Plant Services - November 2007 - (Page 47)

ASSET MANAGEMENT Lubrication cal ferrography and micropatch all help monitor the size, count and distribution of ferrous wear particles and can identify the source, which allows you to predict and prevent catastrophic failure. Sampling frequencies Although an equipment manufacturer’s recommendations provide a good starting point for developing preventive maintenance practices, sampling intervals can easily vary. Criticality to production is the most important factor in determining which units or components you test and how often. Extreme operating conditions also are important sampling considerations. Dirt, system debris and water tend to separate from the oil when system temperatures cool. Representative samples require sampling be done while the system is operating or immediately after shutdown. time. Don’t let unidentified bottlenecks in turnaround time degrade the value of fluid analysis results and recommendations. Ensure sample label information is accurate and complete. Clearly identify any special instructions. Use a trackable mail service for sending samples to the laboratory but demand to receive your results electronically. Understand that laboratory turnaround time begins when the sample is received and ends when results have been sent to the user. Therefore, 24-hour turnaround means it takes 24 hours from receipt of the sample by the laboratory to log it, test it, analyze the results and send a report. Review reports, take action Timing is critical Trend analysis works best when sampling intervals are consistent and samples are shipped immediately. Maintenance personnel responsible for sampling should be well trained – and re-trained when necessary – on the appropriate sampling point(s), frequency and designated method for each piece of equipment being tested. For proper trend analysis, hydraulics, gear systems and pumps should be sampled quarterly at minimum. Take samples from either a vacuum pump through the fill port or from a permanently installed petcock. Be sure to flush at least five times the volume of any dead space before catching the sample. If a drain plug is the only way to catch a sample, be sure to allow five times the volume of the sample container to flow before catching the sample. Use a separate container to collect the forerunning oil to avoid contaminating the clean sample container. When reviewing your most negative reports, consider the results in light of other available diagnostic information such as vibration analysis, thermography and in-line sensors. Either act on the analyst’s recommendations or order more testing. If re-sampling is recommended, immediately sample again or at half the normal interval to verify results. Otherwise, closely monitor the unit and sample again at the normal interval. Cautionary reports might flag some wear and contamination results, although those results don’t necessarily indicate a particular failure mode or are significant enough to warrant action. Retain them for later reference as more data is collected on subsequent samples – trends will be easier to spot and the appropriate action to take clearer. Review normal reports as time permits. Knowing where you started helps in recognizing trends when reviewing historical data. Manage the data Know the equipment, share the knowledge Accurate, thorough and complete fluid and equipment information allows for better, in-depth analysis and increases the value of a data analyst’s comments and recommendations. Give your laboratory the most current, accurate equipment identification information, including make, model, application, filter types and micron ratings, sump capacity, operating hours on both the unit and the fluid and whether the fluid has been changed. Consult every resource available to you – procurement records, inventory databases and OEM service manuals are good places to start. After the laboratory has the information, request a copy to verify the accuracy and promptly communicate any needed changes. Every laboratory’s system for managing sample information is unique, but all of them rely on the information you submit with the sample to set alarm and severity limits. Missing or inaccurate information limits data interpretation. Take an active role in minimizing sample turnaround November 2007 The size of your operation and ambition of your goals and resources dictate the best and most efficient means for receiving and managing test data. Web-based applications should have data management reporting capability such as problem summaries, sampling frequencies and turnaround tracking. Personal data management software applications should be able to import data, build data management reports, cusInitial evaluation In deciding if a fluid analysis laboratory is right for you, ask yourself the following: • Can it meet all my program’s requirements? • Can it perform the testing in an appropriate amount of time? • Can I call any laboratory location with questions, or am I limited to just the one to which we sent the sample? • How does the laboratory ensure consistency from location to location? • Will I always be able to speak with an analyst? • Is training available to ensure everyone involved is on the same page? www.PLANTSERVICES.com 47 http://www.PLANTSERVICES.com

Table of Contents Feed for the Digital Edition of Plant Services - November 2007

Plant Services - November 2007 Contents New Tools Letters Let Us Know Where to Put the Gas Up and Running How are you Fighting Crisis? What Works Why is the Best Practice Transfer so Hard? Who are you Going to Call? Chained to Power Mobile Mindset Making Money in the Lube Lab Grabbing a Moving Target Bagging the BTUs Keeping Mellow Preserving Health and Safety The Power of Reliability Excellence

Plant Services - November 2007

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