Lubrication Management

Lubrication Management

Competence Center Maintenance

Lubrication Management Equipment availability

Lube Performance 𝑂𝐶𝑅 =

𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑜𝑖𝑙 𝑐𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 𝑖𝑛𝑠𝑡𝑎𝑙𝑙𝑒𝑑 𝑜𝑖𝑙 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 KPI’s

Handle and storage

Troubleshooting

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Application

People

Oil Analysis

November 1, 2016 P08 Lubrication Management, CC Maintenance, 2016-11-14

This document contains proprietary information which shall not be used and disclosed without Omya explicit written authorization .

Agenda

Lubrication chart Lubrication routines Lubrication performance indicator

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November 1, 2016 This document contains proprietary information which shall not be used and disclosed without Omya explicit written authorization .

Why is important the LUBRICATION CHART?

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Lubrication chart • The Lubrication Chart is one of the most important document in the plant, talking about reliability.

• All the information regarding machinery lubrication is integrated in one document.

• Lubrication points, type of lubricant and quantity and frequency of its application

• Lubrication activities and its frequency. (Revision, Cleaning, Application, Sampling, Change and Filtering)

• Is the main input to create the lubrication routines

• It must be available for all maintenance and production departments (Just in case)

• It must be managed by the lubrication responsible 5


Let’s Save Money!!!

• You’ve heard the expression, “why is there always enough time to do it over, but never enough time to do it right the first time?” Restarted in a maintenance context, “Why is there always enough time (and money) to fix a broken machine but never enough time (or money) to prevent it from failing?” Fuente: Jim Fitch, Noria Corporation

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Lubrication chart

Lubrication chart is the base of the lubrication program To develop the lubrication, it is required an adequate knowledge of

• Equipment to be lubricated • Lubricant properties

• Selection and application • Lubrication and re-grease frequencies • Lubrication and re-lubrication methods

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P08 Lubrication Management, CC Maintenance, 2016-11-14


Lubrication chart

The lubrication chart consists of a template where all relevant information is gathered • Equipment identification including the specific lubrication points, • Type, designation and amount of lubricant applied, • Identification of activity type and the corresponding frequency,

together with all necessary information about: • Sampling, if required • Services • Inspections, frequency • Cleaning, frequency • Re-greasing or oil top-up, frequency and quantity • Grease or oil replacement, frequency 8

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Lubrication chart

• Lubrication chart is an essential tool to structure and build lubrication PMR’s (Preventive Maintenance Routines)

From where to gather all necessary information?

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Flowsheet & plant equipment list

Make sure that you have reliable information 10



Identification of all equipment elements to be lubricated

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Identification of lubricant type and quantity installed

Operating manuals

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Source: SEW and Siemens Flender Operating manuals P08 Lubrication Management, CC Maintenance, 2016-11-14


Inspections and cleaning

Operating manuals Experience

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Source: SEW and Siemens Flender Operating manuals P08 Lubrication Management, CC Maintenance, 2016-11-14


Re-application quantities

• Re-lubrication quantities suitable for each bearing are in a direct correlation with: • the bearing size and • the location of the lubrication point related to the

bearing

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Re-lubrication amounts - calculations

• Re-lubrication from the side • Re-lubrication from the center Gp = 0,005 * D * B

Gp = 0,002 * D * B

where Gp = grease quantity to be added when replenishing, [g] D = bearing outside diameter, [mm] B = total bearing width (for thrust bearings use total height H), [mm] Source: SKF

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Re-lubrication amounts - bearing dimensions

Source: SKF

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Re-lubrication amounts - bearing dimensions

• Bearing dimensions to be considered for calculations

Gp = 0,005 * D * B Source: SKF

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Re-application quantities and frequency

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Lubricant replacement – time based (1)

• Grease replacement intervals (SKF example) L10h

Class of machine

(operating hours)

Household machines, agricultural machines, instruments, technical apparatus for medical use

300 ... 3000

Machines used for short periods or intermittently; Electric hand tools, lifting tackle in workshops, construction machines

3000 ... 8’000

Machines too work with high operational reliability during short periods of intermittently; Lifts (elevators), cranes for packaged goods or slings of drums, bales etc.

8’000 ... 12’000

Machines for use 8 hours per day but not always fully utilized; Gear drives for general purposes, electrical motors for industrial use, rotary crushers

10’000 ... 25’000

Machines for use 8 hours per day and fully utilized; Machine tools, woodworking machines, machines for the engineering industry, cranes for bulk materials, ventilator fans, conveyor belts, printing equipment, separators and centrifuges

20’000 ... 30’000

Machines for continuous use 24 hours a day; Rolling mill gear units, medium sized electrical machinery, compressors, mine hoists, pumps, textile machinery

40’000 ... 50’000

Water work machinery, rotary furnaces, cable stranding machines, propulsion machinery for ocean-going vessels

60’000.. 100’000

Large electric machinery, power plant, mine pumps and mine ventilator fans, tunnel shaft bearings for ocean-going vessels

~ 100000

Source SKF

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Lubricant replacement – time based (1)

• Equipment operating manuals

Source: SEW and Siemens Flender Operating manuals

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Lubricant replacement – condition based

• The first step in setting up an oil analysis program is to select the systems to be monitored Main criteria in selection of the system is the equipment criticality and not oil volume itself!

