Up Time Magazine- June/July 2008

The PdM lab technician who was responsible for processing the samples through our on-site lab received specific training at the vendor’s sight. PdM Manager (Full Access) Analysts (Full Access) Jeffrey Energy Center Front Line Support Customers (Read Only) Engineering Maintenance Operations Engineering critical machines is sent to the professional lab for RPVOT, Demulsibility and QSA tests. Back Line Support Implementation Once training was completed, primary sampling locations were identified on all equipServer ment being tested and the installation of valves and ports began. One person was assigned to process the samples Full Access Link through the in-house oil lab. Read Only Link The people responsible for pulling samples were all trained in the proper sample gathering techniques. For locations where sample valves or ports could not be installed immediately, they were scheduled for installation during outage. On those machines where samples would be pulled from a reservoir, personnel developed a metal insert tube to be used as a guide for controlling the depth and location of the plastic tubing. This method insured an accurate and consistent method of acquiring these types of samples. The next challenge was to determine the type and frequency of tests to be performed on each type of machine. By understanding the information our in-house lab could provide, we were confident we could determine the health of both the lubricant and the machinery. This allowed us to strategically identify the types of tests we would have our professional lab conduct. Referencing the written material from our training, we determined the type of tests that would enhance our overall testing scheme. From this assessment, we scheduled specific monthly tests through our in-house lab on each piece of equipment, complimented with a backup, quarterly and yearly testing scheme from our professional lab. Westar Predictive Maintenance Network Off-Site Oil Analysis (If Inhouse Lab Is Unavailable) An off-site oil lab may be used when the lab personnel are on extended leave or the lab is out of service to ensure the oil program stays up to date. These test results are downloaded into the in-house database for trending and analyzing. These tests include: Viscosity, Particle Count, Wear Particle Concentration and Crackle Test. Hutchinson Front Line Support Maintenance Operations Engineering Gordon Evans Front Line Support Maintenance Operations Tier 1 Tier 2 Tier 3 Figure 1 - Wide Area Networking Software sentative be notified through e-mail and a phone call. The plant PdM representative then further investigates the possible problem. A resample of the oil may be requested to either verify the analysis results or to be sent to the professional lab for further analysis. Working closely with the professional lab, we developed report files that can be dumped directly into our in-house lab software so test information can Equipment be viewed and tracked by Main Turbines company personnel. Boiler Feed Pump The analyst at each plant location is responsible for reviewing the oil analysis results, determining any abnormalities, determining the urgency of repair for any oil related problems, creating oil reports and work requests and any follow-up work that may be needed after repair work has been performed. Oil Limits and Alarms Normal 17/15/12 17/15/12 17/15/12 17/15/12 18/16/13 19/17/15 18/16/13 18/16/13 18/16/13 17/15/12 17/15/12 17/15/12 High Normal 18/16/13 18/16/13 18/16/13 18/16/13 19/17/14 20/18/16 19/17/14 19/17/14 19/17/14 18/16/13 18/16/13 18/16/13 Alert 19/17/14 19/17/14 19/17/14 19/17/14 20/18/15 21/19/17 20/18/15 20/18/15 20/18/15 19/17/14 19/17/14 19/17/14 Alarm 20/18/15 20/18/15 20/18/15 20/18/15 21/19/16 22/20/18 21/19/16 21/19/16 21/19/16 20/18/15 20/18/15 20/18/15 Extreme 21/19/16 21/19/16 21/19/16 21/19/16 22/20/17 23/21/19 22/20/17 22/20/17 22/20/17 21/19/16 21/19/16 21/19/16 Off-site Quarterly Oil Analysis In addition to the monthly in-house oil samples, every three months oil samples are sent to a professional oil lab for additional testing that cannot be performed with the in-house lab. These test results are downloaded into the inhouse database for trending and analyzing. These tests include: Elemental Analysis (Atomic Emission Spectroscopy), FTIR (Infrared Analysis) and TAN (Total Acid Number). Fans E.H.C. Pulverizers Soot Blowing Air Compressors Rotary Air Heater (Gearboxes) Coal Conveyor (Gearboxes) Wind Turbines Boiler Circ Pumps Gas Turbines Combustion Turbines In-house Monthly Oil Analysis The selected equipment from all plant locations is analyzed once a month through the on-site oil lab, and the analyst at each plant location analyzes the data from each oil sample. There are three main vectors for analysis: chemistry, contamination and wear. This is achieved through dielectric count, ferrous and non-ferrous index, particle count, water content and wear debris analysis. Any abnormality found during testing by the lab personnel requires that the affected plant PdM reprewww.uptimemagazine.com Water Alarms Measurement Water (% of Change) Water (in PPM) Normal 0 0 High Normal 0.1 100 Alert 0.05 500 Alarm 0.08 800 Extreme 0.10 1000 Viscosity Alarms Measurement % of Change (Up) % of Change (Down) Yearly Off-Site Oil Analysis Once per year, an additional sample from Normal 0 0 High Normal 5 5 Alert 10 10 Alarm 15 15 Extreme 20 20 Figure 2 - Oil Limits and Alarms, In-House Oil Lab 25 http://www.uptimemagazine.com

Table of Contents Feed for the Digital Edition of Up Time Magazine- June/July 2008

Up Time Magazine- June/July 2008 Contents Upfront Upclose: The True Cause of Most Machine Failures Information Technology: Finding Future Perfect Lubrication: Building an Oil Analysis Winner Maintenance Management: Hidden Ways to Increase Safety Infrared: Air Barriers Lower Energy Costs, Increase Profits Motor Testing: Efficient Motor Repair, Part Deux Precision Maintenance: Good Maintenance, Smart Maintenance Reliability: Common Errors in Root Cause Analysis Ultrasound: Avoid the Baghouse Blues Vibration: Don't Let Your Sensors Get Eaten Alive Upgrade: Lining It All Up

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