My name is Terry Roehm, Rotating Equipment Specialist and today’s author for the BoilerRock Blog. I will be continuing the discussion on Lubrication Programs and the basics of a good program.
Part 1 of the overview for a lubrication program for rotating equipment discussed that it is one of the very important condition-based programs used to monitor the health of your rotating equipment. Condition based programs are used to assist the plant personnel with achieving the desired on-stream production rates of the process units while improving the safety for both the productions unit and the equipment itself.
Lubrication Programs Should:
o fit the site while providing ownership and accountability
o be specific and have measurable goals
o be well defined and detailed
o have management approval and backing
Rotating Equipment included in the Lubrication Program
Driven Equipment:
o Compressors / Blowers (Centrifugal, Screw, Reciprocating, Etc.)
o Fans (Fin Fans, HVAC, Process, Etc.)
o Pumps (Centrifugal, Gear, Reciprocating, Etc.)
• Drivers (Electric motors, Gas Turbines, Gearboxes, Steam Turbines, Etc.)
• Other Critical Equipment (Valving/Actuators, Wellhead Equipment, Etc.)
Included in the Lubrication Program
Activities should vary based on your site, the type of equipment and criticality, but the following are items that should be included in a high-quality lubrication program:
1) Identification of a lubricant champion (person in charge of the lubrication program that the site realizes has ownership and responsibilities to the program)
2) Identification of job responsibilities for the different aspects of the lubrication program.
3) Development of a training program for your lubrication program.
4) Identification of each piece of equipment that requires lubrication.
5) Identification of the lubricant required or each piece of equipment.
a) Consolidating the lubricants as much as possible
b) Identifying the correct lube oil level for equipment
c) Identifying the frequency and method of re-lubrication (oil or grease)
6) Development and maintaining lubrication program procedures.
7) Development of a record keeping system and maintaining of the records in an appropriate CMMS.
8) Routine site audits of your lubrication program.
9) Establishing requirements for your lubricant supplier.
10) Establishing methodology for your warehouse and unit lubricant storage and replenishment.
11) Establish methodology for disposal of used lubricants (to be considered as waste and must be handled and labelled as such and to contact HES for disposal information)
12) Establish lubricant condition monitoring program (oil sampling & analysis)
a) Identify the equipment to be included in the lubrication condition monitoring program.
b) Identify who and how to take the lubricant samples.
c) Identification of where the lubricant samples are to be analysed and how the results are communicated.
d) Identify how the results of the lubricant analysis program are to be incorporated into the maintenance program.
Implementing and performing a lubrication program may be a cultural change for many plants. The change will not be overnight and needs to be slow and steady to achieve the goals. Not all people will react the same and working shoulder to shoulder with management’s direction will help with the cultural changing. Building a culture of continuous improvement will provide a direction that all people can associate with and will want to get on board.
Actions to Take:
1) Review your current lubrication program against this guideline. Are changes required?
2) Determine what equipment is included in your current lubrication program and if your systems are adequate.
3) Review how your lubricant is selected.
Terry Roehm is a Rotating Equipment Specialist with 40+ years experience in both the upstream and downstream businesses of the Oil and Gas Industry. He is a member of the American Petroleum Institute (API) serving on task forces for the mechanical subcommittee and is a past advisory committee member for the Texas A&M Turbomachinery Symposium. He has held various positions in maintenance and engineering involving specification, selection, procurement, testing, installation, startup, troubleshooting and turnaround planning for the rotating equipment. He has established programs, provided and developed training opportunities and has completed audits for companies to improve their operating and maintaining of rotating equipment. He has a Mechanical Engineering Degree from Purdue University and is a registered Professional Engineer in the states of Kentucky and Texas.