In This Issue:

• Up Front: Lube-Fumes Cause Explosion

• Book Bits: Three Steps of Proactive Maintenance

• Today's Tip: Oil Sampling Pointer

• Q & A: Tracking Oil Consumption

Readers Challenge

Lube-Fumes Cause Explosion

While working as a lube salesman in the Toronto area, I was called to visit a customer who had experienced a lube-related problem. Over the weekend, a welder had been working on a large gearbox that was drained of our gear oil.

As a result of the welding, the accumulated fumes in the gearbox exploded. The force was so great it broke the bolts holding the heavy inspection plate, which shot up and damaged the ceiling. Nobody was hurt, except for a bad case of ringing in the ears.

Any enclosed tank or gearbox that previously held a lubricant could cause an explosion. Consider leaving them open to the air. (Submitted by Tom Muckian, Manager of Technical Services, Whitmore Group. Thanks Tom!)

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Book Bits

Three Steps of Proactive Maintenance

From the "Tribology Data Handbook"

Whenever a proactive maintenance strategy is applied, three steps are necessary to ensure that its benefits are achieved. Because proactive maintenance, by definition, involves continuous monitoring and controlling of machine failure root causes, the first step is simply to set a target, or standard, associated with each root cause.

In oil analysis, root causes of greatest importance relate to fluid contamination (particles, moisture, heat, coolant, etc.) and additive degradation. However, the process of defining precise and challenging targets (for example, high cleanliness) is only the first step. Control of the fluid's conditions within these targets must then be achieved and sustained. This is the second step and often includes an audit of how fluids become contaminated and then systematically eliminating these entry points. Often better filtration and the use of separators are required.

The third step is the vital action element of providing the feedback loop of an oil analysis program. When exceptions occur (for example, over target results) remedial actions can then be immediately commissioned. Using the proactive maintenance strategy, contamination control becomes a disciplined activity of monitoring and controlling high fluid cleanliness, not a crude activity of trending dirt levels.

More information about the "Tribology Data Handbook"

Today's Tip

Oil Sampling Pointer

• For reservoirs, drop tube oil sampling is rarely the ideal method. However, if it cannot be avoided it is important to consistently sample as close to the active fluid zone as possible. Measure the standoff distance desired from the bottom of the sump and attach the drop tube with wire ties (or other suitable method) that distance from the end of a rod. Consistency in sample location will help make the analysis results more suitable for trending.

   

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Q & A

Tracking Oil Consumption

"How should I calculate the oil consumption ratio for our plant equipment and what target should I aim to achieve?"

The consumption ratio is the ratio of how much oil is added to the system in a period (normally a year) to the actual volume of fluid the system holds.

Consumption ratio = Total Oil Added/Total System Volume

Aim to achieve a target reduction program of 50 percent per year and seek a goal of less than 0.1.

Consider also the disposal ratio which is the ratio of the volume of oil drained from the system in a period to the actual volume of the system. The difference between the two ratios will indicate the leakage ratio (or in the case of crankcase engines, the burn ratio) which should be minimized as much as possible, for both environmental and financial reasons.

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