POWER October 2014 - 18

LMP should include continuing education
and training; equipment and application
surveys; knowledge of the product, equipment,
and lubrication storage conditions;
and a proactive maintenance program that
includes oil analysis testing.
Begin with the End in Mind
The main reasons for setting up an LMP
are to prevent unplanned downtime from
equipment failure; increase output capability,
profitability, productivity; and reduce
the carbon footprint. An LMP should
define an objective that " begins with the
end in mind. "
A program capable of defining and
controlling the entire lubrication process
proactively through conditionbased
monitoring (CBM) techniques will
ultimately increase productivity and reliability.
The first tenet in an LMP is to
understand that lubricants are application-specific.
Knowing how to properly
use the lubricant is just as valuable as
the lubricant itself. Poor lubrication
techniques and processes will likely lead
to shortened equipment life and unforeseen
outages at the worst possible time,
such as in the middle of the peak summer
season.
Equipment and application surveys are
the next step in an LMP to provide facilities
a clear picture of existing lubrication
practices and maintenance procedures.
The initial plant survey and lubrication audit
becomes the foundation for the entire
LMP and sets expectations.
Implementation of CBM will compare
historical data and trends against engineering
facts to detect, highlight, and
analyze potential problems before they
occur. The key to this approach is that
once the root issue has been defined,
corrective action can and should be taken
when it is most advantageous for the
user. Oil analysis is another part of the
baseline information included in an LMP
to help identify potential equipment concerns
and track trends following lubrication
changes.
In power plants today, parameters are
far less predictable and static than in the
past due to frequent load changes resulting
from solar and wind generation. Given
that reality, how can an LMP and training
help staff control for those variations
in operating conditions? Knowledgeable
plant personnel trained in lubrication fundamentals
will be able to identify a potential
problem rather than experiencing
equipment failure.
It is not enough for management to
agree with implementing the correct lubrication
practices. Rather, all staff operating
and managing the equipment
need lubrication knowledge. Training will
be even more important in the future as
experienced personnel retire, and as multifunctional
or cross-trained personnel
perform different functions.
Lubrication Planning and
Predictive Maintenance
Every facility plans downtime for routine
maintenance, equipment rebuild, plant
expansions, and other reasons. Planned
downtime is designed to ensure equipment
is maintained and production goals
are met. Lubrication-related downtime can
be caused by:
■ Low-grade/commodity lubricants
■ Under- or over-lubrication
■ No lubrication
■ Using the wrong lubricant
■ Missed lubrication cycles
■ Excessive wear
■ Increased operational temperatures
■ Contamination of oils and greases
■ Seal damage
■ Compatibility problems
■ Leaks
These are just some of the problems every
facility can experience.
Planning is a key part of proper lubrication
management. There are three basic
types of maintenance: corrective (fix what
just failed), preventive (fix on a timebased
frequency whether it needs it or
not), and predictive (monitor the equipment
to see if the data shows that an item
is moving toward failure and make repairs
just before it fails).
Many successful companies are changing
to predictive maintenance programs,
focusing on oil analysis, vibration analysis,
thermography, and fluid and system
cleanliness to improve the reliability of
equipment. They can then perform maintenance
at the optimum time, rather
than on some arbitrary schedule. Paying
attention to monitoring the details
is measurement-driven and deploys data
analysis to make risk-informed decisions.
Proper lubrication practices not
only require knowledge but also a proactive
approach.
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Ask the Experts
Overall, lubricants make up a small portion
of O&M costs, but improper usage
and choosing the wrong lubricant affects
the bottom line and business operating
profits. Making sure that fundamental
lubrication practices are being handled
correctly has huge benefits over time.
If sustainable operations are the goal,
proper lubrication practices and an LMP
can help achieve a reliable, cost-effective
plant operation.
Making a big decision can be easier
with the help of a professional. Lubrication
is a specialty; becoming an expert requires
education and experience. Though
there are many distributors to choose
from, Hydrotex is one company that offers
LMPs and on-site training presented
by knowledgeable lubrication consultants.
The key to success is finding a company
that not only can recommend the right
high-performance lubricants for the applications
but also can recommend reliability
solutions. Focus on the overall solution
tailored to fit your goals. ■
-John Bickley, PE is the vice president of
sustainable utility sales for Hydrotex.
18
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POWER October 2014

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