Machinery Lubrication magazine published by Noria Corporation
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ML PUBLISHER Mike Ramsey - mramsey@noria.com GROUP PUBLISHER Brett O'Kelley - bokelley@noria.com EDITOR-IN-CHIEF Jason Sowards - jsowards@noria.com SENIOR EDITOR Jim Fitch - jfitch@noria.com TECHNICAL WRITERS Wes Cash - wcash@noria.com Alejandro Meza - ameza@noria.com Bennett Fitch - bfitch@noria.com Loren Green - lgreen@noria.com Michael Brown - mbrown@noria.com Garrett Bapp - gbapp@noria.com CREATIVE DIRECTOR Ryan Kiker - rkiker@noria.com GRAPHIC ARTISTS Patrick Clark - pclark@noria.com Josh Couch - jcouch@noria.com Greg Rex - grex@noria.com ADVERTISING SALES Tim Davidson - tdavidson@noria.com 800-597-5460, ext. 224 MEDIA PRODUCTION MANAGER Ally Katz - akatz@noria.com CORRESPONDENCE You may address articles, case studies, special requests and other correspondence to: Editor-in-Chief MACHINERY LUBRICATION Noria Corporation 1328 E. 43rd Court • Tulsa, Oklahoma 74105 Phone: 918-749-1400 Fax: 918-746-0925 Email address: editor@noria.com MACHINERY LUBRICATION Volume 17 - Issue 1 January-February 2017 ( USPS 021-695) is published bimonthly by Noria Corporation, 1328 E. 43rd Court, Tulsa, OK 74105-4124. 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Noria shall not be liable for any inju- ries, loss of profits, business, goodwill, data, interruption of business, nor for incidental or consequential merchantability or fitness of purpose, or damages related to the use of information or recommendations provided. Machinery Lubrication inspections. When this happens, reliability is marginalized and maintenance budgets are wasted. As a review, Inspection 2.0 can be summa- rized by the following tenets: • Culture of reliability by inspection (RBI) • Advanced, tactical inspector skills • Machine inspection readiness with inspec- tion windows • Advanced inspection tools and aids • Inspection protocol that is aligned to failure modes • Early fault and root cause emphasis • Origin of more than 90 percent of unsched- uled work orders Tactical Inspections Are Purposeful Inspections With the exception of taste, our four other senses can be effectively used, individually or collectively, for frequent tactical inspections. The concept of tactical inspections is inspection with a purpose. It is not just going through the motions down a checklist. For instance, you don't just look at oil but rather examine it for specific reasons. The inspectors must know the reasons. This examination seeks to answer several questions about the health of the oil, the health of the machine and the state of the oil to protect the machine from premature failure. Inspectors should be hunting for something that often is inherently hard to find or notice. The machine, through the oil, will telegraph a signal. The strength of that signal increases as functional failure approaches. (See my article in the July- August 2016 issue of Machinery Lubrication for a discussion on the P-F interval.) Early fault detec- tion is the objective and is best achieved by tactical inspections. I'll talk about how this can be done visually. There are no scientific instruments, sensors, algorithms or computers that can outperform the eyes and mind of a human inspector. To get the most out of your sense of sight, you need to know what you're looking for. Start by constructing a list of root causes and symptoms. Inspection seeks to find critical states of the oil that cause failure (roots of failure) or reveals active failure in progress (symptoms). As an example, for a diesel engine oil this might be the oil level, soot dispersancy, fuel dilution, coolant contamination and sludge. For an industrial gearbox, you might want to look for a wrong oil level, dirty oil, water contamination, excessive wear debris, aerated oil and an overextended oil drain. By knowing the questions, you can work backward to define the tactical inspection protocol that provides the answers. This is a two-step process: 1. Causes and Symptoms (C&S) — For every machine or system component, list what is important to find (ranked by importance). 2. Critical Occurrence States (COS) — For each item on this list, create an inspection protocol that would reveal the state of occurrence (the earlier the better). A Well-trained Eye Using the industrial gearbox example, let's rank the causes and symptoms guided by past experi- ence and help from technical advisors. After each item on the following list are one or more ways to enable earlier alerts by visual inspection. 1. Wrong Oil Level: Level gauge inspections 2. Dirty Oil: Exposed headspace (vents, breather, hatch, etc.), filter in bypass, rapid rise in the filter pressure differential, entrained air problems, sediment in bottom sediment and water (BS&W) bowls, blotter test sediment It's far better to do 100 frequent "screening" inspections than one monthly or quarterly laboratory analysis.