Monitoring and Reducing Consumption Flashcards
Name 5 devices for lube applications that are considered ALL LOSS methods.
Open mist Drip Brush Oil cup Bottle oiler
Oilers go to each machine regularly. Name three things an oiler can do in addition to lubricating machines.
Make a visual inspection.
Listen to the machine
Vibration analysis
Take oil samples
Name three oil analysis tests used to determine the level of oil deterioration due to oxidation, or remaining useful life, for used oil.
IR Infrared spectroscopy
TAN Total Acid Number
Viscosity
Rotary Bomb Oxidation Test
Lubricants should be purchased in ____________ containers to reduce waste.
Bulk packaging
Oil Conservation can be divided into three categories. What are they?
Recover
Reduce
Recycle
Name three factors that should be evaluated when determining the total cost to a firm for a lenient attitude towards high oil losses?
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.)
Briefly describe what a firm’s first step should be once they decide to control oil losses?
The task of controlling & monitoring lubricant losses should be assigned to several departments that interact & work together for one common goal.
What environmental and other service factors should be considered when recommending lubricants on a lubrication survey?
Operating temperature
Atmospheric Contamination – Dirt, Water, etc
Filtration
Hours of operation
List seven items that should appear on a lubrication survey?
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
Name three ways methods for arranging a lubrication survey?
Process Flow
By Area
By Route
Name two advantages for computerizing a lubrication survey?
Easier updating
Easier scheduling
Name four ways in which a lubrication survey may be structured?
Lube Route
Application type
Method
Lubricant
What is the primary source for lubrication recommendations on a survey? Name two others?
Equipment Manufacturer
Plant Experience/Knowledge
Personal Experience/Knowledge
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?
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
What may be done to optimize the lubrication recommendations after the initial survey has been completed?
Sampling lubes in service, inspecting gear & bearing conditions for adjustment & change frequency.
Name the three most important areas to be covered in a lubricator’s training class?
Names of Products and Applications
Fundamentals of Lubrication
Importance of Cleanliness
In a large plant, it is impossible for the lubrication engineer to supervise every aspect of the lubrication program. Therefore, well written ______________ are needed.
Lubrication procedures
List four benefits that can be derived from maintenance cost analysis in conjunction with a lubrication scheduling program.
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
A comprehensive oil management program would include product specifications based on the __________ program rather than specific lubrication requirements.
Total
When new equipment enters the mill, the first function of the lubricant specialist is:
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.
An oil management system survey of used oil would show what five things?
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
What steps should be taken when changing lubricant suppliers?
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.
List five departments in a company that could be involved in an oil loss management program.
Maintenance Engineering Operations Environmental Accounting
Small reservoirs typically use sight glasses. What is typically found on large reservoirs?
Electronic float gauge
Float level gauge
Ultrasound gauge
Infrared gauge
