Machinery Lubrication magazine published by Noria Corporation
Issue link: http://www.e-digitaleditions.com/i/520842
www.machinerylubrication.com | May- June 2015 | 39 Contamination Control This strategic element is perhaps the most important part of a proactive lubrication program. It doesn't work independently of the other factors mentioned here, but it is a requirement in most of the lubricant's life cycle. Contamination control refers to all prac- tices related to lubricant cleanliness. There are three important steps to consistently maintain clean lubricants: 1. Set a specifi c and verifi able target cleanliness level for each machine based on criticality and machine contaminant sensitivity. 2. In order to achieve the selected target, fi rst modify machine and maintenance practices to restrict contaminant ingression. Next, select fi ltration to remove and control contaminant levels within the target. 3. Frequently monitor contaminant levels to confi rm that cleanliness is stable and well within the target. In addition, do not forget about grease. Although you may not be able to fi lter or dry it, you can prevent grease from becoming contaminated. Some grease contamination can also be monitored through lab analysis. Lubricant Analysis How can a process be controlled if it is not measured or moni- tored? Oil analysis is an excellent tool for monitoring the oil and machine condition. Its purpose is to confi rm the lubricant's quality and type, measure the lubricant's health/condition, esti- mate the lubricant's remaining useful life, identify and measure contaminants and abnormal wear, fi nd root causes of failures, and support the optimization of lubrication intervals and other maintenance practices. An effective oil analysis program includes three primary stages: program design, program setup and fi eld implementation/contin- uous improvement. Program Design The oil analysis program should be designed according to specifi c targets or goals. Machines to be sampled, laboratory selec- tion, test slates, limits, sampling frequencies, interpretation of results and corrective/proac- tive actions are the leading factors to defi ne at this stage. Program Setup This stage involves making the necessary machine modifi cations for appro- priate sampling procedures, setting up the oil analysis program with the selected laboratory, and providing the required training and tools for those responsible for oil sampling and interpreting lab reports. Field Implementation and Continuous Improvement Once the resources have been provided, it is time to implement the program. This includes taking oil samples properly, documenting the process and sending samples out for analysis. When the results are received, they must be interpreted so proactive/corrective actions can be taken. A periodic analysis of the program is also needed to verify its adequacy and opportunities for improvement. Lubricant Disposal Once the lubricants and contaminated materials (like oil fi lters) have reached the end of their useful life, they must be disposed of in a proper manner according to local regulations and corporate poli- cies. The goal is to protect the environment from potential contamination while maintaining safety at your facility. Controlling lubricant leaks is also important for operating machinery as well as for safety and environmental protection. An effective program for leak detection and control should be in place. This type of program offers many benefi ts, such as decreasing lubricant consumption, minimizing safety risks, reducing the risk of lubricant starvation in the machine, controlling environmental contamination, achieving higher productivity levels and lowering costs. Program Implementation Management A lubrication program consists of different elements that interact with a common purpose. It is necessary to manage all of these factors to keep them working effi ciently. Among the essential elements for a reliability-centered lubrication program include: • Top management support, teamwork and communication • A motivation and rewards program • Involvement of affected areas within the organization such as human resources, purchasing and production • Appropriate training for all involved personnel • Clear, detailed procedures and work instructions • Effective records and proper handling of information • Product identifi cation • Safety procedures • Environmental awareness • Applicable regulations, standards and corporate policies • Metrics and key performance indicators (KPIs) Properly combining these elements will allow you to achieve an effective and rewarding program implementation. About the Author Alejandro Meza is a senior technical consultant with Noria Corpora- tion. He has more than 20 years of experience in the lubricant industry, technical services, quality assurance, training, consulting and devel- opment in the United States, Brazil, Mexico and the Americas region. Contact Alejandro at ameza@noria.com. ML BOOKSTORE 40% of lubrication professionals say training of personnel is the most important factor for continuous improvement of a lubrication program, based on a recent survey at MachineryLubrication.com.