Oil analysis implemented 11 2001

Not only can you reduce maintenance cost and machinedowntime, but if implemented meticulously, maintenance and operations personnel will develop a passion for continuous improvement.. Le

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 DuPontWestinghouse Savannah River Co (currently)

(803)557-6352 mike.weiksner@srs.gov

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 meterdirected activities?

• Do you know how many types of oil are used atyour facilities and if your oils are stored and

Step 2 Utilize Maintenance Optimization to determine

“best practices” and for justifying maintenance program changes.

• This step allows you to assess your overallmaintenance practices for a given machine,perform a cost analysis to calculate the savings forprogram implementation, and document a

technical baseline for the actions that are taken

Work Management

Proactive/Predictive Maintenance

Maintenance

Optimization

CAE

E-Mail Notification

Electronic Paging

The Maintenance Model

Application Program Interface

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 analysistraining and educate them in lubrication fundamentals.

Permit and encourage certification for those who desire it

• Learn about oil and lubrication, bring in theindustry experts

• Learn about proper sampling techniques andpractices

• Learn about oil contamination, the sources, thetypes and affects

• Learn about oil tests and testing instruments

• Investigate multiple companies who supply oilanalysis equipment

• Visit an oil analysis lab

Step 5 Purchase some oil analysis equipment.

• Provides relatively fast, consistent and repeatableresults

• Includes software that has ability to plot andtrend data, set and generate alarms, customizeand 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 thetype 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 beseparate from other technologies

• Need to purchase oil sample bottles and some labsample processing equipment (i.e sample shaker)

Step 7 Analyze and baseline several machine oil reservoirsfor 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 thoseinvolved in the program, and with experiencedmaintenance personnel

• Think about how the machine operates and themachine operating conditions

Step 8 Set machine target cleanliness levels and purchaseportable filtration equipment/components Establish the

practice of oil analysis and filtering on as many reservoirs aspossible

• Filtration of oil within reservoirs will achievetarget cleanliness faster and more effectivelythen draining and replacing the oil, or, draining,flushing the reservoir and replacing the oil

Furthermore, filtering significantly reduceswaste 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 activitiesand extend overhaul schedules Change oil onlywhen the condition of the oil no longer meets themachine requirements

• Consolidate your oils and reduce inventories

• Set up oil dispensing facilities to ensure clean oilused 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