Lubrication audit

Lubrication Audit

Sabita Mishra

Figure 2 Ref. AIMAN (Italian Association of Maintenance Engineers)and IRI (International Research Institute) in conjunction with SKF

Factors that Enable Lubrication Excellence

• People Preparedness. People are trained to modern lubrication skill standards and have certified competencies.

• Machine Preparedness. Machines have the necessary design and accouterments for quality inspection, lubrication, contamination control, oil sampling, etc.

• Precision Lubricants. Lubricants are correctly selected across key physical, chemical and performance properties, including base oil, viscosity, additives, film strength, oxidation stability, etc.

• Precision Lubrication. Lubrication procedures, frequencies, amounts, locations, etc., are precisely designed to achieve the reliability objectives.

• Oil Analysis. This includes optimal selection of the oil analysis lab, test slate, sampling frequency, alarm limits, troubleshooting rationale, etc.

Advantages of an Audit Identify duplication of lubricants Learn about your hidden lubrication costs Learn of potential safety and environmental issues Cost out the R.O.I. of automating some of your

critical production equipment Up-dated manuals as required for your current

automated lubrication system A customized plan to reduce cost, improve

productivity and safety, listing the opportunities in priority sequence

Equipment Survey Overview Develop an equipment list Routine inspection, equipment survey and visual inspection Identify and label equipments with equipment number and

description Equipment pictures Machine criticality assessment and operating parameters Identify lubricant sections from the OEM manual Technical data sheet for the selected lubricant for the equipment Selected lubricant MSDS Leakage reports Equipment temperature environment Oil sampling as required Lubrication inspection, top offs Reliability, mean time between failure data on the equipments Safety and operational hazards

Equipment Assessment

Lubricant Survey Overview Lubricant technical selection practices Lubricant application practices Oil analysis program practices Condition control practices Lubrication practices standardization (SOPs) Long term lubricant stability Lubrication survey and lubricant vendor selection Consolidate lubricants Set lubrication preventive maintenance (PM) frequency Root cause mapping and correction Program effectiveness reporting Program management and personal development

Lubricant Survey Overview (Cont’d)

Eliminate unnecessary oil changes Eliminate premature aging of lubricants Verifying, defining lubrication practices Verifying, defining re-lubrication activities like volumes,

frequencies, route sequences, machine upgrades etc. Purchase necessary lubrication equipment and tools Perform financial analysis review and establish a cost basis Reduce the number of lubricants in use and thereby reduce the

chances for mis-application and cross contamination Contamination control practices Upgrading knowledge level Develop a lubrication manual

Lubricant Selection Chart

Storage and Handling Survey Overview Lubricant delivery, storage and handling practices should be

followed Wasteful practices of products, duplication and excess inventory

should be eliminated Storage room temperature extremes should be avoided Fluctuating temperatures should be avoided Containers should not be stored in a humid environment First in first out (FIFO) system should be maintained such that

stocks are rotated properly All new drums should be filtered to an appropriate level. Use a

ß3=200 filters for lubricants below 150 cSt @ 40⁰C. Use ß6=100 filters for lubricants above 150 cSt @ 40⁰C

All drums and containers should be labeled and color coded and filtered drums should be labeled as such with the date of filtration.

Storage and Handling Survey Overview Filtered drums should be fit with an appropriate air filter to offer

air flow a path of least resistance allowing moisture and solid particulate to be captured prior to entering the drum.

When new oil is transferred to the top-up container, it should be transferred through a filter.

Oils should be stored in fluid storage racks Fluid storage racks should have oil and air filtration Proper dispensing containers should be used and stored in an

explosion proof cabinet Drums should be stored horizontally and covered to keep excess

moisture and dirt from settling on them. The openings (bungs) should be at 3 and 9 o’clock positions to minimize the amount of breathing in the drums

Drums should be fitted with dispensing taps with covers

Storage and Handling Practices

Storage and Handling Practices

Storage and Handling Practices

Safety Survey Overview MSDS are available and are reviewed Lock out procedures are followed Leakage control Spill response is in place Handling practices maintain a safe environment Lubrication equipment use is understood Sampling procedures are followed Training to ensure effectiveness and consistency Proper documentation and reports and manuals Proper fire hazard precautions are taken

Typical Checklist for an Audit

Typical Audit

Oil storage and dispensing:-Oils stored in fluid storage racksFluid storage racks have oil filtrationFluid storage racks have air filtrationUse of proper dispensing containersLubricant stocks properly rotatedBulk oil changes performed using a filter carts

Typical Audit

Oil sampling techniques:-Oil sampling procedures are documentedNew oil deliveries are sampledOil sampling ports are properly locatedProper oil sampling hardware is installedSample ports are properly labeledAutomatic monthly scheduled oil change in place

Typical Audit

Contaminant ingression control:-Proper air breathers are installed on equipmentAdditional offline filtration is installed on critical

equipmentLubrication ports are installedOff line filter carts are available and employed

regularlyWater stripping equipment is availableOffline filtration and oil filter changes are

performed on condition

Typical Audit

Oil analysis program:-Proper sampling frequencies are definedOil analysis test slates are well definedProper limits and targets are employed by

machine typeOil analysis data is effectively communicated

through the companyA process exists for troubleshooting exception

conditions

Typical Audit

Program Management:-Equipment criticality assessed and determinedRegular and condition based PMs in placeOil changes are based on condition Qualified and trained technicians dispense

lubricantsPM schedules are tracked in a databaseTrend charts showing sample/analysis

performance are publicly displayed

Continuous Improvement