Efficient Plant May 2019 - 24

feature | lubrication strategies

When taking samples for oil
analysis, always pre-flush
sampling equipment and
draw your samples from the
same spot, using the same
procedure and equipment
each time.

Contributing editor
Ken Bannister is
co-author, with Heinz
Bloch, of the book
Practical Lubrication
for Industrial Facilities,
3rd Edition (The
Fairmont Press,
Lilburn, GA). As
managing partner and
principal consultant
for Engtech Industries
Inc., Innerkip, Ontario,
he specializes in
the implementation
of lubricationeffectiveness
reviews to ISO
55001 standards,
asset-management
systems, and training.
Contact: kbannister@
engtechindustries.com
or 519-469-9173.

interpretation of data. This, in turn, can
lead to poor decision-making and mistrust of PdM technologies.
S Strive for accuracy and consistency in data collection. Always take
the sample data from the same test
point(s) under the same operating
conditions and ensure sampling is
scheduled in a timely and consistent
manner to develop accurate trends.
S When an imminent failure is
successfully predicted, act immediately to
minimize downtime and loss of service.
The theory behind successful PdM is
inherently simple: Take sample data from a
single or series of collection points in an engineered
consistent manner, trend the results, and take immediate remedial action once pre-set control limits are
breached.

RAMP-UP APPROACH
As with all management-program launches, using
an engineered incremental ramp-up approach to
implementation will better guarantee success due to
the more finite degree of program manageability. The
following three steps depict a typical PdM change
journey moving from a reactive environment. Note
that Steps 1 and 2 are interchangeable and often determined in conjunction with one another:
1. Choose a suitable pilot. The first step in manageability requires the selection of a suitable pilot to commence
the PdM program. A typical pilot can include:
S all equipment located within a designated floor,
room, physical area
S a type or group of similar equipment (pumps, compressors)
S designated manufacturing line
S designated equipment piece.
Pilot assets are mainly chosen as a result of localized high-failure rate requiring immediate attention,
but can be chosen because they have a reliable work
history archive, are convenient, allow easy access, or
are easily adaptable to the chosen PdM method or
tool to be used.
2. Choose a suitable PdM method or tool. The choice
of suitable methods or tools will often be determined

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by immediate need, budget, or legacy. When making a
choice, document the reasoning behind it and the
expectations it should fulfill. There are several PdM
tools available to the lubrication technician. Here are
pros and cons of the most popular choices:
S Fault-code analysis (FCA) is the simplest and least
expensive PdM tool. FCA is a methodology for identifying equipment failure or faults by setting up a coding
system tracked on the completed work order. The
process is greatly facilitated by setting up a computerized maintenance management software (CMMS) or
enterprise asset management (EAM) system to record
and report on the failure codes. This will allow you to
easily identify repeat or cyclical failure incidents.
The FCA method is also excellent for checking the
effectiveness of the preventive-maintenance approach.
If the task does not include preventive action for the
failure type, then it must be revised. If the task is set
up to prevent the failure, then the task schedule must
be revised to prevent failure before it occurs. This
method is inexpensive to introduce and very effective,
but relies heavily on the discipline to code all failures
and proactively pull reports on a regular basis.
S Wear-particle analysis (WPA), or oil analysis, examines the condition of the lubricant(s) used in moving
equipment. Oil is sampled on a regular basis and sent
to an approved laboratory to perform tests for additive
depletion and wear-particle inclusions.
In turn, the laboratory delivers a diagnostic report
on the sample, complete with recommendations.
Likened to a medical blood test, sampling and testing
a machine's oil will indicate when to change the oil,
based on its condition and whether undesirable wear
metals or other indicating elements are present. By
understanding the working conditions, laboratory
technicians can accurately diagnose any impending
machine problems.
Inexpensive to administer, the sample quality relies
heavily on acquiring the sample in an engineered,
consistent manner on a regular basis. This program
is easily set up within the PM work-order system.
Working with the laboratory to set up sampling techniques and hardware requirements will significantly
reduce the risk of collecting poor samples. Here are
some basic tenets:
+ Sample when machine is running under load.

MAY 2019

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Efficient Plant May 2019

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