Folks,

There is a very interesting article about improving equipment performance through good lubrication practices by Jim Crissman and John Gobert of Port Arthur Refinery (Texas), Valero Refining Co., in Petroleum Technology Quarterly (Q3 2006), ISSN 1362-363X, Cranbeth Allen Publishing Ltd. UK.

It gives data and charts showing a dramatic reduction in no. of failures (from 541 in 2000 to 277 in 2004). The cost reductions are about $1m pa. Similar figures for steam turbines etc. What is interesting (to me) is that there are actual numbers quoted, not jusr percentage changes.

One observation on contamination control caught my attention. Quote No one will ever see a 55-gallon steel drum to store lubricant at the facility Unquote.

There is quite a long discussion on the managemnt process, commitment, training, partnership with lub vendor, use of related PdM techniques etc. Well worth reading, in my view.

I have always believed that keeping the equipment clean, dry and properly lubricated contributes to eliminating more than half of all machinery failures. Here is some hard data in support.

This message has been edited. Last edited by: Vee,

Sounds interesting.

Is this article available free on-line by any chance?

Pete,
I dont know, but try their website. I have the e-mail address of the authors if that does not work. Send me a note at eml@effective-maintenance.com and I will send you their address.

I was asked why do we need a lubrication program when we already have a vibration program in place. My subsequent thought led me to think that implementing a proper lubrication program should be the first priority before embarking on vibration program. This leaves vibration to detecting problems which are not related to lubrication eg misalignment, unbalance, etc. Anybody agrees or disagrees?

This message has been edited. Last edited by: Josh,

Lubrication is your #1 program and everybody's! No exception. Equipment rebuld, QC/QA and setup are next and alignment/setup to inculde piping as well as shaft-to-shaft alignment. Then comes PdM and PM --- or, this is the way I see it.

With all else in place; PdM becomes very hi-priority. It will lead to planned scheduled maintenance extending MTBF.

I would add to that: it is the "simpliest" and least expensive one to put in place with instant pay-off

Steven,
At the risk of disagreeing with you, may I suggest that keeping equipment clean is the simplest and cheapest, followed by keeping it dry, then followed by lubrication? But there is no doubt that good lubrication provides the best results of all.
Let us not forget that keeping bolts tight and things properly aligned is quite important. Finally rotating machinery has to be kept well balanced.
If we did all of these well, we can eliminate 60-70% of failures. A further 10% will come with good PM compliance, even if the PMs themselves are not perfect. Can you imagine what that will do our costs and resources? We will have people to do RCAs, KPI development, Audits etc., not be chasing our tails all the time.
To do all this properly, our people must be fully on board, skilled, motivated and 'thinking' reliability. A 'people focus' can deliver great results.
Only after all this is in place do we need to invest in more sophisticated methods e.g., RCM. Unfortunately the glamour lies with gadgets and most people are searching for silver bullets. To fill this market, there is an army of consultants and vendors who will keep the economy going - not necessarily our machinery!

Vee I don't agree at all, my first approach is: keep the equipment clean and lubricated

A lubrication program does not mean we have to make "expensive agreements" with all sort of vendors and similar things brewed by people who don't know the difference between brake fluid and coca cola, but

1) supplying the right amount of lubricant (not too much nor too little)
2) using the proper lubricant (and don't get carried away by vendor marketting stuff) For a chain drive I would use SAE 10W30 or SAE 30, but not SAE 120 EP gearoil
3) Don't take an empty can that have been lying around to fill a gearbox
4) Never let a drum stand upright, (in rain and with no cap)

Al these things come back to cleanliness, I have not seen the mechanic/technician who adore working on equipment that is dirty, shaking or leaking. Normally they are watching these things from a safe distance

Steven,

I think we are in violent agreement and you have misunderstood my comment. I am all pro-lub too!

I would be a disaster in politics

Vee, the basics, just as you outlined must be set first, without that we could come with tons of silver bullets, and still have a lot of "unexpected" breakdowns.

You are right we should number cleanliness as number one

Dirty equipment will scare away operators and techs, and people will do hasty jobs, just to get as soon as possible out that area.

The will not be looking at lose nuts, proper alignment, proper lubrication, or small improvements that are essential to provide quality jobs.

quote:

Vee I don't agree at all

OOPS.. should be disagree

How to keep equipment clean & dry if the plant is in a tropical climate & nearby a iron ore smelting plant with the iron dust flying around?

I heard Jap plants do 5S for their plant areas for this purpose. Do you do the same or equivalent for office & plant areas?

As a man who has been involved in vibrations at least for the last twenty five years, I am a firm believer of "lubricant cleanliness first!".

Unfortunately our engineering training is not tailored towards that. (At least 30 yrs ago that is how it was.) In my seminars, I always ask this question: "Would you take your boy to a doctor who has had only 3 hrs of training in blood, the essential fluid of the body" The answer of course is "No!". Then I say, "But us mechanical engineers are trained in oil and lubrication for three hours in the machine elements class and you let us mingle with your machines?"

I hope training is better these days. It took Jim Fitch (Noria) a few hours to make a believer out of me.

Regards
Ibrahim H Caglayan, PhD
Ankara TURKEY

Ibrahim,
Well said; one would think it would appeal to common sense, but as we all know, how common is common sense? One of the reasons for the success of TPM is the great emphasis it place son cleanliness and discipline.

Did you get a copy of this article ?

quote:

Originally posted by electricpete:
Sounds interesting.

Is this article available free on-line by any chance?