many operators can recognize subtle differences between normal and abnormal. This is often referred to as operator-driven inspection (ODI) and is preferred by many organizations, such as those who rigorously follow the principles of Total Productive Maintenance (TPM). The effectiveness of ODI is heavily influenced by maintenance culture and the skills of the operator to take full responsibility for each element of the inspection plan. Other issues are also at play here, including machine readi­ ness and availability of needed inspection tools/aids. Asking the operator to see what he does not want to see can be unpleasant, tedious, and, at times, thankless. When issues are discovered, there is the need for these operators to make the case for maintenance to troubleshoot or repair or perhaps make other adjustments to reinstate healthy and reliable conditions. The industrial and commercial assets of large organizations are increas­ ingly running lean staff. This can stretch operators beyond practical limits in performing all the inspections needed to ensure the required level of reliabil­ ity and safety. In such cases, the responsibility must be shared or completely delegated to skilled full-time inspectors. Typical examples used to demonstrate compliance If operator-driven inspection is used, the inspection plan should include Detailed description of inspection tasks, inspection frequency, inspec­ tion points, and inspection skills Method of collecting and reporting data and other findings Training requirement program by operators Competency verification program for operators

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6.1.5.2 Inspector generalist Some inspectors may be designated specialists who work full-time in all (or certain) disciplines of condition monitoring. Or perhaps the inspector is the resident expert who only does inspection routes. The difference is the ability to have more rigorous training and continuous practice. By combining broad and deep inspection knowledge with a linguistic understanding of other con­ dition monitoring technologies (e.g., oil analysis, vibration, thermography, etc.), the value and effectiveness of the expert inspector can be considerable, especially when most needed.

94 Machine and Lubricant Inspection Inspection expertise can be both horizontally and vertically integrated. Horizontal integration is a cross-disciplinary inspection. Inspector knowledge would include skills in many technical disciplines relating to lubrication, tri­ bology, oil analysis, mechanical machine design, electrical, instrumentation, safety, and operational inspections. He is the inspector jack-of-all-trades, also known as a generalist. Often it makes little sense to conduct one survey for lubrication, fol­ lowed by a similar inspection for electrical systems on the same machine. If a plant has different maintenance planners for different maintenance functions (mechanical, electrical, production, etc.), inspections can easily be divided once the information has been gathered. The critical path is getting good data and all the data. However, beware that some inspectors may be good at mechanical but barely guess at other disciplines like electrical and instrumentation. Ultimately, we seek skillful and dependable completion of the entire inspec­ tion plan by one or more inspectors with the time, skills, and resources to perform their tasks. Typical examples used to demonstrate compliance If inspector-generalists are used, the inspection plan should include Documented cross-discipline inspection skills needed based on the plant’s machines and operating conditions A plan to integrate skills using generalists without compromising the effectiveness of the inspection tasks A planning and scheduling function that incorporates inspector generalists Evidence of appropriate and timely dissemination of data and findings to responsible parties

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6.1.6 Inspection points Inspection points are physical locations on the machine that must be defined clearly in the inspection plan. These could be couplings, shaft/seal interfaces, breathers, hose connections, sight glasses, gauges, reservoirs, etc. Some inspection points are not visible. For instance, consider the inspection task of touching the upper inside wall of the gear case through the fill port with your fingers. The objective is to inspect for moisture condensation and soft deposits. This inspection point is not visible but necessary to assess certain headspace and lubricant

6.1 Inspection Plan 95

conditions. Another example might be the use of a probe or dipstick to reach into the machine to collect inspection data. Some inspection points may need to be created or installed. A large, inspection-ready machine is usually accessorized with an array of inspec­ tion windows, gauges, test points, sample valves, sediment bowls, etc., that are required to fully achieve the inspection objective. Inspection readiness enables better inspection quality (effectiveness) and often faster inspection, too. This is similar to a machine designed for maintainability. While there may be some costs associated with inspection hardware installation by the asset owner, the ROI can yield multiples of that initial cost due to the ease and accuracy of the information retrieved. This is an import­ ant element of a machine’s functional maintainability. Inspection points and tasks are PMs that require careful thought and consideration influenced by many factors already discussed (failure modes, criticality, machine type, etc.). That said, inspection points must not be left to the inspectors’ personal judgment or decided on the fly. It is very much an engineering process to achieve optimum results. Related to lubricated mechanical machinery, inspection points often include the following, but note that not all are associated with physical points on the machine (abnormal sounds, for instance):

• • • • • •

Frictional wear and corrosion zones (gear flanks, bearings, shafts, cyl­ inder walls, etc.) Magnetic debris collection points including debris in bottom sediment, on magnetic plugs, and on chip collectors Heat and temperature profile. The temperature of the machine by the use of gauges and/or temperature guns (non-contact thermometers), heat guns, pyrometers, and thermography cameras to detect changes in temperature and localized hot spots Borescope and visual aid inspection points Contamination control including filters, breathers, and other ingression points. Filter condition using pressure differential gauges and bypass indicators. Potential contaminant ingress sites, e.g., hatches, cleanout covers, vents, seals, etc. Dirt and other contaminants on the machine exterior. The serviceable condition of breathers and vents Visual and instrument lubricant inspections. Changing lubricant color and clarity. Abnormal indications of entrained air and surface foam. Evidence of emulsified or free water. The presence of foam, varnish, sludge, and excessive turbidity

96 Machine and Lubricant Inspection

• • • • • • • •

Certain gauge and meter inspections. Fluid pressure using portable or machine-installed gauges or transducers Tank and sump zones, including headspace. Presence of tank or res­ ervoir bottom sediment and water (BS&W). Headspace conditions in tanks, reservoirs, gear cases, etc. Seals and leakage points. Leakage past gaskets, seals, actuators, fittings, unions, ports, and hoses Tubing, hose, and connectors The volume of lubricant in the machine by the use of level gauges, sight glasses, dipsticks, or inspection portals/hatches Abnormal machine operating sounds Abnormal machine operating movements, such as looseness or exces­ sive vibration Whether labeling remains legible

Typical examples used to demonstrate compliance Related to inspection points, the inspection plan should include An engineering process to select and optimize the inspection points with the designated inspection tasks A documented list of inspection points by asset/machine Where applicable, annotated images or illustrations of the inspection points, especially where required for clear understanding (used on route sheets or portable inspection devices/data collectors) Mark or tagging of inspection points where required

• • • •

6.1.7 Inspection tasks and methods Inspection tasks can be simple (e.g., determining the oil level from the sight glass) or a bit more complex (e.g., the interpretation of a blotter). If the task or method involves many steps or requires special techniques or tools, the inspection plan must reference a procedure. The procedure is a documented method of performing certain inspection steps with tools and the means of data collection. Because machine designs and operating conditions vary considerably within an asset class (process pumps for instance) the inspection tasks could also vary considerably. As discussed, many inspections require specific skills, tools, inspection aids, instruments, access, etc., that also influence when and how they might be used in an inspection plan. Understandably, machine criticality and ranked failure modes affect this, as well. As with most activities in maintenance, inspection also seeks to

6.1 Inspection Plan 97

achieve an optimum state. We do not want to over-inspect and we certainly do not want to under-inspect. Many factors influence the optimum state and many inspection decisions are influenced by it. 6.1.7.1 Machine diagnostics and troubleshooting Many inspections or condition monitoring tests report similar or identical alarms. As such they could be viewed as redundant. However, if the condition is serious enough a backup value may be well justified to provide a confirm­ ing result. In other cases, the secondary test might be requested only after a questionable and abnormal screening test or inspection. This secondary test might be referred to as an exception test. Many condition monitoring tests or inspections are performed for vigi­ lant screening. Troubleshooting, exception tests, and/or more in-depth diag­ nostic analysis might follow an observed aberrant or concerning condition. For example, abnormal levels of ferrous debris found during an inspection on a mag-plug could be followed by wear particle characterization (e.g., analyt­ ical ferrography), full-spectrum vibration analysis, and IR scans of critical components. In another case, if the inspection finds a roller bearing running hot and with 20 dB ultrasound gains, exception testing might include both a ferrous density test and viscosity analysis using a field lubricant test kit. In general, the condition monitoring objective would be to:

• • • • •

Localize the problem within the machine train Identify the offending conditions or root cause(s) Establish a degree of severity or magnitude of risk Estimate the remaining useful life (RUL) if left unattended (P-F interval) Establish a plan to remediate or mitigate the problem to avoid costly repairs and downtime

6.1.7.2 Developing machine-specific tasks As stated, the inspection list for the machine, component, or asset categories that follows is general in nature. They may or may not apply to your specific machine. Optimizing the inspection plan for best results takes careful thought and should be developed in the context or with knowledge of the following: 1. 2. 3. 4.