• Oil analysis program steps

• Establish the sampling frequency (considering machine and oil age – both are moving targets, readjustments required) • Determine the cleanliness target of oil sample • Ensure proper sampling methods and techniques • Ensure a proper evaluation and documentation of sampling results (history and graphical trend analysis are essential parts of the evaluation process)

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Lubricant replacement

• Condition based and time based lubricant replacement information are part of lubrication chart

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Agenda


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Lubrication routines

Lubrication Chart Lubrication chart Hac

Equipment Name

Lubricant

Element To Lubricate

Type 241-AD1 241-AD2 241-SP1 241-SP2 241-SP3 241-SP4 241-VA1 241-VA3 241-VA7.M1 301-СА1 302-СА1 361-AD1.M1 361-MD2.M1 361-MD4.M1

Auxiliary Drive Gearbox Auxiliary Drive Gearbox Pump YРУ-800/ 400 Pump YРУ-800/ 400 Pump YРУ-800/ 400 Pump YРУ-800/ 400 Slurry valve Slurry valve Valve motor Electric bridge crane l/ c 12,5t Electric bridge crane l/ c 25t Auxiliary Drive Electric motor Main Drive Electric motor Main Drive Electric motor

Auxiliary drive motor bearings Auxiliary drive motor bearings Motor bearings Motor bearings Motor bearings Motor bearings Motor bearings Motor bearings Bearings of electric motor 5kW Bearings of electric motor 2,2kW Motor bearings Auxiliary drive motor bearings Auxiliary drive motor bearings Auxiliary drive motor bearings

Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease

Revision Date

Designation Value Unit Lithol-24 Lithol-24 Lithol-24 Lithol-24 Lithol-24 Lithol-24 Lithol-24 Lithol-24 Lithol-24 Lithol-24 Lithol-24 Lithol-24 Lithol-24 Lithol-24

Nov 10

ACTIVITY TYPE Quantity Installed

0.2 0.2 0.7 0.7 0.7 0.7 0.15 0.15 0.2 0.1 0.2 0.3 0.3 0.3

kg kg kg kg kg kg kg kg kg kg kg kg kg kg

Sample

Inspection

Clean

Freq Unit Freq Unit 1 1 1 1 1 1 1 1 1 1 1 1 1 1

w w w w w w w w w w w w w w

1 1 1 1 1 1 1 1 1 1 1 1 1 1

w w w w w w w w w w w w w w

Condition Of Equipment stopped

running

Reapplication

Change

Lube Points

Application Method

2 2 2 2 2 2 2 2 4 2 2 2 2 2

Manual Manual Manual Manual Manual Manual Manual Manual Manual packed lubr. Manual packed lubr. Manual packed lubr. Manual Manual Manual

Date Of Modification

Freq Unit Quant. Unit Freq Unit 6 6 6 6 6 6 6 6 6 6 6 6 6 6

m m m m m m m m m m m m m m

0.20 0.20 0.70 0.70 0.70 0.70 0.15 0.15 0.20 0.10 0.10 0.30 0.30 0.30

kg kg kg kg kg kg kg kg kg kg kg kg kg kg

6 6 6 6 6 6 6 6 6 6 6 6 6 6

m m m m m m m m m m m m m m


Process flow

Equipment physical location

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• Lubrication routines are check list developed to help lubrication technicians to apply in systematic way the required activities

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Walk-by inspection Walk-by inspections use our human senses to monitor the condition of our equipment

Touch

Visual

Audio

Smell

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Walk by inspection – lubrication related topics

• Lubrication related topics must be included in the walk by check lists: • Housekeeping • Inspections • • • • • • • • • • • • 27

Oil level, Blocked oil breathers Damaged seals Oil and grease leakages Open gear boxes Open lubrication tanks Oil flow in lubrication system Pressure drop per oil filters Oil temperature Bearings temperature Oil smell Oil color

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Walk by inspection – topics selection Operating manuals

Source: SEW and Siemens Flender Operating manuals

Experience 28



Agenda


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Lubrication performance indicator

Oil Consumption Ratio (OCR) • KPI measuring and evaluating the overall lubrication situation / performance of a plant, tracked on yearly base 𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑜𝑖𝑙 𝑐𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 𝑂𝐶𝑅 = 𝑖𝑛𝑠𝑡𝑎𝑙𝑙𝑒𝑑 𝑜𝑖𝑙 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦

• only volume of oil installed over 5 liters shall be taken into consideration. • mobile equipment as e.g. trucks used in the quarry shall not be considered for the calculation

Good practice value 0.45 to 0.85 30

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Lubrication points inventory

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Centralized Lubrication Systems

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Lubrication Activities • Revision • Simple activities such as oil and grease levels • Proactive tasks for hidden failures (centralized systems) • Simple activities to test the function of automated systems • Measure of wear in bearings roller elements (during the grease change) • Inspection of lubrication systems which are only accessible in a stopped state of the machinery (e.g., pipes for bearing lubrication in separators) • Cleaning • Activities related with housekeeping to keep machinery neat and with appropriate cleanliness • Cleaning activities must be scheduled to be performed without putting at risk the personnel safety

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Lubrication Activities • Application • Grease relubrication in motors and bearing houses • Sampling • To perform oil change in base on condition • Activities to draw an oil sample in order to perform field test as well as routinely laboratory oil analysis • Change • Oil changes by frequency. • Small equipment with low probability of failure and impact (screw conveyors, hydraulic couplings, etc.) • Filtering • Filter critical equipment ( main speed reducers) in a regular basis or according with the oil analysis results

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Questions?

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Lubrication Management

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