Transcript The Maintenance Model

Oil Analysis Implementation Strategy
J. Mike Weiksner
BSME - Auburn University - 1978
25 Years in Industry (EMO)
Hold Certifications in Vibration & Oil Analysis
Member of the ICML Advisory Board, STLE
Proctor & Gamble, Kimberly Clark, E.I. DuPont
Westinghouse Savannah River Co. (currently)
(803)557-6352 [email protected]
Oil Analysis can have a major impact within a
maintenance organization. Not only can you
reduce maintenance cost and machine
downtime, but if implemented meticulously,
maintenance and operations personnel will
develop a passion for continuous
improvement. Learn through an 11 step
strategy how to implement an Oil Analysis
program that will improve equipment
reliability and enhance your Predictive
Maintenance Program.
Step 1. Evaluate your lubrication practices.
• Are you currently performing time or meter
directed activities?
• Do you know how many types of oil are used at
your facilities and if your oils are stored and
dispensed properly?
• Do you understand the differences between the
types of oil and greases used at your facilities?
• Are you currently using an off site oil analysis
lab and if so, can you interpret the reports?
Step 2. Utilize Maintenance Optimization to determine
“best practices” and for justifying maintenance program
changes.
• This step allows you to assess your overall
maintenance practices for a given machine,
perform a cost analysis to calculate the savings for
program implementation, and document a
technical baseline for the actions that are taken.
The Maintenance Model
Application Program Interface
CAE
Work Management
E-Mail
Notification
Electronic
Paging
Maintenance
Optimization
Proactive/Predictive
Maintenance
Step 3. Select or obtain volunteer maintenance
personnel to support the lubrication program.
• The key to this step is in finding
maintenance personnel who have a
genuine interest in improving maintenance
and who will want to work/learn using a
computer. Although preferred,
maintenance personnel do not necessarily
need oil or lubrication experience.
Step 4. Send all of your oil program personnel to oil analysis
training and educate them in lubrication fundamentals.
Permit and encourage certification for those who desire it.
• Learn about oil and lubrication, bring in the
industry experts
• Learn about proper sampling techniques and
practices
• Learn about oil contamination, the sources, the
types and affects
• Learn about oil tests and testing instruments
• Investigate multiple companies who supply oil
analysis equipment
• Visit an oil analysis lab
Step 5. Purchase some oil analysis equipment.
• Provides relatively fast, consistent and repeatable
results.
• Includes software that has ability to plot and
trend data, set and generate alarms, customize
and generate reports, and can be networked
• Basic tests would include particle count
(contamination index), wear particle count,
viscosity change and moisture presence.
• Base lab instruments and test equipment on the
type of machines/oil to be monitored.
Step 6. Select a location for setting up the oil
analysis instruments and for the testing/processing of
oil samples.
• Should have sufficient space for growth and be
separate from other technologies.
• Need to purchase oil sample bottles and some lab
sample processing equipment (i.e. sample shaker)
Step 7. Analyze and baseline several machine oil reservoirs
for contamination,viscosity change and the presence of
moisture. Run these same tests on stored lubricants.
• Practice and develop your skills in testing
• Discuss the tests and what you find with those
involved in the program, and with experienced
maintenance personnel
• Think about how the machine operates and the
machine operating conditions
Step 8. Set machine target cleanliness levels and purchase
portable filtration equipment/components. Establish the
practice of oil analysis and filtering on as many reservoirs as
possible.
• Filtration of oil within reservoirs will achieve
target cleanliness faster and more effectively
then draining and replacing the oil, or, draining,
flushing the reservoir and replacing the oil.
Furthermore, filtering significantly reduces
waste oil generation and disposal costs.
• Control moisture infiltration
Step 9. Utilize oil testing to make programmatic
maintenance changes, and changes to your lubrication
practices.
• Eliminate time directed maintenance activities
and extend overhaul schedules. Change oil only
when the condition of the oil no longer meets the
machine requirements.
• Consolidate your oils and reduce inventories
• Set up oil dispensing facilities to ensure clean oil
used in equipment
• Reduce waste oil generation through filtering
• Consolidate multiple facility oil programs,
testing and off site contracts
Step 10. Trend and track oil related
equipment failures. Document savings and
use to justify additional lab equipment.
Consider the benefits of purchasing advanced
oil analysis equipment such as Ferrogram
making equipment and a FT-IR. As an
alternative to the investment of additional
laboratory equipment, consider utilizing an
off site oil analysis lab to confirm internal
tests and perform root cause exception testing.
No. 1 Supply Pump, 285-H
Outboard Bearing, No. 1
Supply Pump 285-H
October 2001
Step 11. Establish ongoing training,
education of plant personnel and
revisions/upgrades to lab hardware and
software. Rotate maintenance personnel
and other PDM personnel into the oil
analysis program.
How Does Oil Analysis Increase the
Effectiveness of Your Condition Monitoring
Program ?
• Energy consumption and operating temperatures can be
reduced
• Improves analysis capability of journal bearings
• Can optimize data collection by collecting samples at the same
time (ie vibration monitoring)
• Helps to discern between contamination, oil degradation and
machine wear
• Complements ultrasonic analyses
• Improves application of lubricants and can extend a oil useful
life
• Keeps lubricant suppliers in check and control of machine
lubrication
• Is a Proactive Tool [ie Spike Energy(gSe), Motor Current]
providing the analyst with early diagnostic information