Machine design, application, and age Availability of installed inspection-ready windows, access ports, sen­ sors, etc. Operating conditions and exposures of the machine The criticality of the machine (probability and consequences of failure)

98 Machine and Lubricant Inspection 5. 6.

7. 8. 9.

Ranked failure modes specific to the machine and unique operating conditions Online monitoring sensors and probes (accelerometers, ultrasound, wear debris sensors, X-Y-Z proximity probes, optical sensors, ther­ mometers, pressure, flow, fluid level, Key-phasor probes, etc.) and other available asset protection systems Availability of condition monitoring instruments, tools, and aids for inspectors Availability and skills of inspection personnel Safety and environmental considerations

From that information the inspection plan can state the inspection tasks needed, the time interval or inspection state (run, stop, repair), individual inspection procedure, alarm code system for reportable conditions, and the inspection skills required. Typical examples used to demonstrate compliance Related to inspection tasks, the inspection plan should include Machine-specific tasks based on the above list of items, as applicable The time interval or operating condition interval The inspection state (run, stop, repair) The individual inspection procedure (aided by photos, illustrations, parts lists, safety precautions, etc.) Alarm code system for reportable conditions Inspection skills requirement

• • • • • •

6.1.7.3 Inspection technicians and inspection analysts Vertically integrated inspection deploys deeper subject matter expertise in the field of inspection. Even this is difficult to achieve considering all the possible inspection disciplines across all the types of machines found in large industrial plants. Vibration analysis, oil analysis, acoustics analysis, and infrared thermography have extensive education curriculums with cor­ responding certification testing requirements. These are professional career paths that are recognized by ISO 18436 and three levels of competency (Cat 1, 2 & 3). Currently, no equivalent curriculum or competency testing is available for inspection technicians and inspection analysts. For ICML 55.1 discussion purposes, an inspection technician is a spe­ cialist with Cat 1 or 2 credentials in the field of inspection. He/she has the skills to perform many inspection tasks on many machine types. He/she also

6.1 Inspection Plan 99

has above-average subject matter competency in many other ancillary inspec­ tion tasks and methods. Inspection technicians are people who perform regu­ lar inspection routes and practice extensively in their field. The inspection analyst is a resident expert with deep subject matter knowledge and experience across many disciplines (mechanical, electrical, instrumentation, safety, etc.) on inspection tasks and methods. The inspection analyst does not have job cross-functionality. He/she is often not an opera­ tor, mechanic, electrician, or lube tech. Access to this degree of inspection knowledge is essential for process critical machines and systems. Inspection analysts are trained and certified and have extensive experi­ ence performing inspections. They have the ability to see what others cannot see. They do not just look or hear but rather examine carefully and probe further. They also have a good toolbox of needed inspection aids. They have encyclopedic knowledge on various inspection subjects but also the other technical areas of condition monitoring. A good inspection analyst is frequently called in to assist in trouble­ shooting efforts. Alternatively, he/she can be deployed to perform inspection routes on machines designated as high value (critical) or which are known as bad actors. An inspection analyst is a certified Cat 3 inspector. As noted, there are no current inspector certifications similar to what exists for oil analysis, vibration analysis, and thermography. In the meantime, such designations of skills and competency can be done at the plant level and might follow the three skill-progressive categories for machine condition inspectors:

• • •

Mechanical condition inspector 1 (MCI 1): An inspector performs daily rounds of mostly visual inspection tasks. Few inspection aids are involved and no instruments. Mechanical condition inspector 2 (MCI 2): An inspector who is trained in most inspection tasks of mechanical machinery and lubrication. He/she has basic knowledge of other instrument or technology-based inspection tasks and methods as well. He/she has basic troubleshooting skills. Mechanical condition inspector 3 (MCI 3): An inspector who has extensive troubleshooting skills as well as condition monitoring data analysis skills. Additionally, he/she has extensive knowledge of TPM, RCM, and condition-based maintenance. He/she can develop inspec­ tion plans, define the needs for training, identify needed modifications to machines to make them inspection ready, and select required inspec­ tion aids and tools.

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Typical examples used to demonstrate compliance For inspection technicians and analysts, the inspection plan should include A clear description of the roles and functions of both technicians and analysts related to lubricated mechanical assets Depth of knowledge and competency on inspection subjects (special­ ties) is defined and categorized Where and when specific inspection points and tasks require techni­ cians and analysts are categorized The tools needed and available for use by technicians and analysts

• • • •

6.1.8 Inspector skills, training, and qualifications Understandably, there is a need for qualified inspectors who possess the skills needed to perform the tasks and methods in the inspection plan. The more complex the inspection method or task, the more need for detailed inspection procedure and training by the inspector to that procedure. An inspector must qualify to perform inspections. This means a scheduler cannot give the assignment for inspection to a person without regard to demonstrated competency including education, work experience, and responsibility. As an example, three inspector certification cat­ egories (MCI 1, MCI 2, and MCI 3) are discussed in the previous Section 6.1.7. All must be defined in the inspection plan and aligned to the plant’s reliability and inspection objectives. Typical examples used to demonstrate compliance Related to training and inspection competency, the inspection plan should include Cohesive alignment of the skills required to perform the tasks in the inspection plan related to inspector responsibilities Training and curriculum required to prepare and qualify an inspector, corresponding to the inspector job description (operator, generalist, technician, analyst) and categories (Cat 1, 2 & 3) Means of qualification by either demonstration or testing

• • •

6.1.9 Tools and machine modifications needed The inspection tasks and methods should list each of the tools or inspection aids needed. Many inspections require these tools to complete the inspection task or simply enable the inspection to be performed more precisely and with

6.1 Inspection Plan 101

better, more reliable results. Similar to instrument-based condition monitor­ ing, inspections risk the occurrence of false positive or false negative findings or results. Inspection must be enabled to achieve condition monitoring quality and effectiveness to their full potential. Typically this entails a need for modifying and accessorizing machines for improved inspection. This may include the addition of hardware such as sight glasses, sample ports, and view windows. There are often costs associated with retrofits and other machine modifi­ cations. And some of these changes can present risks associated with humanagency failures from machine disturbances and defective parts/installations. However, if the modifications are properly engineered, sourced, and installed the benefits over the long term can be long-lasting and significant. The following are examples of machine inspection-readiness practices, accessories, instruments, and devices that can substantially enhance and enable inspection readiness. 6.1.9.1 Inspection windows An inspection window is effectively a portal used by the inspector to see within and past the steel plate walls of the machine. The lubricant is the common medium and can serve as the inspector’s eyes and ears to what is happening inside the machine. Certain hardware accessories can function as windows including those below. Oil level gauge: These can be electronic, mechanical, or a device that provides a visual indication of the oil level. High oil levels might represent in-leaks (cross-contamination) of coolant, fuel, or other lubricants. Low oil levels can be caused by high oil consumption or out-leaks. Oil level gauges should be marked to show the normal range for stopped machines as well as running machines, depending on the machine type. Especially the person doing oil top-ups and oil changes should posi­ tion level gauges for convenient viewing. The level gauges should be care­ fully mounted to prevent misrepresentation of actual sump levels (trapped oil inside gauge body, for instance), sludge buildup in a pipe connected (between gauge and sump), and air lock due to restricted ventilation issues (plugged vent holes) or venturi zones (vena contracta region). Sight glasses: Good sight glasses are more than oil-level gauges. They can communicate key transient conditions associated with localized areas of the machine. These include bottom, sediment, and water (BS&W) bowls, inline sight glasses (to confirm oil flow), and clear piping/hose for fluid inspections. One of the most effective sight glasses is a BS&W bowl.

