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The purpose of this technical project is to clarify the maintenance plan and determine the applicable points of the oil analysis so as to provide greater benefits. 
Maintenance program maintenance refers to the work of keeping something in a normal state. Taking maintenance measures can prevent equipment failure and repair the degradation of conventional equipment.
When used, most equipment requires regular maintenance, adjusting the conveyor belt, maintaining alignment, and proper lubrication of rotating equipment is necessary. There are several ways to learn how to perform maintenance work, such as using responsive maintenance, preventive maintenance, predictive maintenance, or reliability-centered maintenance.
Responsive maintenance (RM) is fundamentally based on the idea of ​​"enabling the equipment to operate until it is scrapped." No measures are taken to maintain the equipment. Although this does not have any maintenance costs, repeated equipment replacement can incur high costs. Over 55% of an ordinary factory's maintenance resources and maintenance operations are still responsive.
Preventive Maintenance (PM) includes various measures taken in accordance with schedules to detect and prevent component degradation. The implementation of preventive maintenance aims to save costs by controlling degradation, maintaining or extending the service life. The disadvantage of this maintenance is that it requires a lot of manpower. More than 31% of an ordinary factory's maintenance resources and maintenance operations are preventive. Predictive maintenance (PdM) refers to measures taken according to actual conditions. This maintenance can eliminate the source of stress before it causes any damage, extend the service life, and eliminate almost all catastrophic failures. The advantage is that regular maintenance operations can greatly reduce overtime costs, reduce parts inventory, and increase plant reliability. The disadvantages are huge investment in diagnostic equipment and training costs for personnel. More than 12% of maintenance resources and maintenance operations in an ordinary factory are predictive.
Reliability-centric maintenance (RCM) provides the process for determining the required maintenance of all equipment in its operating environment. In a factory, not all devices are equally important, and the probability of failure of different devices varies. The reliability-centric maintenance (RCM) approach uses all available maintenance methods: 10% is responsive, 35% is preventive, and up to 55% predictive maintenance. This maintenance requires a lot of start-up costs, training, equipment, and so on.
Reliability-centered maintenance (RCM) enables tight integration of plant resources and requirements, increasing equipment reliability and reducing costs.
Oil Analysis (OA) and Maintenance Solutions The question is, what kind of maintenance method does the oil analysis belong to? Consider the following scenario:
• Preventative maintenance (PM) is based on time. Maintenance operations such as replacing lubricants are based on time. Some factories change lubricants monthly, quarterly or annually. They do not care about the actual condition of the lubricant and its performance. This method of maintenance does not use lubricant analysis as a tool.
â— If a factory reduces the running time and conducts regular analysis of the lubricant to determine its actual condition and lubrication effect, the factory may extend the oil change period before the next maintenance cycle. This situation is reliability-centric predictive maintenance (PdM), and measures taken to determine maintenance tasks based on quantitative conditions.
• If a plant uses oil analysis to determine the condition of the equipment in operation, the oil analysis is reliability-centric maintenance (RCM). Keep in mind that reliability-centric maintenance (RCM) provides for the maintenance of all equipment in its operating environment.
In these circumstances, the oil analysis well supports predictive maintenance or reliability-centered maintenance plans.
Signum Oil Analysis ExxonMobil uses the following methods to determine the physical properties of the lubricant, the degree of contamination, and the wear trends of the equipment.
Viscosity (ASTM D445 assay): shows the change in liquid resistance to flow. Viscosity test results can be displayed through other liquids, showing physical changes or contamination.
Oxidation (Fourier Transform Infrared Spectrometer (FTIR) Assay): Determine the harmful byproducts of thermal degradation. The oxidizing properties of lubricating oils are physical changes.
Nitrification (FRIR Assay): Determination of harmful by-products from fuel combustion. Lubrication of lubricating oils is a physical change that is identical to oxidation.
Ethylene Glycol (FTIR/ASTM D2982): Determine if engine coolant is present.
Fuel Dilution: Reduces viscosity but may accelerate wear. It can cause soot accumulation in the engine.
Haze (FTIR assay): Detects by-products from unburned fuel, which is also a type of contamination.
Moisture content (FTIR/hotplate/Karl Fisher ASTM D1744 assay): Determine if moisture is present. Moisture is a potentially harmful liquid contaminant that accelerates physical changes in the lubricant and causes the metal surface to decompose rapidly.
Total Base Number (TBN) (ASTM 4739 Assay): Determines the ability of acidity to neutralize. This is a physical change in lubricants.
Total Acid Number (TAN) (ASTM D664): Determines/identifies oxidation and contamination of acidic by-products. The total acid value is a physical change.
Fuel Dilution (Gas Chromatography): Determine if fuel and other contaminants are present.
Elemental Analysis (ICP Spectrometry) (Inductively Coupled Plasma): Determines whether additives and metal debris are present.
ISO Particle Count (ISO4406): Determines the size and amount of solid contaminants.
Number of worn particles (PQ) index: Determination of mass of metal particles in an oil sample Ultracentrifuge: Assess water-soluble submicron contaminants that will form systemic precipitates.
The importance of incorporating Signum oil analysis into oil analysis in your maintenance program is obvious, but how to make it an important part of your maintenance platform will often make you feel at a loss.
