Lubrication Management
Competence Center Maintenance
Lubrication Management Equipment availability
Lube Performance ππΆπ
=
ππππππ‘ππ£π πππ ππππ π’πππ‘πππ πππ π‘πππππ πππ πππππππ‘π¦ KPIβs
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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November 1, 2016 This document contains proprietary information which shall not be used and disclosed without Omya explicit written authorization .
Lubrication chart β’ The Lubrication Chart is one of the most important document in the plant, talking about reliability.
β’ All the information regarding machinery lubrication is integrated in one document.
β’ Lubrication points, type of lubricant and quantity and frequency of its application
β’ Lubrication activities and its frequency. (Revision, Cleaning, Application, Sampling, Change and Filtering)
β’ Is the main input to create the lubrication routines
β’ It must be available for all maintenance and production departments (Just in case)
β’ It must be managed by the lubrication responsible 5
November 1, 2016 This document contains proprietary information which shall not be used and disclosed without Omya explicit written authorization .
Letβs Save Money!!!
β’ Youβve heard the expression, βwhy is there always enough time to do it over, but never enough time to do it right the first time?β Restarted in a maintenance context, βWhy is there always enough time (and money) to fix a broken machine but never enough time (or money) to prevent it from failing?β Fuente: Jim Fitch, Noria Corporation
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November 1, 2016 This document contains proprietary information which shall not be used and disclosed without Omya explicit written authorization .
Lubrication chart
Lubrication chart is the base of the lubrication program To develop the lubrication, it is required an adequate knowledge of
β’ Equipment to be lubricated β’ Lubricant properties
β’ Selection and application β’ Lubrication and re-grease frequencies β’ Lubrication and re-lubrication methods
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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 .
Lubrication chart
The lubrication chart consists of a template where all relevant information is gathered β’ Equipment identification including the specific lubrication points, β’ Type, designation and amount of lubricant applied, β’ Identification of activity type and the corresponding frequency,
together with all necessary information about: β’ Sampling, if required β’ Services β’ Inspections, frequency β’ Cleaning, frequency β’ Re-greasing or oil top-up, frequency and quantity β’ Grease or oil replacement, frequency 8
November 1, 2016
P08 Lubrication Management, CC Maintenance, 2016-11-14
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Lubrication chart
β’ Lubrication chart is an essential tool to structure and build lubrication PMRβs (Preventive Maintenance Routines)
From where to gather all necessary information?
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November 1, 2016 This document contains proprietary information which shall not be used and disclosed without Omya explicit written authorization .
Flowsheet & plant equipment list
Make sure that you have reliable information 10
November 1, 2016 P08 Lubrication Management, CC Maintenance, 2016-11-14
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Identification of all equipment elements to be lubricated
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November 1, 2016
P08 Lubrication Management, CC Maintenance, 2016-11-14
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Identification of lubricant type and quantity installed
Operating manuals
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November 1, 2016
Source: SEW and Siemens Flender Operating manuals 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 .
Inspections and cleaning
Operating manuals Experience
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November 1, 2016
Source: SEW and Siemens Flender Operating manuals 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 .
Re-application quantities
β’ Re-lubrication quantities suitable for each bearing are in a direct correlation with: β’ the bearing size and β’ the location of the lubrication point related to the
bearing
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November 1, 2016
P08 Lubrication Management, CC Maintenance, 2016-11-14
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Re-lubrication amounts - calculations
β’ Re-lubrication from the side β’ 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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November 1, 2016
P08 Lubrication Management, CC Maintenance, 2016-11-14
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Re-lubrication amounts - bearing dimensions
Source: SKF
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November 1, 2016 P08 Lubrication Management, CC Maintenance, 2016-11-14
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Re-lubrication amounts - bearing dimensions
β’ Bearing dimensions to be considered for calculations
Gp = 0,005 * D * B Source: SKF
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November 1, 2016
P08 Lubrication Management, CC Maintenance, 2016-11-14
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Re-application quantities and frequency
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November 1, 2016
P08 Lubrication Management, CC Maintenance, 2016-11-14
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Lubricant replacement β time based (1)
β’ 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 ... 8β000
Machines too work with high operational reliability during short periods of intermittently; Lifts (elevators), cranes for packaged goods or slings of drums, bales etc.