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Part-movement windows: Many machines need windows to verify the proper movement of parts such as oil rings, collar oilers, slingers, flingers, couplings, actuators, etc. Certain belts, screws, chains, and gear drives must be made visible to an inspector. Instruments and inspection aids can serve this function as well. Ferro sites: These are magnets flooded in oil and placed behind inspec­ tion windows. They are usually located on the return line where the ferro­ magnetic debris is the highest. The window can periodically be opened to clean the magnet and to gain closer inspection. 6.1.9.2 Lubricant sampling and corrosion gauges Sampling ports: These can be located on return lines, live zones in sumps, or other strategic locations for quick sampling and inspection of fluids at the machine. In addition to visual inspection, a technician can perform a simple blotter spot test to establish the presence of sediment, sludge, wear metals, and other impurities. Likewise, the same disposable pipette can be used to place some of the oil on a hot plate to test for emulsified and free water (crackle test). Corrosion gauges: A corrosion gauge is a rod or other surface made of metal prone to corrosion. The most common examples are steel and copper. The rod is fished out periodically and inspected for evidence of corrosion. The presence of corrosive agents in the lubricant and/or a lack of corro­ sion inhibitors in the additive package (commonly associated with additive depletion) can result in corrosion on the gauge surface. Any corrosion on the gauges is likely also to be occurring elsewhere in the machine. 6.1.9.3 Instrumentation There are numerous options for the selection of sensors and gauges that can provide effective real-time information on machine/lubricant health condi­ tions and overall performance. These include vacuum gauges, temperature gauges, proximity probes, flow meters, free-water alarms, and load sensors. Most of these instruments can report digital or analog readings at the machine and are viewable by the inspectors. 6.1.9.4 Hatches, inspection lids, access ports, and cleanout covers Bolt-down hatches and tank tops can produce a tight seal (with gasketing and caulking in cases) but are not inspection-friendly. Retrofitting a suitable hinged door and transparent inspection window may be an option, if required.

6.1 Inspection Plan 103

6.1.9.5 Inspector toolbox Inspectors have many options for portable inspection tools and aids. These include devices that are attached to mobile devices such as cell phones. The following is a list of common inspector tools related to lubricants and lubrication:

• • • • • • • • • • • • • • • • •

Lab-in-a-box kits Portable oil analysis instruments Blotter spot kits Varnish gauge Oil content gauge (grease) Stethoscope Stroboscope Microscope Borescope Water separation test Sediment test Oil color gauge Viscosity comparator High-intensity flashlight Laser inspection tools Inspection mirrors Leak detection instruments (ultrasound, UV dyes, etc.)

Typical examples used to demonstrate compliance The inspection plan should include the following related to tools and machine modifications As defined by the inspection points and inspection tasks, the machine should be modified to best enable convenient and quality inspections. These include inspection windows, sampling ports, corrosion gauges, instrumentation, and access ports As defined by the inspection points and inspection tasks, the inspector should have portable tools and aids to best enable convenient and qual­ ity inspections

• •

6.1.10 Inspection findings and data collection The type of inspection data to be collected and the manner in which it will be reported need to be included in the inspection plan. This can reduce the variability

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that could occur, for instance, by two inspectors doing the same inspections on the same inspection point using the same methods and inspection aids. It is preferred if data collection is uniform and has structure. This is the concept behind using a structured form or checklist on a handheld data col­ lector or manual paper-based data collection. Inspection is data acquisition that is meaningful, quality, and timely. This data does not stand alone but rather needs to be an integral part of the overall condition monitoring scheme. Handheld electronic data collectors can show images and compara­ tors to help more precisely score an inspection result or finding. Rather than a binary yes-or-no response, it may be scaled, say from 1-10. A range of comparator images or a short narrative using the data collector’s software interface defines each possible result on this scale. This reduces individual subjectivity and provides a scalable, analog-like feature to capture and quan­ tify the degree of changing conditions. Whereas it is important to identify an active change, it is far more important to report a precipitous rate-of-change. Numerical data collection from inspection routes can be integrated with condition monitoring software to show patterns of changing conditions across an array of data types on the same machine and machine condition. Furthermore, it is important to achieve unification of inspection plans and data collection with other condition monitoring activities. Typical examples used to demonstrate compliance The inspection plan should include the following means to collect and interpret data during the inspection process A structured and uniform method of data collection that can be used by multiple inspectors with consistent results Where applicable, the use of comparator images to enable scalable data capture of observed or measured conditions

• •

6.1.11 Inspection routes Many inspection points can be compiled and arranged into a route for a given plant or job site. This is especially helpful when a specialized inspection instrument or tool is used on only a few machines and inspection points. Its use can be scheduled like many other route-based condition monitoring data collection tasks. For example, a portable water contamination tester (for lubricants) may only be needed on machines that are used intermittently and are exposed to water sources. In other cases, it might not be a particular tool that is required but rather a particular skill that one inspector might have but others do not. Of

6.1 Inspection Plan 105

course, this skill may be associated with a tool or instruction. A person who is trained in ultraviolet leak detection, for instance. Patch testing and wear debris analysis are also specialized skills. Most inspections are done daily by the same inspectors or operators who are assigned to a group of machines. These are sometimes referred to as “rounds,” “walk about,” or “walk around” inspections. They in no way should be viewed as trivial or unimportant to machine condition monitoring. Additionally, an inspection can be condition-based, triggered by con­ cerning data or observation that was flagged during a routine inspection, portable data collector, or remote condition monitoring data. In such cases, routes are not needed and the activity is more diagnostic or troubleshooting in nature. Typical examples used to demonstrate compliance The inspection plan should include the following related to routes and on-condition inspections The timing and frequency of inspection routes should be documented in the inspection plan Routes should be structured according to tools needed, required inspec­ tor skills, and other factors as defined in the inspection plan Non-route inspections should be scheduled on-condition

• • •

6.1.12 Health and safety issues Inspection procedures should be called out for each machine inspection task or method as defined in the inspection plan. All inspection procedures should fully cover any relevant health and safety policy or best practices. Typical examples used to demonstrate compliance All inspection procedures should fully cover any relevant health and safety policy or best practices

•

6.1.13 Metrics and compliance All areas of business and business processes require measurement and report­ ing. From this information, managers can make better, more informed deci­ sions based on accurate representation of the state of their machines. This is both at a macro level (the forest) and a micro level (the trees). So, too, man­ agers need lagging indicators (what just happened) and leading indicators (what is going to happen).

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Data for these metrics can come from numerous different condition monitoring sources and then be filtered or streamlined to make them ready for decision-makers’ use. Just like other forms of condition monitoring, inspection is a valuable source of information related to machine reliability and asset management. This is especially the case when the data quality is at a high level as defined by this standard. Metrics need to also include compliance. Inspections often trigger work orders to remediate current problems found by inspectors. Some work orders trigger the need for more probing inspections or troubleshooting tasks. Compliance tracking, measurement, and reporting may also be needed to ver­ ify that all inspection routes are being effectively completed. The following are examples of KPIs that an inspection/condition mon­ itoring program might report:

• • • • •

• •

Reportable condition: This is an abnormal condition that requires cor­ rection. A reportable condition could be either a root cause or an active failure event or fault. Root cause saves: This is the percent of reportable conditions that were detected and remediated in the proactive domain. The higher this num­ ber, the better. All RC saves leave RUL unchanged. Predictive saves: This refers to reportable conditions that have advanced to the predictive domain and are detected and remediated prior to oper­ ational failure. The RUL of the machine was lowered during the time the reportable condition remained undetected and uncorrected in the predictive domain. Misses: This refers to the percentage of reportable conditions that advance to an undetected operational failure. The lower this number, the better. Overall condition monitoring effectiveness (OCME): This metric defines the overall effectiveness of condition monitoring (inspection combined with technology-based condition monitoring). This is quan­ tified as the average change in percent of remaining useful life (RUL) across all machines and reportable conditions during the reporting period. The higher this number, the more effective condition monitoring is at detecting and correcting reportable conditions early. Condition monitoring interval: This refers to the time interval between technology-based condition monitoring events (vibration, oil sampling, thermography, etc.). Inspection interval: This refers to the time interval between machine inspections by operators and technicians.

6.2 Practical Implementation of the Inspection Plan 107

LAGGING (What just happened)

LEADING (What is going to happen)

Table 6.1

Leading and lagging indicators.

MICRO (Trees) Particle count Viscosity Elemental analysis Varnish potential Moisture analysis Oxidation stability

MACRO (Forest) Contamination control compliance Fluid properties compliance PM compliance

Wear debris analysis

Percent planned maintenance

Thermography Vibration analysis

Uptime/downtime

Acoustics

Overtime hours

Table 6.1 describes how different metrics are viewed in the context of scale and time. Typical examples used to demonstrate compliance A metrics program, including KPIs, developed to track compliance and performance of the inspection program A metrics program unified with all condition monitoring functions The metrics encompass macro/micro indicators of performance, as well as leading and lagging indicators The metrics are communicated to all stakeholders

• • • •

6.1.14 Audits of the inspection plan The organization should routinely conduct audits of the inspection plan. A culture of continuous improvement of the inspection plan should exist. Needed revisions or changes to the inspection plan should be done promptly.

