Monitoring and Reducing Consumption

Question 0

Name 5 devices for lube applications that are considered ALL LOSS methods.

Answer 0

Open mist
Drip
Brush
Oil cup
Bottle oiler

Question 1

Oilers go to each machine regularly. Name three things an oiler can do in addition to lubricating machines.

Answer 1

Make a visual inspection.
Listen to the machine
Vibration analysis
Take oil samples

Question 2

Name three oil analysis tests used to determine the level of oil deterioration due to oxidation, or remaining useful life, for used oil.

Answer 2

IR Infrared spectroscopy
TAN Total Acid Number
Viscosity
Rotary Bomb Oxidation Test

Question 3

Lubricants should be purchased in ____________ containers to reduce waste.

Answer 3

Bulk packaging

Question 4

Oil Conservation can be divided into three categories. What are they?

Answer 4

Recover
Reduce
Recycle

Question 5

Name three factors that should be evaluated when determining the total cost to a firm for a lenient attitude towards high oil losses?

Answer 5

The cost of lubricating oil for normal change-outs plus disposal and labour costs.
The cost of all lubricant purchases over a specified time period.
The hidden costs associated with lubricant loss (through change out or leaks.)

Question 6

Briefly describe what a firm’s first step should be once they decide to control oil losses?

Answer 6

The task of controlling & monitoring lubricant losses should be assigned to several departments that interact & work together for one common goal.

Question 7

What environmental and other service factors should be considered when recommending lubricants on a lubrication survey?

Answer 7

Operating temperature
Atmospheric Contamination – Dirt, Water, etc
Filtration
Hours of operation

Question 8

List seven items that should appear on a lubrication survey?

Answer 8

Department (and or location) Equipment Name/Number
Part to be lubricated Method of Application
Name of Lubricant and amount Service / Change Interval
Equipment (components and lube points)
Comments

Question 9

Name three ways methods for arranging a lubrication survey?

Answer 9

Process Flow
By Area
By Route

Question 10

Name two advantages for computerizing a lubrication survey?

Answer 10

Easier updating

Easier scheduling

Question 11

Name four ways in which a lubrication survey may be structured?

Answer 11

Lube Route
Application type
Method
Lubricant

Question 12

What is the primary source for lubrication recommendations on a survey? Name two others?

Answer 12

Equipment Manufacturer
Plant Experience/Knowledge
Personal Experience/Knowledge

Question 13

Name at least two benefits of a lubricating survey that may be expected by the maintenance department? By the purchasing agent? By the lubricant distributor?

Answer 13

Maintenance: 
Reduced lubrication related failures 
Lubrication scheduling & instruction 
Purchasing: 
Reduced number of Lubricants 
Most economical packaging 
Distributor:
Most economical Packaging / Reduced number of Lubes 
Knowing what products / Packages to stock

Question 14

What may be done to optimize the lubrication recommendations after the initial survey has been completed?

Answer 14

Sampling lubes in service, inspecting gear & bearing conditions for adjustment & change frequency.

Question 15

Name the three most important areas to be covered in a lubricator’s training class?

Answer 15

Names of Products and Applications
Fundamentals of Lubrication
Importance of Cleanliness

Question 16

In a large plant, it is impossible for the lubrication engineer to supervise every aspect of the lubrication program. Therefore, well written ______________ are needed.

Answer 16

Lubrication procedures

Question 17

List four benefits that can be derived from maintenance cost analysis in conjunction with a lubrication scheduling program.

Answer 17

Helps optimize use of personnel
Insures optimum type, amount and frequency of lubrication
Balances cost of lubrication
Oil analysis and maintenance with equipment life
Minimizes consumption
Wasted and excess inventory

Question 18

A comprehensive oil management program would include product specifications based on the __________ program rather than specific lubrication requirements.

Answer 18

Total

Question 19

When new equipment enters the mill, the first function of the lubricant specialist is:

Answer 19

Read OEM manual, identify lube points, verify lubricant needed, find out if equipment is shipped dry, determine flushing procedure.
Verify that lubricants are in stock, add the equipment to the scheduling program, assign one person to be responsible for the lubrication program.

Question 20

An oil management system survey of used oil would show what five things?

Answer 20

Quantity of oil purchased
Quantity of oil sent for disposal
Amount consumed, wasted, recycled, reused
Methods and cost of fluid disposal
Proposed methods of reducing consumption or waste

Question 21

What steps should be taken when changing lubricant suppliers?

Answer 21

1) Follow OEM recommendations for each machine.
2) Consolidate lubricants where possible.
3) Test competitive products for compatibility, or flush thoroughly.
4) Analyze new oil to establish a base line.

Question 22

List five departments in a company that could be involved in an oil loss management program.

Answer 22

Maintenance
Engineering
Operations
Environmental
Accounting

Question 23

Small reservoirs typically use sight glasses. What is typically found on large reservoirs?

Answer 23

Electronic float gauge
Float level gauge
Ultrasound gauge
Infrared gauge

Question 24

When monitoring & reducing consumption what three areas are critical to making the program proceed?

Answer 24

Hardware
Report system
Establishment of standards

Question 25

Name four types of hardware that can be used to monitor and prevent lubricant losses?

Answer 25

Fill line totaling meters
Level arms
Pump low-level shut down switch
Sight Glasses

Question 26

What frequency is recommended when monitoring critical areas?

Answer 26

Hourly

Question 27

What frequency of reporting is recommended when monitoring high loss areas?

Answer 27

Weekly

Question 28

In terms of packaging, what package is more conducive to reducing lubricant usage?

Answer 28

Bulk

Because you use the portion that normally would be left over in the various containers.

Question 29

In order to reduce lubricant usage, is it better to use equipment with grease lubrication or equipment with oil lubrication? Briefly explain?

Answer 29

Grease Lubrication

Because of less leaking and containment needed.

Question 30

When considering site specifications, name three things that will help reduce lubricant consumption?

Answer 30

No easily accessible sewers
Easy access for repairs
Drainage of all likely leak areas to central sump.

Question 31

In terms of oil recovery and reuse, where should collection tanks be located, what should they be equipped with and why?

Answer 31

Locate collection tanks in central areas with heat to enhance water separation.

Question 32

Other than continuous filtration, what is another option for those system, which tend to get contaminated?

Answer 32

Use twin tanks so that one tank can be cleaned if necessary while the other one is being used.

Question 33

A 55 gallon drum of oil weighs approximately _________ pounds.

Answer 33

450 pounds

Question 34

How is most waste oil recycled?

Answer 34

It’s burned as fuel in boilers.

Question 35

Conservation of used oils becomes increasingly important for economic, supply and _____________ reasons.

Answer 35

Environmental