Machinery Lubrication magazine published by Noria Corporation
Issue link: https://www.e-digitaleditions.com/i/1189076
24 | November - December 2019 | www . machinerylubrication.com Novelis The Novelis plant in Terre Haute, Indiana, is an aluminum-rolling facility. When two of its staff members attended a machinery lubrication training course, it sparked the mill's journey to transform its lubricant storage and handling practices, which were contributing to major equipment failures. Oils and greases had been stored every- where and in all types of containers. Milk cartons were even utilized as dispensing containers. By disposing of 1,200 gallons of waste oil and 1,200 pounds of grease, as well as 45 empty barrels, totes and kegs, the plant freed up 10,000 square feet of storage space. A list of necessar y lubricants was compiled. Those no longer needed were discarded, while the others were organized into a central storage area. Eventually, the mill was able to consolidate from 50 different oils and greases to 19 lubricants, and from 10 vendors to two suppliers. A new lube room also allowed better control of the storage climate. Previously, some bulk lubricants had been stored outdoors, exposing them to moisture, debris and a wide range of temperatures. Sealable and refillable containers were procured, along with filter carts and bulk storage with filtration, to help combat this problem. A filtration standard was then established to ensure lubricant integrity. A culture change helped all employees understand that hydraulic oil leaks were no longer acceptable. is resulted in a 75 percent reduction in leaks in just one year. By keeping the hydraulic oil clean, cool and dry, the oil's service life also increased. Operational checks of the hydraulic systems have been implemented to alert the plant when a filter needs to be changed or when temperatures rise too high. Air-cooled heat exchangers were installed to prevent water from entering the systems. Adding desiccant breathers to the reservoirs has also helped to keep out moisture. Finally, an audit was conducted to create a lube point list. With this list, a task-routing tool was used to catalog each lube point with a schedule, specific lubricant and necessary practices for the task. e tool also allows the schedule to be adjusted based on calculations that can identify the proper amount and timing for grease applications. e results have been significant cost savings in oil and grease expenses. Resolute Forest Products A few years ago, the Resolute Forest Products' Saint‐Felicien pulp and paper mill in Quebec, Canada, launched an initiative to increase the reliability of its entire kraft mill. e goals included improving the lubrication program and lube room storage and handling practices. Before the modifications were made, lubri - cant drums were placed on the ground, with some on racks to fill containers that had no identification. Four filtration units were used for any type of oil. Tools and other items were 2019 LUBE ROOM CHALLENGE Honorable Mentions In the old lube room at the Novelis plant, oils and greases were stored everywhere. BEFORE The new lube room incorporates bulk storage with filtration, filter carts, and sealable and refillable containers. AFTER Before modifications were made to the Resolute Forest Products' lube room, oil drums were placed on the ground, while tools and other items were stored in old cabinets with no identification or organization. BEFORE