6.2 Practical Implementation of the Inspection Plan The development of the inspection plan serves as a detailed engineering specification for a comprehensive inspection program related to lubricated

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mechanical assets. It also provides a framework for implementation. The plan and implementation must be fully aligned and complete before the full ben­ efit can be achieved. Typical examples used to demonstrate compliance Implementation of the inspection program is compliant with the breath and depth of the inspection plan The inspection plan serves as a program manual for standard practice and uniform use over time

• •

7

Condition Monitoring and Lubricant

Analysis

Auditable Section 55.1.5.7: Condition Monitoring

and Lubricant Analysis

Preface No lubrication program management plan is complete without a condition monitoring and lubricant analysis element. Section 5.7 of the ICML 55.1 Standard – Condition Monitoring and Lubricant Analysis – recognizes and supports lubricant analysis as a primary condition monitoring (CM) tech­ nique foundational and core to the successful implementation of the lubrica­ tion management plan. Lubricant analysis provides essential test data and information relating to the lubricant or machine condition that is used to assure proper lubrica­ tion of components and machinery is taking place and will continue to do so. Furthermore, this information is used to contribute to the organization’s knowledge and understanding of lubricated machines and component health. Using standardized ASTM testing methods to assure data accuracy, all lubrication test results and subsequent data trends can be used with 109

110

Condition Monitoring and Lubricant Analysis

Figure 7.1

Typical laboratory lubricant (oil) analysis report. Courtesy Spectro Scientific.

confidence alongside other condition monitoring (CM) technologies as part of any best-practice proactive/predictive maintenance program. Trusted lubrication test data can be employed to support and schedule planned and corrective lubrication activity. In addition, the same test data can support root cause analysis (RCA) functions associated with the symptoms of failure and/or impending failure of a lubricant, lubrication system, com­ ponent, or machine. Lubricant analysis provides the maintenance and reliability engineering department with a scoreboard-style report for each lubricant sample tested. This report delivers vital trend data and information that can provide mean­ ing and interpretation to current operating conditions, pending failure, and post-failure analysis critical for continued machine/component/lubricant reli­ ability, availability, and maintainability. Figure 7.1 shows a detailed typical laboratory oil analysis report. We can see that the report is broken down into multiple sections. The upper left section details the customer requesting the analysis and the equipment/component/machine and lubricant being tested. The section on the right details the results of the laboratory anal ­ ysis from which a diagnostic analysis statement and recommended

7.1 Lubricant Analysis Information 111

actions are detailed on the lower left-hand side of the report in the diagnosis box. The laboratory analysis results are broken down into sections. The first section provides details of the oil being sampled, the date sampled, and the length of time in use. The next section details the oil’s condition of health and whether or not it is still fit for duty. The next three sections detail sources of contamination wear metal levels, and any oil additives being used. A final section indicates any other additional tests called for by the customer. Figure 7.2 shows a style of report that includes reference to a common reporting method for fluid cleanliness referred to as the ISO 4406 method for coding solid particle contamination levels in fluids. A three-number code system is used to define fluid particle concentration levels at >4 micron, >6 micron, and >14 micron in size. Based on the particle concentration levels found in the fluid for each size grouping, a corresponding cleanliness rating number is then assigned. Figure 7.2 example depicts these values as an ISO 4406 cleanliness number value with its corresponding par­ ticle count value in parts/ml just below. Color-coding depicted in both figures is used to denote that a worsening or critical state has been reached. These conditions are based on markers set by the laboratory in accordance with the customer’s specific operating parameters and conditions of use. The table on the right in Figure 7.2 shows current sample results com­ pared and trended against an original virgin stock sample and previous working samples. This comparison allows the lab technician to detect trends taking place.

7.1 Lubricant Analysis Information In general terms, lubricant analysis provides the organization with valuable information broken down into the typical following sections: 7.1.1 Lubricant baseline signature data Once a lubricant has been chosen through the use of a design requirement evaluation or a lubricant consolidation process, it requires a baseline property signature derived from testing a virgin stock sample. This baseline signature is used to compare “in-service” samples of the same lubricant to determine 1) if the “in-service” lubricant sample being tested has a similar signature to the specified service lubricant to establish whether it is the correct lubricant currently being used in service, or if it is a completely different lubricant in use, and 2) if the current lubricant in service has been cross-contaminated with a different lubricant type.

112

Condition Monitoring and Lubricant Analysis

7.1 Lubricant Analysis Information 113

Figure 7.2 Typical laboratory ISO 4406 based oil analysis report. Courtesy Spectro Scientific.

Typical examples used to demonstrate compliance Consolidated lubricant list denoted by machine Lubricant analysis report archive Process for remedial action if an incorrect lubricant is found in a reservoir

• • •

7.1.2 Lubricant remaining useful life The health and remaining useful life (RUL) of a lubricant with respect to its physical, chemical, and performance properties is tested through examination of the oil condition, cleanliness, wear metals present and additive losses and compared to the oil baseline signature levels. Any lubricant property change detrimental to lubricant and machine life is noted on the oil analysis report by the laboratory technician through the use of color-coding alarms and diag­ nostic statements/recommendations to clean or change the lubricant. Typical examples used to demonstrate compliance Laboratory analysis report archive RUL recommended limit matrix or chart (color code limits values)

• •

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Condition Monitoring and Lubricant Analysis

7.1.3 Failure indicators Failure indicators that support or refute root cause investigations can include the following:

• • • •

Contaminants Excessive heat and radiation Abnormal findings related to installation, speed, alignment, and balance Indications of inadequate lubrication conditions, including inadequate film formation, over-lubrication, and under lubrtication

These indicators are monitored conditions traceable through oil analysis and related predictive maintenance technologies that include vibration analysis, infrared thermography, laser alignment, and balancing, as well as reservoir debris analysis, filter analysis, and lubricated component surface inspection. Typical examples used to demonstrate compliance Lubricant analysis report archive Internal/external predictive maintenance reports referencing lubricant analysis with other predictive technology findings Processes and training materials promoting cross-link use between the use of oil analysis and other predictive technologies Process for providing failure reports to reliability analyst/department

• • • •

7.1.4 Wear metal analysis Machine or component health revealed through lubricant analysis is repre­ sented in the wear metals section of the lubricant analysis report. Alarm color codes and diagnostic statements are used to make the maintenance depart­ ment aware of pending failures should no remedial action be taken. Typical examples used to demonstrate compliance Lubricant analysis report archive Process for remedial action if machine/component health danger is reported on the oil analysis report

• •

7.1.5 Contamination control device failure The effectiveness and performance of contamination control devices such as filters, breathers, coolers, etc., can be monitored through lubricant analysis testing. Major changes in oil conditions and elevated contamination levels are all telltale signs of contamination control device failure.

7.2 Assuring Effective Execution of Lubricant Analysis 115

Typical examples used to demonstrate compliance Lubricant analysis report archive Process for remedial action if contamination control devices require replacement

• •

7.2 Assuring Effective Execution of Lubricant Analysis Lubricant analysis is accomplished using a compilation of data derived from multiple laboratory tests performed on the lubricant sample. To assure the effective execution of lubricant analysis, the organization must consider/ determine the following deliberations. Determine which lubricated components/machines, and the specific lubricant(s) they use, will receive lubricant analysis. Success in the production and maintenance world is generally measured in terms of reliability, availability, quality, and throughput. These are perfor­ mance indicators that are continually measured against preset targets to deter­ mine if the equipment is performing within specifications, and to expectations. In any engineered environment there will be production lines, machinery, or components that are deemed more critical than others to the equipment’s health and operation’s success. These are generally monitored more closely than non-critical assets and are strong candidates for lubricant analysis. Where lubricated equipment and components are involved, lubricant analysis has proven to be an effective early predictor of impending failure through the detection of changes to the condition of the lubricant and lubricated components. Analyzing change in the condition of the lubricant and lubricated components is an integral part of any condition monitoring (CM) program. Condition monitoring programs will often use one or a combination of the following methods to identify equipment failure:

• • •

Failure Mode and Effects Analysis (FMEA) Root Cause Failure Analysis (RCFA) Failure Reporting, Analysis, and Corrective Action System (FRACAS)

FMEA is a leading indicator used to predict how a failure may occur and ascertain where lubricant analysis may be used to predict the early onset of failure. This allows proactive measures to be deployed to ensure operational performance targets continue to be met. RCFA and FRACAS are lagging indicators used after a failure has occurred to determine its cause, and also to determine whether similar failures can be better predicted and prevented in the future using lubricant analysis. For a detailed explanation of FMEA, RCFA, and FRACAS, refer to Chapter 8 – Fault/Failure Troubleshooting and Root Cause Analysis.

