Machinery Lubrication magazine published by Noria Corporation
Issue link: https://www.e-digitaleditions.com/i/1080534
www . machinerylubrication.com | January - February 2019 | 11 not be done overnight. A long-term plan was created, with completion not expected until 2020. Along the way, the action plans were updated continuously. e first phase of the plan spanned from 2016 to 2019. As the program progressed, this time frame was extended an additional year. e most important actions of 2017 were to establish a centralized lubrication unit and to purchase dedicated, sealed and color-coded lubricant transfer containers. Establishing key performance indicators (KPIs) was also a priority. For 2018, the main focus was on developing well-written sampling procedures and affixing minimess valves for sampling purposes. Lubricant Storage and Handling YCC's cement production line consists of five sections: the crusher, raw mill, kiln, cement mill and packing house. Every section had been managing its lubrication program individually. Each section also had its own lube storage, which resulted in five storage areas in one production line. All these storage areas were located in an open location with no filtration or breather system. Storing lubricant drums in the open area exposed them to cement dust and high atmospheric temperatures, which normally would rise to 131 degrees F during summer. ey also utilized a single-handle pump for different types of lubricants. In addition, the lubricant transfer containers and funnels used for top-up tasks and filling small gearboxes with oil incor- porated an open design. Employing these types of transfer containers led to the ingression of dust during the filling process. Moving to best practices for lubricant storage and handling was done in two phases. e first phase involved the lube room. Among the most important practices for this room were keeping all lubricant drums in a closed environment with no dust ingression and placing three closed cabinets inside the room for storing oil transfer containers, grease guns and other accessories. YCC invested in color- coded oil transfer containers that were sealable and dedicated to one type of lubricant to mini- mize cross-contamination and to ensure the filled oil in a component would be clean. e lubricant identification system (LIS) developed by Noria Corporation was applied with a minor modification to meet Yanbu Cement's requirement for a color-blind cate- gory. e system consists of different sections to indicate the lubricant, product name, viscosity grade and base oil type. Each type of lubricant also has its own color and shape. For example, a red label with a heart is used to identify a VG 320 mineral oil, while black with a clock shape is used to specify a VG 46 hydraulic oil. e goal of the second phase was to attain lubrication excellence in terms of lubricant storage and handling. A centralized lubrica- tion unit was key to these efforts. e 40-foot container has two internal compartments EQUIPMENT NO. OF EQUIPMENT CAPACITY LITER COST TOTAL REPLACEMENT COST SAVINGS IN 2017 Hydraulic Cooler One 3,300 liters $1.60 $5,280 Rotary Kiln Gearboxes Two 1,800 liters $1.81 $3,258 Rotary Kiln Gearbox Two 680 liters $1.83 $1,244 Cement Mill Gearbox One 2,500 liters $1.73 $4,333 Vertical Mill Gearboxes Two 7,000 liters $1.73 $12,133 Support Roller Bear ings of Rotary Kiln Five 960 liters $1.83 $1,757 Pan conveyor Gearbox One 415 liters $1.77 $733 Total $28,738 Contributions of the oil analysis program in maintenance cost savings for 2017. Oil drums were stored along a pathway and exposed to cement dust and high atmospheric temperatures. The new centralized lubrication unit consists of two storage and handling compartments and is designed with an external dispensing station for emergency use during night shifts. During the rainy session, water often collected on top of the oil drums.