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Lubrication AuditSabita Mishra

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

Factors that Enable Lubrication ExcellencePeople 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 AuditIdentify duplication of lubricantsLearn about your hidden lubrication costsLearn of potential safety and environmental issuesCost out the R.O.I. of automating some of your critical production equipmentUp-dated manuals as required for your current automated lubrication systemA customized plan to reduce cost, improve productivity and safety, listing the opportunities in priority sequence

Equipment Survey OverviewDevelop an equipment listRoutine inspection, equipment survey and visual inspectionIdentify and label equipments with equipment number and descriptionEquipment picturesMachine criticality assessment and operating parametersIdentify lubricant sections from the OEM manualTechnical data sheet for the selected lubricant for the equipmentSelected lubricant MSDSLeakage reportsEquipment temperature environmentOil sampling as requiredLubrication inspection, top offsReliability, mean time between failure data on the equipmentsSafety and operational hazards

Equipment Assessment

Lubricant Survey OverviewLubricant technical selection practicesLubricant application practicesOil analysis program practicesCondition control practicesLubrication practices standardization (SOPs)Long term lubricant stabilityLubrication survey and lubricant vendor selectionConsolidate lubricantsSet lubrication preventive maintenance (PM) frequencyRoot cause mapping and correctionProgram effectiveness reportingProgram management and personal development

Lubricant Survey Overview (Contd)Eliminate unnecessary oil changesEliminate premature aging of lubricantsVerifying, defining lubrication practicesVerifying, defining re-lubrication activities like volumes, frequencies, route sequences, machine upgrades etc.Purchase necessary lubrication equipment and toolsPerform financial analysis review and establish a cost basisReduce the number of lubricants in use and thereby reduce the chances for mis-application and cross contaminationContamination control practicesUpgrading knowledge levelDevelop a lubrication manual

Lubricant Selection Chart

Storage and Handling Survey OverviewLubricant delivery, storage and handling practices should be followedWasteful practices of products, duplication and excess inventory should be eliminatedStorage room temperature extremes should be avoidedFluctuating temperatures should be avoidedContainers should not be stored in a humid environmentFirst in first out (FIFO) system should be maintained such that stocks are rotated properlyAll new drums should be filtered to an appropriate level. Use a 3=200 filters for lubricants below 150 cSt @ 40C. Use 6=100 filters for lubricants above 150 cSt @ 40CAll 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 OverviewFiltered 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 racksFluid storage racks should have oil and air filtrationProper dispensing containers should be used and stored in an explosion proof cabinetDrums 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 oclock 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 OverviewMSDS are available and are reviewedLock out procedures are followedLeakage controlSpill response is in placeHandling practices maintain a safe environmentLubrication equipment use is understoodSampling procedures are followedTraining to ensure effectiveness and consistencyProper documentation and reports and manualsProper fire hazard precautions are taken

Typical Checklist for an Audit

Typical AuditOil 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 AuditOil 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 AuditContaminant 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 AuditOil 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 AuditProgram 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