116 Condition Monitoring and Lubricant Analysis Typical examples used to demonstrate compliance Asset management plan that identifies the use of lubricant analysis Maintenance management plan that identifies the use of lubricant analysis Lubrication management plan that identifies the use of lubricant analysis Reliability reports dictating the use of lubricant analysis Lubricant analysis plan (if separate from the lubrication management plan) Lubrication mapping report for all lubricated equipment identifying lubricant analysis points Lubricant analysis PM schedule and/or route plan identifying lubricant analysis instructions for lubricated equipment Decision matrix/process for when to perform lubricant analysis Lubrication manual that includes the above

• • • • • • • • •

Determine the combination of lubricant analysis tests required to provide adequate data and subsequent information to ascertain the target conditions for the lubricant and/or the lubricated component/machine. Some lubricant analysis tests will need to be conducted routinely, oth­ ers only periodically or when a specified condition/exception is found or reached. When determining what lubricant analysis tests are needed, performing a FMEA exercise (see Chapter 8) can identify possible failure modes that can be used to develop an accurate lubricant analysis test slate. A test slate is a list of beneficial laboratory tests to be performed on the lubricant sample for a specific component, machine, application, or lubricant type. Performing FMEA helps ascertain which assets are critical to the oper­ ation, as well as promoting an understanding of what can typically go wrong with the component/machine being examined, to determine what tests need to be run. For example, it is generally accepted that upwards of 80% of machine failures are due to dirty/contaminated oil resulting from inneffective lubri­ cation practices. As depicted in Figure 7.2, the ISO 4406 cleanliness ratings clearly show whether your filtration system/process is working well or not. Moisture is also a major contamination issue in many applications that can be tested for (i.e., ppm water). Determining lubricant analysis test slates for individual components/ machines can be intimidating when initiating a lubricant analysis program, because selecting and running the wrong tests for a component can quickly ren­ der the program ineffective. ASTM Standards 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

7.2 Assuring Effective Execution of Lubricant Analysis 117

Figure 7.3

Compressor types and their lubricated components.

Lubricating Oil for Auxiliary Power Plant Equipment, and D7874 – Standard Guide for Applying Failure Mode and Effect Analysis (FMEA) to In-Service Lubricant Testing are good references to assist in building a relevant test slate. Starting small and building on a test slate over time as knowledge (and possi­ bly budget) grows can help build a strong foundation for the program. It may also be effective to perform simple screening tests and more advanced tests (e.g., analytical ferrography) if data warrants further investigation. 7.2.1 Test slate example for compressors Compressed air is used in a variety of fleet and industrial applications. Since compressors provide power for many machines throughout a plant, they become an important component to monitor in the reliability program. Figure 7.3 illustrates the types and components of the three main compres­ sors types that can be monitored with lubricant analysis. Monitoring inlet air quality in compressors can vary in importance depending on the compressor type. In centrifugal compressors, it is rare for ambient air conditions to significantly affect fluid life. Air inlet quality can become more of an issue in reciprocating compressors and rotary screw

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Condition Monitoring and Lubricant Analysis

compressors where airflow comes in direct contact with the fluid. Most new rotary compressors are factory filled with polyglycol-based lubricants. For compressors that come equipped with polyglycol or polyglycol/polyolester­ based compressor fluids, the following test slate requirements are appropriate to test and trend using oil analysis:

• • • • • •

Acid number Viscosity ISO particle count Elemental spectroscopy FTIR (oxidation, organic contaminants from acid gases) LSV

Exception testing:

• • •

Varnish Analytical ferrography RPVOT

7.2.2 Test slate example for pumps Pumps are commonly found in industrial and fleet applications. Positive dis­ placement or centrifugal pump designs are the most favored. Both types of pumps contain bearings appropriate to monitor as part of the lubricant analysis program. Rotary positive displacement pumps contain lubricated gears, screws, lobes, or vanes (see Figure 7.4) often lubricated by the fluid they are pumping. Along with mechanical seal failure, bearing failure is a leading cause of pump failure. Air, moisture, process chemicals, and particulate all contribute to premature bearing failure. Because of this, most pump bearings do not reach their theoretical fatigue life (L10). Performing the correct oil analysis tests on pump bearings can identify areas to help improve the Mean Time Between Failures. (MTBF) A recommended oil analysis test slate for pumps could include:

• • • • • • • •

Kinematic viscosity Moisture by Karl Fischer ISO particle count Acid number LSV Elemental spectroscopy Infrared spectroscopy Exception testing

7.3 Analytical Ferrography 119

Figure 7.4

Pump types and their lubricated components.

7.3 Analytical Ferrography When analyzing data, it is recommended to trend a few samples and establish proper alarm limits before making any critical decisions about the compo­ nent. Sampling studies or guidance from the OEM can help when establish­ ing a lubricant analysis program. Lastly, trending the oxidation life of the oil is critical and can be done using several techniques synergistically. LSV, acid number, and FTIR can be used to trend oxidation levels and ensure proper additives remain intact within the oil. Oxidation and oxidation by-products can cause the oil to be ineffec­ tive at lubricating the bearings, which must be addressed immediately when

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detected to avoid bearing failure. If oxidation becomes severe, the lubricant will corrode critical pump surfaces and will deposit silt or lacquer at servo valves. As an exception test, microscopic analysis using analytical ferrogra­ phy or SEM is considered appropriate to determine the nature and origin of wear particles. As these techniques can be considered subjective, it is recom­ mended a trained oil analysis technician perform them. 7.3.1 Test slate example for gearboxes Gear systems are found in many different industrial and mobile applications. Gears are used to transfer motion and power from one revolving shaft to another, or from a revolving shaft to a reciprocating element. Gears can with­ stand large amounts of load while controlling the speed, torque, and direction of rotating axles within a system. Gear tooth geometry plays a large role in tooth wear generation and must be managed with a proper understanding of gear tooth geometry, lubri­ cant additives, and lubricant analysis data. Gear wear can be aggravated by misalignment, poor lubrication practice, and contamination. In high-load sit­ uations, extreme pressure additive lubricants may be appropriate to manage extreme load conditions. Once gears are worn past their operational tolerances, gear slippage, grinding, jamming, or tooth breakage can occur, requiring an overhaul or replacement, which can result in significant downtime. Since downtime on gearboxes can be costly, most gearbox manufacturers will recommend incor­ porating lubricant analysis as part of a condition monitoring program to man­ age and trend potential gearbox failure. When considering lubrication application methods, gear systems are classified into two categories: splash lubricated and pressure lubricated. In splash (also called bath-lubricated) gearboxes, the gear runs partially sub­ merged in the oil, whereas in pressure-fed systems, oil is taken from the gear case, pumped through a filter, a heat exchanger (if required), a pressure relief valve, and then delivered back to the unit, often under pressure. Both types of lubricated systems can be monitored by lubricant analysis, though the tests may differ slightly. When analyzing the lubricant test data, it is always best to trend a few samples and establish proper alarm limits before making any critical deci­ sions about the component. Sampling studies or guidance from the OEM can help when first beginning the oil analysis program. Obtaining a proper sam­ ple is critical and it is important not to sample from the bottom of the gearbox where sludge and excess wear particles tend to gather, as doing so can lead to false positive results, particularly in the category of wear.

