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Selecting Machines for Oil Analysis
Ronald M. Astronomo, Preventive Maintenance Engineer,
Union Cement Corporation
Starting your quest as a Reliability Engineer for a Manufacturing
Plant, conduct 1st an assessment whether Oil Condition Monitoring
is part of the current Maintenance System, you know it is your
advantage so as not to start from scratch or re-invent the wheel.
If it was partly started but not as you’ve envisioned it
should be, then critique the existing program and identify opportunities
for improvement on the existing system.
If Oil Condition Monitoring is not part of the Existing Maintenance
System, then the following steps are my suggestion,
1. Create an Equipment Checklist According to your Manufacturing
Process Flow and Identify Oil Lubricated and Grease Lubricated
Equipment.
a.) Use your Equipment Registry System to Identify the Asset
Group Header, Asset Codes, Asset Description, Oil Types, Quantity
and Viscosity of each.
b.) Do the same for Grease Lubricated Equipment, and identify
equipment that are repackable (ex. most Plummer Block Bearings)
and non-repackable bearings (ex. most Flange or Y-Bearings). Create
the Table or Checklists in a spreadsheet or MS Excel.
c.) If the Equipment Registry System does not contain enough
details of the information such as, Oil Types, Quantity and Viscosity,
then;
2. Conduct a “Walk-Around” the Plant and List the
Oil Type, Quantity and Viscosities of each by checking the Equipment
Name Plates, especially for Gearbox or Reducers.
a.) For Hydraulic Tanks, Oil Re-circulation Reservoirs or Re-circulation
Systems, identify your future oil sampling points. For your future
convenience, install a ball valve regulated extraction points
on all Oil Re-circulation Reservoirs.
b.) For Grease Lubricated Equipment, this also a good opportunity
to identify the number of bearings and the lubrication points
of each equipment in your checklists.
c.) Finally, a good opportunity also for you to see the actual
condition of the equipment.
3. Update your Checklists.
a.) Highlight Large Quantity Oil Reservoir or Re-circulation Systems
and Reducers.
b.) Identify Reservoir or Circulation Systems with On-Line and/or
Off-Line Filtration Systems, and determine as well specification
of the Filter Element.
c.) For Grease Lubricated, highlight equipment with Centralize
Lubrication System.
d.) Finally, complete the Equipment Specification according to
the Model, Brand, Criticality Rating, Speed, etc..
4. As a start, Prioritize Monthly Oil Sampling on Large Reservoir
or Hydraulic Tanks and Reducers.
a.) Contact your Oil/Lubrication Suppliers for Technical Assistance
for Used Oil Analysis.
b.) Study possibilities in the future to establish an Oil Analysis
Program in the Plant. To acquire Oil Analysis Equipment, Lube
Kits, and train key personnel’s in the plant.
5. Monitor and Trend in a Monthly Basis the Oil Analysis Results.
a.) A simple spreadsheet will help you trend the results for
metal analysis, Viscosity, TAN, etc…
b.) Increase Sampling Frequency if the parameter trends increases.
This will give you a good judgment to properly schedule your change-oil
and servicing of the equipment.
6. Finally, Assess now your Checklist if you can still extend
Oil Sampling on Small Reducers.
7. Study possibilities as well to standardize the Branding and
Oil Types of your Lubrication Requirement. It will help you reduce
your Lubrication Inventory Costs and simplify your Lubrication
needs.
See other responses
to this Readers Challenge.
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