Category: Lubrication

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.

My name is Terry Roehm, Rotating Equipment Specialist and today’s author for the BoilerRock Blog.  I will be discussing Lubrication Programs and some of the basics of a good program in part 1 for this topic.

The rotating equipment used in a plant is essentially the heartbeat of the plant. Rotating equipment is used to move gases and liquids throughout the plant, allowing the different production process units to perform their intended duties. To provide the desired on-stream production rates of these units, the rotating equipment must be reliable. Maintaining the equipment’s reliability at the desired high level is a process that requires many different people’s abilities and skills. The rotating equipment must be both maintained and operated in a manner that allows continuous on-stream production in-order to stay competitive. While improving the reliability of the rotating equipment, safety will be improved for both the productions unit and the equipment itself.

One of the reliability programs that is associated with rotating equipment is the lubrication program. Rotating equipment has components that rotate, slide or move requiring the friction to be reduced to prevent wear resulting in failure. The goal of a well-developed lubrication program is to ensure that all equipment receives and maintains the required levels of quality lubrication such that no equipment fails due to inadequate or improper lubrication while performing its intended purpose. A quality lubrication program will reduce the mean time between failures (MTBF) of the rotating equipment thus bringing down the maintenance costs. With higher MTBF’s, the rotating equipment will operate longer which reduces operating costs that are associated not only the repairs, but potential unit outages and incidental costs.

Each plant should develop a lubrication program that fits that site while providing ownership and accountability.

• lubrication program requires management’s buy-in and leadership.
• lubrication program is to define its purpose, details, person in charge, expectations and training of the program’s activities.
• it is crucial that the program is well understood throughout the plant with all people.
• to ensure that the program is providing the expected benefit, key performance indicators (KPI’s) are to be established and tracked.
• if the program is not providing the expected results it needs to be modified or replaced.
• audit performed by an outside source can provide benefits for the success or failures of the programs

A lubrication program is more than here is what
is to be lubricated

The lubrication program is more than here is what is to be lubricated. The lubricant program is to ensure that:

• equipment requiring lubrication is identified
• lubricant requirements are identified
• lubricant selection is rationalized and suitable for the application
• lubricant is provided by a reputable supplier per the determined requirements
• lubricant is stored in an appropriate manner
• lubricant is replenished with the right type, frequency, quantity and method
• lubricant is sampled in an appropriate manner
• oil testing/analysis requirements are chosen based on the requirements of the equipment
• appropriate action is taken based on analysis results
• lubricant stock is rationalized
• history is maintained in an appropriate CMMS

Rotating equipment included in the program should include any rotating equipment, critical (typically unspared equipment that can cause business interruptions/losses) and non-critical (typically spared or equipment that does not greatly affect business losses).

lubrication program may be a cultural change

Implementing and performing a lubrication program may be a cultural change for a plant. Any changes will not be implemented 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 hopefully want to get on board.

Actions to Take:

1)  Review your current lubrication program against this guideline and what is included in your current lubrication program.
2)  Do you currently have KPI for your lubrication program?  Review which way your KPI’s are trending.
3)  Review your current training strategy.
4)  Take a field trip–Review your current oil storage area and talk with your Maintenance/Operations staff about their knowledge of your lubrication program.

If any of this seems overwhelming or you need help with your lubrication program, BoilerRock can assist with the establishing, identification, development, training or auditing that will benefit your plant.

 

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 Mechanical Engineering Degree from Purdue University and is a registered Professional Engineer in the states of Kentucky and Texas.