7.3 Analytical Ferrography 121

A recommended oil analysis test slate for gearboxes will include:

• • • • • • •

Viscosity Moisture Elemental analysis Particle count (optional in splash systems) Ferrous density (optional in splash systems) LSV FTIR

Exception Testing: Analytical Ferrography 7.3.2 Test slate example for hydraulic systems Hydraulic systems are found in industrial, mobile, and aviation applica­ tions. They are used to transmit power to operate the equipment. Hydraulic systems are compact and efficient. The fluid used in a hydraulic system is used to transmit the force (power) in the system. Because so much depends on the hydraulic fluid itself to operate the system, chemical stability, fluid cleanliness, flash point, fire point, viscosity, and oxidation resistance all play important roles in the management of the hydraulic fluid. In most mobile and industrial hydraulic systems, mineral and synthetic hydrocarbon fluids are used. For aviation and aerospace applications, phos­ phate esters are typically used. In hydraulic systems, dirt and water contamination is typically the pri­ mary cause of failure. Hydraulic systems have filters and routine monitoring is performed to detect early signs of contamination. Filtration effectiveness is monitored closely because tolerances in a hydraulic system are very close. The clearance on servo valves is often between forty and eighty microns, and the clearances on actuators can be as small as ten microns. Therefore, particles larger than four microns can cause serious wear problems in hydraulic systems. The hydraulic system manufacturer will typically recommend an oil cleanliness rating based on the ISO 4406 rating system. Continually running above the recommended ISO code will lead to premature seal failures, leak­ age, and mechanical system wear. Most OEMs will recommend lubricant analysis to trend and manage the critical hydraulic fluid. A recommended oil analysis test slate for the hydraulic system will include:

• • •

Viscosity Particle count Moisture

122

• • • •

Condition Monitoring and Lubricant Analysis

LSV Elemental spectroscopy FTIR (specifically oxidation) Ferrous debris

Exception Testing: Analytical Ferrography 7.3.3 Test slate example for bearings Bearings are designed to reduce friction, support moving loads, and main­ tain alignment. There are two categories of bearings: plain (journal) bearing and rolling element bearings. In plain bearing applications, the lubricant is applied to the solid bearing surface through holes in the bearing and distrib­ uted using grooves cut in the bearing surface. The oil path is designed to always introduce oil away from the load zone. In rolling element bearings, the actual bearing itself is typically grease lubricated. Proper grease lubrication on the bearing is necessary for optimal life. Major causes of bearing failures include:

• • • • • • • •

Defective bearings Misalignment/improper installation Incorrect shaft and housing fitting Inadequate lubrication Contamination Ineffective seals Fretting Passing of electric current through the bearing

Oil and grease analysis can be used to monitor these potential failure modes and extend bearing life. When analyzing the lubricant analysis data, it is always best to trend a few samples and establish proper alarm limits before making any critical decisions about the component. Sampling studies or guidance from the OEM can help when first beginning the oil analysis pro­ gram. Getting a good, consistent sample each time is critical and ensures data confidence. Typical failure modes that may be seen in a lubricant analysis report could include:

• • •

Fatigue wear Corrosion Electrical erosion

7.3 Analytical Ferrography 123

• •

Plastic deformation Fracture or cracking

Lubricant analysis can be used to detect these early signs of failure modes. A recommended oil analysis test slate for monitoring bearings will include:

• • • • • • •

Viscosity* Particle count Moisture LSV Elemental spectroscopy FTIR (specifically oxidation) Ferrous debris

Exception Testing: Analytical Ferrography *For grease-lubricated bearings, consider performing consistency testing such as rheology-related testing. Typical examples used to demonstrate compliance Laboratory lubricant test and target condition table for all machines and systems/points tested Lubricant analysis test requirement decision matrix/report Machine failure mode / lubricant analysis test detection matrix/table/ report Lubrication manual that includes the above

• • • •

To determine the appropriate interval for sampling and analysis of lubricants, an accurate sampling interval is a critical aspect of any condition monitoring (CM) program. If set too long, there is a risk that a failure mode event may be missed. If set too short, there is a risk of creating a program that is too rigor­ ous to maintain, resulting in redundancy of effort and no long-term success. If new to managing a CM program, the easiest resource to consult about sampling intervals is the original equipment manufacturer (OEM). Upon purchase of equipment, the OEM will likely have provided some guidance regarding optimal sampling intervals. Some OEMs may even have guidelines where sampling is required to maintain the warranty on the equipment. Be aware that an OEM may not have based their sampling frequencies on your ambient or working condition factors; always ask the OEM for their deci­ sion factors and recalibrate with their assistance to your actual conditions. As the CM program matures (i.e., more data is gathered and employees receive more training), additional analytical techniques can be used to determine the

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Condition Monitoring and Lubricant Analysis

optimal times to sample. Optimal sampling intervals should effectively detect problems before they become failures beyond repair (i.e., needing to shut down the component) without over-sampling and detecting little change over a long period of time. There are numerous analytical techniques that can be implemented in a CM program to optimize sampling intervals. The following methods can be discussed:

• • • •

P-F interval Machine criticality Failure risk profile (using time, mileage, or analytics) Insurance or regulatory requirements

7.3.4 The P-F interval The P-F interval is an analytical technique defined as the time between “P” (when the potential machine failure is first detected) and “F” (when the machine has functional failure). Short P-F intervals make it difficult to use data to detect and catch problems before functional failure occurs; therefore, reliability professionals prefer a longer P-F interval so problems can be identi­ fied closer to “P” and addressed before “F” is reached (hopeful, but not always the case). Taking a machine offline creates several potential issues ranging from safety to production dollars lost. Avoiding this is imperative and the more frequently “F” can be avoided, the more successful the reliability program will be. Figure 7.5 depicts how a P-F interval is defined for each machine. Referring back to Figures 7.1 and 7.2, alarm states are referenced using color. In Figure 7.5 yellow represents alarm state 1 (potential failure), while red represents alarm state 2 (functional failure). Trending lubricant sample results, we can plot the P-F curve and accurately determine when an alarm state is close to breach or has been passed, thus enabling appropriate action to be taken in a timely manner. The steepness of the P-F curve can be used to optimize sampling fre­ quency. This will increase the chance of catching problems before equipment is required to be taken offline for service. 7.3.5 Machine criticality Machine criticality is simply defined as how critical the machine is to the process or functionality of the space. If not careful, machine criticality can become subjective. Therefore, it is best to use analytical techniques to deter­ mine machine criticality.

7.3 Analytical Ferrography 125

Figure 7.5

Typical P-F interval diagram. Courtesy ENGTECH Industries Inc.

In Section 7.2 above, the process of FMEA was discussed. FMEA pro­ vides an analytical method to ensure the correct equipment is selected for testing and the right tests are being used to evaluate specific failure modes. Once the FMEA process is defined and the machines are selected, imple­ menting a sampling interval can begin. In general, sample intervals should be short enough to provide at least two samples prior to failure. If the P-F interval is known, it can be used to define this interval; if not, the P-F interval can be generated by performing a sampling study. So far, these analytical techniques are utilized by mature programs able to take advantage of available data to make ccurate decisions specific to any particular machine or production line. For those starting out, however, using more general rules of thumb (e.g., sampling quarterly on all critical machines) is required. Allowing sample data to drive changes to the sampling interval is an excellent way to optimize sampling intervals. 7.3.6 Failure risk profile and analytics As programs advance, organizations may want to understand how long until the failure occurs (e.g., how many miles or hours to failure?) Sensor technol­ ogy and prognostic data can be used to make this information available to the end user.

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Condition Monitoring and Lubricant Analysis

The use of a prognostic data analysis approach provides an estimate of a component/machine’s Remaining Useful Life (RUL) from its current usage pattern and approximate lifetime (MTBF). The input data is a history of measurements of the component. Input data can facilitate an estimated determination of the current component/machine degradation rate as plotted on the P-F curve. Implementing prognostic techniques not only helps anticipate the time to failure but also establishes a pattern of measurement that can minimize costs. This prognostic concept can be directly applied to optimization of sam­ pling intervals. For example, if sampling is based on ½ RUL versus stan­ dard recommendations, the costs of sampling could be significantly reduced (i.e., use the degradation rate to determine sampling frequency). Appropriate software would be needed to implement such a technique. Sensor technology is not new to industry. As industry progresses, so does its need to attain more real-time data. It is common to see sensors used in vibration analysis since it is easy to mount them on the outside of the machine and still extract reliable data. Oil sensors, however, need to be in the flow of the oil, so mounting such sensors is more challenging. Some of the more common parameters monitored by sensors include wear particles (ferrous), particle counts, and additive concentration. The sen­ sors need to be rugged enough to withstand constant oil flow, potentially dirty oil, and hot oil. If these items can be overcome, oil sensors do a great job supplying data during the intervals between sampling, and they may catch a problem right after an oil sample interval that can be addressed right away. 7.3.7 Regulatory and insurance requirements Condition-based maintenance strategies are implemented to manage downtime on equipment. Upon equipment purchase, an OEM will likely provide a war­ ranty associated with the purchase that may offer or require lubricant analysis services. For the duration of the warranty, the OEM may require lubricant anal­ ysis to be performed on a time-frequency basis for the warranty to stay valid. If deciding to go with another laboratory that is not used by the OEM, make sure the OEM approves the laboratory and will still cover the issues identified by that lab’s lubricant analysis. Regulatory bodies may also demand evidence of lubricant testing to ensure operating certificates are issued and stay current. Typical examples used to demonstrate compliance Lubricant sampling interval matrix/table/report Potential failure (P-F) analysis report for lubricated assets