The first step: to determine the "critical mission" equipment For each plant in the factory, do not need to perform oil analysis one by one. It is only necessary to detect key equipment that seriously jeopardizes production when unexpected shutdowns occur.
Step 2: Set the sampling frequency How often should you sample once? Weekly, monthly, quarterly, semiannual, or never? Consider the following five factors:
â— Severity of the liquid environment â— Liquid life factors â— Mechanical life factors â— Target results â— Economic effects in the event of a failure The purpose of setting the sampling frequency is to establish a regular pattern of sampling and a reliable trend in the mechanical properties.
Step 3: Registering Your Equipment Registering your equipment information correctly in the lab information is especially important because it helps determine the general trend and plays a key role in the early detection of lubricants or equipment problems. effect.
Step 4: Selecting a representative oil sample The correct and representative oil sample is essential for determining the chemical and physical properties. Please ensure that you use appropriate, repeatable sampling procedures. The sampling device should be very clean before the sampling operation starts. Any residue in the previous oil sample sampling device or sampling container may damage the oil sample characteristics. If the oil sample is not collected correctly, any test result is unreliable.
Step 5: Checking the oil sample By observing the oil sample, a large amount of information can be collected directly. Before each oil sample is sent for analysis, it should be carefully examined. The lubricant in good condition is very clean and bright. The presence of turbidity or turbidity indicates that it contains water, wax, mechanical coolant, refrigerants, or incompatible lubricants. The presence of precipitates and particles indicates that the problem is more serious.
Step 6: Oil samples are labeled for each oil sample in a timely manner. Please send your oil sample immediately using the prescribed shipping materials. If possible, try to use the overnight courier service to transport the samples to shorten the shipping delay.
Step 7: Get Your Results The analysis lab should provide complete and accurate analysis results. Usually within 1-2 working days after the laboratory receives the oil sample, you will be informed by email or online.
Step 8: Understand your analytical results Check the oil sample for important oil sample information (eg sample date, hours/minutes/kilometer, waiting lubricant, etc.). According to "sampling date", trend analysis of oil sample results is performed. Keep in mind that 95% of the oil analysis samples delivered to the laboratory will be analyzed within 36 hours of receiving the oil sample. Trend analysis based on the sampling date can standardize any customer processing and delivery delays.
A complete review of the report can accurately determine the status. Changes in the condition of the equipment are usually consistent with the presence of contaminants or changes in the properties of the lubricating oil. The overall assessment focuses on three areas: equipment conditions, pollution conditions, and lubricating oil conditions. Your report should provide easy-to-read, performance-labeled performance assessments, including the following three ratings:
◠Warning—The existing condition exceeds an acceptable limit or corrective action is required.
Measures should be taken to confirm and correct the situation.
â— Caution - Existing conditions may require monitoring or diagnosis to significantly reduce the impact on equipment and lubrication performance.
â— Normal - Equipment, pollution, and lubrication conditions are within acceptable limits.
Use Signum oil analysis to understand the parts and operation of the equipment. Monitoring ratings and trend warnings are crucial for understanding oil analysis results.
The results of the analysis included general oil sample evaluations that helped identify potential problems, a list of possible causes, and suggested measures for follow-up.
Step 9: Confirming the status of the warning Before replacing or shutting down the device, you should confirm the "warning" of the analysis. Before taking action, consider the following confirmation steps:
â— Check the maintenance/operator records to determine the status â— Use other equipment monitoring tools to confirm the status, such as inspection, vibration instrument or temperature recording method â— Use on-site analysis test for the warning condition â— Send another oil sample to the laboratory Conduct a reanalysis of the tenth step: take corrective measures and record. Once the status is confirmed, corrective measures should be taken. The required records include the date, the replaced parts, and the expenses incurred.
Conclusion Predictive maintenance (PdM) and reliability-centered maintenance (RCM) make use of all of the maintenance technologies mentioned above, including oil analysis. Enhanced Predictive Maintenance (PdM) and Reliability-Centered Maintenance (RCM) programs are characterized by oil analysis that helps detect and identify problems as they occur, ensuring timely repairs.
According to the U.S. Department of Energy, when reliability-centric maintenance (RCM) maintenance technology is successfully implemented, maintenance costs can be reduced from US$18/HP/year using responsive maintenance (RM) methods to reliability-centered The maintenance (RCM) method of $6/HP/year. Specifically, if a factory adopts a reactive maintenance (RM) method and its annual maintenance budget is US$1,000,000, the maintenance-based maintenance (RCM) method can reduce its maintenance budget to US$333,333.
Another benefit of the reliability-centric maintenance (RCM) approach is that employees can increase their knowledge, skills, and time to complete the required work. In addition, the reliability-centric maintenance (RCM) method is used to purchase materials that are necessary for maintenance over a longer period of time, thereby reducing inventory of parts and reducing the cost of storage.
Since the maintenance work is carried out only when it is needed, the reliability and availability of the machinery are greatly increased, and the production volume is also increased.
Introduction Lubricating oil is a new force in mechanical equipment. Just as doctors assess our health through blood analysis, the critical equipment conditions of the factory also need to be monitored to determine if it is functioning properly.
July 31, 2024