Machinery Lubrication magazine published by Noria Corporation
Issue link: https://www.e-digitaleditions.com/i/325287
14 | May - June 2014 | www.machinerylubrication.com Oil Analysis Initially one of the strongest parts of its lubrication program, Sinclair's oil analysis program is now even more robust. During the implementation stages of the new program, the refinery was able to add to its onsite laboratory equipment arsenal. The in-house lab can perform a wide array of screening tests for new oils and provide information on in-service oils. Onsite capabilities include testing for viscosity, elemental analysis, particle counts, water content, acid number and analytical ferrography. Laboratory personnel are trained on all lab equipment and can accommodate urgent samples with quicker turnaround times than shipping a sample to an offsite lab. Since the lab currently is unable to handle all samples, Polaris Laboratories is employed for excep- tion testing and less critical applications. By using both onsite and offsite labs, Sinclair is able to check both labs for accuracy and ensure the results mirror each other. All machines and oils do not undergo the same array of tests. Each oil and machine has its own customized test slate and target levels for contamination and moisture. The test slate takes into consideration the contaminant severity and failure modes for each machine type. For instance, the target cleanliness level for the main gear oil is 17/15/12. However, the target for turbine oils is 15/13/10. This is due to gearboxes being able to handle higher amounts of contamination before excess wear is generated. The same methodology is used for routine oil analysis test slates for each machine type. Similar to the test slates, the alarms and limits for the testing methods have also been customized. There are alarms and limits for all three sides of the oil analysis triangle: physical properties, contamination and wear debris. By monitoring all three factors, the refinery is able to ensure lubricant and machine health and that all contamination control devices are working properly. Of course, the best lab equipment and testing strategies are wasted if you aren't able to obtain a good, consistent sample. This is why Sinclair installed sample valves on all the equipment in its oil analysis program. These sample valves enable the refinery to take clean samples from turbulent zones within the machinery. Lube techs have been trained in the operation of these valves and the proper way to extract a sample from machinery. This has increased the value of the oil analysis data and allowed values to be trended much more easily. Each sampling tactic has its own detailed procedure that breaks down step by step how to attach the sampling device, flush the tubing and take the sample to ensure the maximum amount of data with the minimum amount of data disturbance from outside sources. These procedures are housed in the master lube program file and are provided in paper form to accompany lube techs during their sampling rounds. Sampling rounds are performed monthly on critical machines and quarterly on other equipment. If any alarms or limits are tripped on the test slate, secondary samples are obtained to confirm the results. Once the results are verified, action is taken to correct the issue. The correcting action can range from changing the oil to simply filtering the oil using a filter cart. Once an action has been taken, another sample is obtained to ensure the issue has been corrected. Contamination Control Contamination control at the refinery had been a weakness, but now contam- inant ingression is in check. By modifying machines and training its personnel, Sinclair has greatly reduced the amount of contamina- tion entering its lubricants through lubricant application or normal equipment operation. Operators and mechanics have learned the importance of contamination control and how they can affect a machine's life by something as simple as leaving the breather plug off a machine during operation. The need for change was recognized and well-re- ceived. New devices have been implemented to aid in the exclusion of contaminants, including desiccant breathers, quick-connect fittings and external level gauges. These devices work hand-in-hand with filter carts to decontam- inate new oils being delivered as well as oils that are in use. The filter carts are designated for a single lubricant in order to reduce the risk of cross-contamination between dissimilar fluids. They also employ CoVer story viscosity testing can be conducted onsite. Education is a vital part of making lasting change in any organiza- tion. The Sinclair refinery identified this as a key area of focus early in its lubrication program development. The training it offers is based on an individual's role within the program. Operators and mechanics are expected to complete half-day lubrication awareness training that outlines the fundamentals of lubrication, lubricant health, lubricant application and contamination control. These courses are provided in-house and based upon the shift schedule. Currently, 10 courses are offered with more planned in the future. Lubrication technicians, laboratory personnel and engineers are required to attend a three-day seminar relating to their function in the program, such as oil analysis, lubricant application or machine-specific oil sampling. The lubrication program manager must complete advanced machinery lubrication and oil analysis courses. This advanced training is provided by Noria. Certification through the International Council for Machinery Lubri- cation (ICML) is highly encouraged. The refinery also subscribes to magazines and newsletters to stay up to date on industry best practices and technologies. This emphasis on education has helped the facility successfully achieve a culture change. Although changes initially were met with skepticism and opposition, by providing training and demonstrating the benefits of the new equipment, accessories and practices, this skepticism was eroded and opponents were won over for continued support of the program. Achieving a Culture Change