Machinery Lubrication magazine published by Noria Corporation
Issue link: https://www.e-digitaleditions.com/i/756816
Solge Solge manufactures filtering machines at its site in Daegu, South Korea. With each machine undergoing quality testing, the company needed a clean environment to perform the tests. This would require improving its lube room. At the time, lubricants were not sealed and were contaminated by moisture and particles in the air. Among the many changes made included adding gauges to monitor oil levels, creating additional storage for lubrication tools and using stainless-steel material for storage tanks to help prevent corrosion. Desiccant breathers were mounted on top of the tanks to block moisture and particles, while a clear sight glass was positioned at the bottom to monitor the oil's condition. A large inspec- tion window was also placed on top of each tank for easy and convenient cleaning. To improve the oil cleanliness level, pumps and filters were installed on the tanks. Finally, a heater was employed to help maintain the optimal temperature during winter. Solge is now better able to control the contamination of its new oils as well as any oils treated by purifiers. Lubricants are fully protected from outside contaminants, which has allowed them to remain in good condition longer. Tennessee Valley Authority Paradise Fossil Plant The Paradise Fossil Plant, which is located on the west bank of the Green River in Muhlenberg County, Kentucky, produces more than 7 million megawatt hours of electricity per year. During construction of two of its generating units, a common oil-dispensing room was desig- nated and equipped to house and supply the different oil types required for all powerhouse equipment. The original oil-dispensing system featured 55-gallon metal totes arranged on a steel rack that was attached to a wall. The basic system was designed to allow each tote to be filled from a 55-gallon drum using a common pump. The common pump frequently was not flushed properly between use, which caused cross-contamination. Every tote had a trans- parent sight glass in front to indicate the internal oil level. However, the sight glasses quickly became discolored, resulting in unknown oil levels. A rubber hose was attached to the tote connection in the back and routed to a series of dispensing valves situated below the totes and in-line above a spill trough. This design provided easy gravity- fed oil dispensing into transfer containers but offered no internal oil filtration. The totes were not manufactured for desic- cant breather installation, so as air entered the totes, airborne dirt, moisture and contami- nants could easily pass into the system. The oil transfer process led to oily and slippery floor conditions, posing safety risks. The nature of the system's operation also produced unnec- essary clutter. When the system was disassembled, a residual buildup was observed in the bottom of each tote, which contributed to new oil contamination. In addition, some totes were not properly labeled, increasing the potential of using the wrong oil. When plant personnel attended a 2014 conference presentation on the best prac- tices for an oil-dispensing room, it became obvious that the plant had a great opportu- nity for improvement. After considerable research and deliberation, a new 55-gallon drum workstation was selected to replace the existing oil-dispensing system. Two worksta- tion dispensers were initially ordered for testing and evaluation. Shortly thereafter, 19 additional oil-dispensing workstations were purchased for a total cost of approxi - mately $100,000. With the new workstations, oil is dispensed directly from each new 55-gallon drum. The possibility of oil cross-contamination and particle buildup no longer exists. Desiccant breathers have been installed on each drum to minimize moisture and dirt intrusion. The workstation valves allow oil to be filtered and dispensed directly into smaller transfer containers or filtered back into the drum to improve cleanliness. Sight glasses are no longer necessary, as it is readily apparent when the oil level in a drum is low. The process for replacing drums and filling transfer containers results in fewer oil drips and spills on the concrete floor. Clutter and safety risks have been virtually eliminated. All workstations, drums and transfer containers are also prop - erly color-coded and labeled to reduce the possibility of using the wrong oil. This rehabilitation project has completely transformed the way lube oil is managed at the plant. The bright and freshly painted room now provides a clean and safe environment for storing and dispensing oil. The success of the project demonstrates how significant improve - ments can be achieved when operations, maintenance, engineering and vendors work together. COVER STORY 18 | November - December 2016 | www.machinerylubrication.com Before improvements were made (left), lubricants in the Solge lube room were not sealed and were contaminated by moisture and particles in the air. To block moisture and particles, desiccant breath- ers were mounted on top of the oil tanks (right). The new room is bright, clean and free of clutter. All work- stations, drums and oil containers are color-coded and labeled to reduce the possibility of using the wrong oil. Clutter was common in the old oil-dispensing room at the Paradise Fossil Plant.