8β000 ... 12β000
Machines for use 8 hours per day but not always fully utilized; Gear drives for general purposes, electrical motors for industrial use, rotary crushers
10β000 ... 25β000
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
20β000 ... 30β000
Machines for continuous use 24 hours a day; Rolling mill gear units, medium sized electrical machinery, compressors, mine hoists, pumps, textile machinery
40β000 ... 50β000
Water work machinery, rotary furnaces, cable stranding machines, propulsion machinery for ocean-going vessels
60β000.. 100β000
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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November 1, 2016 P08 Lubrication Management, CC Maintenance, 2016-11-14
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Lubricant replacement β time based (1)
β’ Equipment operating manuals
Source: SEW and Siemens Flender Operating manuals
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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 .
Lubricant replacement β condition based
β’ 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!
β’ Oil analysis program steps
β’ Establish the sampling frequency (considering machine and oil age β both are moving targets, readjustments required) β’ Determine the cleanliness target of oil sample β’ Ensure proper sampling methods and techniques β’ 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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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 .
Lubricant replacement
β’ Condition based and time based lubricant replacement information are part of lubrication chart
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November 1, 2016
P08 Lubrication Management, CC Maintenance, 2016-11-14
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Agenda
Lubrication chart Lubrication routines Lubrication performance indicator
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November 1, 2016
P08 Lubrication Management, CC Maintenance, 2016-11-14
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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-Π‘Π1 302-Π‘Π1 361-AD1.M1 361-MD2.M1 361-MD4.M1
Auxiliary Drive Gearbox Auxiliary Drive Gearbox Pump YΠ Π£-800/ 400 Pump YΠ Π£-800/ 400 Pump YΠ Π£-800/ 400 Pump YΠ Π£-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
Lubrication routines
Process flow
Equipment physical location
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November 1, 2016 P08 Lubrication Management, CC Maintenance, 2016-11-14
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Lubrication routines
β’ Lubrication routines are check list developed to help lubrication technicians to apply in systematic way the required activities
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November 1, 2016
P08 Lubrication Management, CC Maintenance, 2016-11-14
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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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November 1, 2016
P08 Lubrication Management, CC Maintenance, 2016-11-14
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Walk by inspection β lubrication related topics
β’ Lubrication related topics must be included in the walk by check lists: β’ Housekeeping β’ Inspections β’ β’ β’ β’ β’ β’ β’ β’ β’ β’ β’ β’ 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
November 1, 2016
P08 Lubrication Management, CC Maintenance, 2016-11-14
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Walk by inspection β topics selection Operating manuals
Source: SEW and Siemens Flender Operating manuals
Experience 28
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 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 .
Lubrication performance indicator
Oil Consumption Ratio (OCR) β’ KPI measuring and evaluating the overall lubrication situation / performance of a plant, tracked on yearly base ππππππ‘ππ£π πππ ππππ π’πππ‘πππ ππΆπ
= πππ π‘πππππ πππ πππππππ‘π¦
β’ only volume of oil installed over 5 liters shall be taken into consideration. β’ 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
November 1, 2016
P08 Lubrication Management, CC Maintenance, 2016-11-14
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Lubrication points inventory
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Centralized Lubrication Systems
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November 1, 2016 This document contains proprietary information which shall not be used and disclosed without Omya explicit written authorization .
Lubrication Activities β’ Revision β’ Simple activities such as oil and grease levels β’ Proactive tasks for hidden failures (centralized systems) β’ Simple activities to test the function of automated systems β’ Measure of wear in bearings roller elements (during the grease change) β’ Inspection of lubrication systems which are only accessible in a stopped state of the machinery (e.g., pipes for bearing lubrication in separators) β’ Cleaning β’ Activities related with housekeeping to keep machinery neat and with appropriate cleanliness β’ Cleaning activities must be scheduled to be performed without putting at risk the personnel safety
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November 1, 2016 This document contains proprietary information which shall not be used and disclosed without Omya explicit written authorization .
Lubrication Activities β’ Application β’ Grease relubrication in motors and bearing houses β’ Sampling β’ To perform oil change in base on condition β’ Activities to draw an oil sample in order to perform field test as well as routinely laboratory oil analysis β’ Change β’ Oil changes by frequency. β’ Small equipment with low probability of failure and impact (screw conveyors, hydraulic couplings, etc.) β’ Filtering β’ Filter critical equipment ( main speed reducers) in a regular basis or according with the oil analysis results
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November 1, 2016 This document contains proprietary information which shall not be used and disclosed without Omya explicit written authorization .
Questions?
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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 .