• •

7.4 Lubricant Sampling 127

• • • • • • •

Lubricated equipment criticality analysis report Lubricated equipment risk analysis report Lubricated equipment reliability-centered maintenance decision anal­ ysis report Insurance, regulatory, warranty lubrication testing requirement document/list Lubricant analysis PM work order trigger report/decision process Lubricated equipment reliability analytic reports (MTBF, Weibull Analysis) Lubrication manual that includes any of the above

7.4 Lubricant Sampling To extract the lubricant sample, determine the appropriate sampling loca­ tion(s). This location should require a repeatable and useful machine condi­ tion to obtain consistent sample material. In addition, determine the required hardware modifications to the lubricated component or machine to enable non-intrusive or minimally intrusive lubricant sampling. At all times, care must be taken to ensure that a sampling point location or method will not endanger the sample taker or place the machine in jeopardy. Lubricant sampling is the most critical part of any lubricant analysis program. Failure to extract a proper, representative sample from the unit negates the rest of the activities within the program. If the lubricant to be sampled is oil, samples are best extracted from a turbulent flow (live zone sampling) while the machine is operating under typical load and speed conditions. The two main goals of proper oil sampling are to maximize data density and minimize data disturbance. Maximizing data density includes getting the most information possible per milliliter of oil. This may include data points like additive depletion, particle counts, and wear particles. Minimizing data disturbance includes taking samples that are uniform and representative. Processes and procedures, followed consistently by all those involved in the sampling process, can ensure data disturbance is minimized. This section will assist in selecting sampling ports and retrofitting units as needed. This section will also review how to use sampling location to opti­ mize data density to fit a certain need and help define sampling frequency. 7.4.1 Sampling frequency Sampling frequency is defined as the rate at which samples are taken from an individual component. On average, for industrial equipment, maintenance

128

Condition Monitoring and Lubricant Analysis Table 7.1

Commonly recommended oil sample frequencies

Commonly Recommended Oil Sample Frequencies Machine Type Aviation Reciprocating Engine Aviation Gas Turbine Aviation Gearbox Aviation Hydraulics Diesel Engines – Off-Highway Hydraulics – Mobile Equipment Gearbox – High Speed/Duty Transmission, Differential, Final Drive Gas Turbine – Industrial Steam Turbine Air/Gas Compressor Chiller Gearbox – Low Speed/Duty

Hours 20-50 100 100-200 100-200 150 200 300 300 500 500 500 500 1000

Source: The Practical Handbook of Machinery Lubrication, Fourth Edition, Scott R, Fitch J, Leugner T, Noria Corporation, 2012

departments may take samples monthly to quarterly on components that are part of the CM program. Critical components may require more frequent sampling. Factors like P-F interval, machine criticality, insurance liabilities, and OEM warranties can all dictate sample frequency. Table 7.1 offers some sug­ gested hours for oil sampling frequency. 7.4.2 Optimize data density Optimizing data density is defined as taking samples that ensure the most data is available for making a maintenance decision. Optimizing data density very much depends on the sampling location. In general, the component will have a primary sampling location that is used each time the machine is sam­ pled. The primary sampling location is used to make maintenance decisions about the component and should be broad enough to capture a wide variety of issues. In circulating systems, the sampling location is ideally located after the pump, but before any filters. In non-circulating systems, the sample should be taken from the middle portion of the sump using rigid tubing (pipette). To

7.4 Lubricant Sampling 129

Figure 7.6 Primary and secondary oil sample point locations. Source: Practical Lubrication for Industrial Facilities, Fourth Edition, Kenneth E. Bannister, River Publishers, 2023

optimize the data density, proper tools are needed to take a sample and the proper location must be consistently sampled. In some cases, the primary sampling location may prompt further sampling from secondary locations. In Figure 7.6, green represents the primary sampling location and yellow represents the secondary sampling locations. A high iron value at the primary sampling location indicates further isolation of the problem is needed; there­ fore, sampling from each of the secondary locations is appropriate to isolate the problem. 7.4.3 Sample bottles In general, a regular 4oz sample bottle is recommended when taking an oil sample. Filling the bottle a little over ¾ of the way full is recommended so the laboratory has enough headspace in the sample to heat and agitate before running any tests. Sample bottles come in a variety of sizes, but in most cases 4oz bottles will work well. Having a few larger liter-size bottles is also recommended when specialized tests become necessary. Tests like RPVOT, particle count, demulsibility, or air entrainment will require more sample fluid. The cleanliness of the sample bottles impacts the results of the tests. Cleanliness and storage of bottles should always be considered. Bottles can

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Condition Monitoring and Lubricant Analysis

be polyethylene plastic, glass, or PET plastic. The most commonly used bot­ tle type is polyethylene. Users prefer this type because it is easy to visually see any issues with the sample. When reviewing sample bottle cleanliness, a cleanliness certificate should come with each set of sample bottles. The sampling certificate is per ISO 3722 and defines the sample bottle cleanliness as clean, super clean, or ultra clean. Depending on the application being sampled, the cleanliness of the bottle will impact the results. For example, turbine and hydraulics sys­ tems should be sampled with super clean or ultra clean bottles vs. gearbox applications that may just need clean bottles. Consult with the OEM or lab­ oratory for the recommended bottle cleanliness. Keep in mind, the “cleaner” the bottle, the more expensive it will be. Do not use a “cleaner” bottle than necessary when performing oil sampling. 7.4.4 Sampling tools and retrofitting A variety of tools are required to optimize data density and take a consistent, representative sample. Some machines may already be set up to enable easy sampling, but others may need to be retrofitted with valves that can be opened and closed to take a representative sample. Valves, adapters, sample tubes, fittings, vacuum pumps, and pitot tubes all may be appropriate to have in the sampling tool kit. Consult with the OEM or oil analysis laboratory to determine the rec­ ommended method of sampling. Sampling from plug-in style test points is often recommended versus drop tube sampling, which can cause problems since tubing can get stuck in winding parts, move/float around the oil res­ ervoir, or extract sludge from the bottom of the reservoir and create incon­ sistent results. Plug-in test points are more expensive than drop tubing and should be budgeted into the overall cost of the initial installation of the unit. If drop tube sampling must be used, be sure to use rigid tubing like a pitot tube and properly measure the distance into the middle part of the sump. This will ensure consistent sampling each time. Table 7.2 offers suggestions for sampling oil. Typical examples used to demonstrate compliance Sampling point decision diagram/process Lubrication mapping report for all lubricated equipment recommend­ ing sampling points Machine lubrication schematic diagrams depicting sample location points (if not already included in lubrication mapping report)

• • •

7.4 Lubricant Sampling 131 Table 7.2 Oil sampling do’s and don’ts

Oil sampling DO’s and DON’TS Do’s Take a sample from a consistent location Develop written procedures After an oil change, take a baseline sample a few hours after the operation Use the proper sampling hardware for the application Use new tubing for each sample

Don’ts (avoidances) Avoid sampling from the drain plug or bottom of the sump Avoid drop tube sampling Avoid dead legs of machines where oil can sit. If unavoidable, purge first Avoid taking samples from cold, nonrunning machines Avoid inconsistent sampling procedures/methods Purge the line for a few seconds to Avoid sampling downstream of the filter remove contaminants (unless testing filter efficiency) Take samples from turbulent, live zones Avoid cross-contamination of sampling devices Use the appropriate “clean” sample Avoid reservoir samples where data can bottle be diluted (not optimal data density)

• • • • •

Lubricant sampling point decision diagram/process for specifying and/ or setting up a new sampling point Process or training documents for choosing a sample bottle Process or training documents for taking a sample Typical lubricant sampling point BOM report (Bill Of Material) Lubrication manual that includes the above

