Machinery Lubrication magazine published by Noria Corporation
Issue link: https://www.e-digitaleditions.com/i/1103301
ML www . machinerylubrication.com | March - April 2019 | 49 "One of the things I looked at — basically the low-hanging fruit where we could get the best bang for our buck — was lubrication," he noted. "I just saw a ton of things that we could easily fix with relatively few dollars." For instance, Hunt found there was no consistency in the selection of lubricant types or brands across all machinery. Fluid sampling was nonexistent, so oil changes were based on the calendar rather than the condition, leading to inefficient usage and labor costs. Furthermore, most of the oil inventory was stored outdoors — a less than ideal situation, given the Arizona heat and dust storms. Covered cages offered little more than shade. "Everything was outside or tucked into various corners of the maintenance shop," Hunt added. Even the sealed oil drums were no match for regional dust storms. "When a sandstorm or haboob comes through, it's just a wall of dust, and you can't see 10 feet in front of you," Hunt said. "All those OEM breathers were not much more than insect screens because they only go down to 40 microns, the size of a hair. But we've got contaminants going down to below 4 microns, and it's mainly all silica from the sandstorms." Hunt applied his expertise to conduct an audit of conditions at all four plants and mapped out some recommendations. He even touched base with the local representative from a reli- ability equipment vendor to conduct a courtesy assessment, and that vendor's findings corrob- orated his own. is was when he noticed his ICML certification bolstered his position. "e training and certification provide a means to be an authority on the subject," Hunt noted. "And with the reliability vendor matching up to what I was saying almost word for word, everything just clicked. Between the two of us, we were able to get the ball rolling." Clean, Dry and Contaminant-free Since then, Hunt has established a clean and organized lubrication storage room at PSWTP, bringing all drums and containers indoors. is room includes color-coded asset lubricant requirements, containers and, perhaps most importantly, climate control. He also has identi- fied and documented bearing grease frequencies and volumes, and has been replacing the orig- inal desiccant breathers with 2-micron filters to combat the dust more aggressively. Having switched from a calendar- to condition-based schedule, Hunt now samples asset fluids for testing by a third-party lab. He believes the benefits of this new practice outweigh the cost. "External testing has greater benefits than just lowering oil and labor costs," Hunt explained. "We can now understand our machine health. We believe we can get at least 25 percent more useful life out of the assets by paying attention to lubrication needs." Addressing the Culture Just because Hunt initiated these improve- ments at PSWTP did not mean his budding lubrication program would persist. He under- stood that sustained success would constantly face shifting priorities of municipal funding as well as the status-quo mindset among longtime colleagues and suppliers. ese culture issues can make it challenging to move forward, even with a lubrication champion like Hunt. One might expect a program that prolongs machinery life without sacrificing operational efficacy would be an easy sell when seeking funding and adherence, but Hunt frequently finds himself trying to bring his fellow workers and managers up to speed. "ere are a lot of factors involved in trying to get them to understand why we need to test the oil, why we need to put the breathers on, why we should have sample ports or why we should even sample the oil," he said. While certification is not required for everyone in the division, education has helped the decision-makers to work together toward lubrication excellence and made it easier for Hunt's recommendations to be funded and implemented. "e programs only work if managers under- stand what we're trying to do," Hunt said. "So, we're trying to secure best-practice training on all lubrication, where everybody in maintenance has to attend. Sometimes getting the same informa- tion from a complete stranger in a training class is better than getting it from your own team." It's not just managers who can benefit from training but also the hands-on personnel inter- acting directly with lubricants. "One time I was pouring oil into an asset with a transfer container using a single-use, disposable funnel," Hunt recalled. "e well tech watching me said, 'Here, use this funnel. It'll work better.' And he took a large, open funnel and rapped it up against his truck to knock the dirt from it. I said, 'Nah, I'll stick with my disposable.'" As new PdM practices are adopted, Hunt has discovered that it becomes easier to get manage- ment and other staff to follow the decisions being made regarding oil changes. "Our position with them is, 'We've gone to the training, and we're certified in doing it. is is what will get you the longest asset life,'" he said. More Certifications Equal Easier Expansion Fortunately, the City of Chandler does support training. "I realized the importance of good training years ago, and the need to continue learning and applying best practices is non-stop," Hunt added. "Everyone who touches lubricants needs to be trained and certified." In 2017, lubrication technicians from all four of Chandler's water facilities attended Noria Corporation's independent training course covering content from ICML's MLT I body of knowledge and then sat for the certi- fication exam. In addition, one of Chandler's certified senior mechanics based at the Ocotillo Brine Reduction Facility has accepted a role as a PdM technician to work with Hunt across all the treatment plants. With these newly certified personnel now involved with the program, Hunt anticipates smoother acceptance as he coordi- nates expansion of his PSWTP enhancements to Chandler's other water plants. "e cost of certification is best seen as an investment, because ICML is a recognized authority in lubrication," he explained. Hunt also recognizes that the economic impact could be substantial as his certified team expands these practices throughout all the plants, water wells and pumping stations. "e city has adopted a 50-year asset plan, while most of the machinery has an expected life of around 20 years," Hunt said. "If our lubrication program can extend the asset equip- ment five years, then we're only replacing it all once instead of twice in that 50-year time. If we can gain those five years just by doing better oil practices ... well, how much is a treatment plant worth, $150 million? We all know that lubrication is the most controllable thing you can influence." ML