Consider the use of labels where samples will be extracted. 7.4.5 Sample bottle labeling No matter if working with a third-party oil analysis laboratory or performing analysis onsite, developing an equipment list for sample identification is crit­ ical to the success of the program. Proper labeling of equipment and samples ensures a seamless workflow, from taking the sample to putting out the final report. Proper sample bottle labeling cannot happen unless the machine is properly identified. To start this process, an equipment list should be devel­ oped that identifies all the equipment that is part of the CM program. This equipment list will be the foundation for developing labels that will go on every oil sample bottle. This list then gets imported to the software

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Condition Monitoring and Lubricant Analysis

program (internally and/or externally) that produces the final oil sample bottle labels. Ideally, the equipment list should contain the following information:

• • • • •

Machine name or identification number Sample point (some machines may have multiple sample points) Unit type Manufacturer name and model number Fluid manufacturer, fluid name, and grade

Once the laboratory imports the list, they may provide oil sample bottles and labels, or they may provide access to the online site where the equipment list is stored. Most labs will provide access to a site where the labels can be printed; therefore, having a label printer will be required. How to generate the sample bottle labels will vary between laboratories, but the information that should go on every sample bottle should not. Using the equipment list as the foundation, each piece of equipment will be set up to be sampled on a certain frequency (e.g., quarterly, yearly). The user will generate the sample labels accordingly. Every oil sample bottle label should contain the following information:

• • • • • • • • • •

Company name Technician name Date sampled Time sampled Sample method Machine ID Sampling location Date sampled Run hours or mileage/kilometers Any abnormalities with the fluid or machine

Figure 7.7 depicts a typical example of a sample bottle label generated prior to the lubrication specialist or reliability engineer going out to extract the sample from the machine. Typical examples used to demonstrate compliance Lubrication sample bottle labels Label printing software Equipment list with sample fields Process or training documents for labeling an oil sample bottle Lubrication manual that includes the above

• • • • •

To establish routine lubricant analysis results, we must first determine all required optimum cautionary and critical alarm limits and targets. Targets are

7.4 Lubricant Sampling 133

Figure 7.7

Typical oil analysis label with QR code.

typically used to establish normal conditions, as well as abnormal conditions that might lead to impending failure if not attended to quickly. The required testing and limits/targets may vary by machine type and application. 7.4.6 Setting alarm limits – determining optimal, cautionary, and critical limits Determining optimal, cautionary, and critical limits can be one of the more challenging aspects of implementing an oil analysis program. It is important to remember there are a lot of resources available when devel­ oping this important piece of your program. The OEM will likely provide some of this information, but generally the recommendations will not be for all parameters the analyst would like to trend. For example, it may just be for Total Base Number (TBN, or alkalinity number) or ISO 4406 Cleanliness Code. The initial calculation of alarm limits should be developed based upon a review of a statistically acceptable population of pertinent data, along with data associated with different failures (if available). If time permits, a sam­ pling study is recommended to develop a baseline in which the machine is operating under normal conditions. Gather at least four or five samples (more if possible) over time to develop a trend. After this point, start developing averages on normal machine behavior, establishing alarms and condemning limits using simple standard deviation techniques. For example, if the sample data point falls outside of one standard deviation from the average but still within two standard deviations, the sample would be considered marginal; more than two standard deviations away from the average, the sample would be considered critical. Anything within one standard deviation of the mean would be considered normal. While this method is extremely effective, deter­ mining “normal” operating conditions is critical. Use reference documents like ASTM D7669 – Standard Guide for Practical Lubricant Condition Data

134 Condition Monitoring and Lubricant Analysis Trend Analysis to Trend and Manage the Data, and ASTM D7720 – Guide for Statistically Evaluating Measure and Alarm Limits when Using Oil Analysis to Monitor Equipment and Oil for Fitness and Contamination. 7.4.7 Using cause failure analysis to set alarms Failure of a piece of equipment typically will prompt a root cause failure analysis (RCA) to determine what went wrong and what changes are needed to improve the maintenance of the equipment. In the post mortem analysis, oil analysis is typically combined with other forms of RCA studies like metallurgy, etc., to determine exactly what went wrong. Once the root cause is identified, the test that tracks that param­ eter can be trended. Immediately upon failure, it is likely that sampling inter­ vals may increase to gather more data in the near term. In general, sample intervals should be short enough to provide at least two samples prior to failure. The interval can be established for the shortest critical failure mode. To put some more specifics around those statements, data is required. If not available from a previous failure mode, data can be generated by performing a sampling study. When doing a study, take a more conservative approach at the beginning (i.e., sampling more frequently). To demonstrate the process described above, a customer in a manufac­ turing plant is tasked with selecting the test slate and sample frequency on a dozen gearboxes. They decide to sample a select number of gearboxes each month for the first six months of operation and check for the key parame­ ters that deviate in trend significantly month over month. This achieves two things: it helps determine (1) which parameters are helpful to trend in the gearboxes, and (2) how frequently the data changed. After the six-month study, the customer is able to reduce sampling frequency and commence sampling according to the changes in data, also determining specific points to trend to ascertain machine condition. While this is an ideal scenario, some may not have the luxury of performing a study. In these cases, use standards to determine test slates, pick a sampling frequency (maybe quar­ terly to start), and commence the program. Adjust as needed to enhance the program results. 7.4.8 Variation between machines and applications Setting alarm limits based on machine and application are important con­ cepts to address when setting up a CM program. If working with a third-party laboratory, they can assist with choosing the right test slate for the specific

7.4 Lubricant Sampling 135

equipment. For example, a hydraulic system will require very clean oil, so monitoring the particle count will be of primary importance. In the case of a steam turbine, keeping moisture under control will be important and require monitoring of moisture levels as part of the recommended test slate. Alarm limits and test slate will vary between applications, and it is important not to choose just one test slate for all machines. Choosing the right test slate opti­ mizes the time and budget for the program. If tasked with developing alarms and test slates without the help of a third-party laboratory, reference the techniques defined in ASTM D7874 – Standard Guide for Applying Failure Mode and Effect Analysis (FMEA) to In-Service Lubricant Testing. The FMEA process takes an analytical approach to determine and address all possible system or component failure modes and their associated causes and effects on system performance. To apply this pro­ cess effectively will require a thorough understanding of the machine design requirements and equipment operating conditions. Once FMEA is effectively applied, a sampling study can be pursued based on the required tests to help determine alarm limits. Typical examples used to demonstrate compliance Laboratory lubricant test and target condition table for all machines and systems/points tested Setting lubricant analysis cautionary and critical alarm level matrix/ process/training document Oil/Grease analysis test requirement decision matrix/report “How to Read a Lubricant Test Report” training document Lubrication manual that includes any/all of the above

• • • • •

Trends and data comparisons from previous samples and limits/targets can detect significant changes that can identify incipient or impending failure conditions and impaired machine reliability. 7.4.9 Data trending techniques Data can be analyzed and trended over time in several different ways. In a single oil analysis report, several different statistical trending techniques are employed. The ASTM D7669 – Standard Guide for Practical Lubricant Condition Data Trend Analysis outlines several different strategies for trend­ ing data. Some of the more common techniques include the Delta (differ­ ence), Percent Change, Rise-Over-Run Trending, and Cumulative Trending. Table 7.3 outlines the decisions around using each technique.

Types of data trend analysis

Adapted from Ed Eckert and Lisa Williams

Best Use Most effective on equipment used consistently. Works well with real-time data where there is a high sample rate, e.g., online sensors used to trend wear data such as ppm iron, lead, tin or copper, where concentration is important, along with the time required to meet that concentration Used in measuring viscosity, remaining useful life, and rotating pressure vessel oxidation test (RPVOT), where the test values cannot increase or decrease beyond a certain percentage Commonly used for additive metals using an inductively coupled plasma (ICP) rotating disc electrode (RDE) spectrometer where a baseline oil value is compared against samples. When values become too low, other methods should be used to confirm additive depletion, e.g., oxidation, viscosity increase, remaining useful life.

Condition Monitoring and Lubricant Analysis

Analysis Technique Monitor a linear trend with sample Most used method, useful on equipment that is frequently data sampled with consistent sampling intervals Rise-Over-Run Looks at current vs. previous data Best for detecting abnormal sample points and when sampling intervals points while factoring in time on Trending equipment and the standard sample are consistent; at variable sample intervals can produce uncertain interval results Calculates the change of the current Effective with certain data points Percentage evaluating large groups of the same data point over the previous data Change equipment with approximately point as a percentage the same sample interval. Not effective with data showing element concentrations at