Up Time Magazine- June/July 2008

Alarming Scheme Referencing our training material once again, we began to apply alarming levels to the different types of testing parameters. By taking recommendations from training and looking closely at historical sample data, we put an alarming scheme in place that would be both effective and logical based on our current lubrication and equipment health conditions (Figure 2). We did not set alarms we could not truly achieve at this time, but would adjust these alarms as machine improvements and conditions changed. Two wheel filter carts are being purchased to address high particle counts and water in closed systems. Database: JEFFREY2.rbm Area: CCB - COAL CONVEYOR BELTS R ef Oil S ample Date S ample # Unit Us age - ? Oil Us age - ? Oil Added - gus Wear F errous Idx - Idx L C ont F errous - Idx L C ont NonF e - Idx C ontamination C ontam Idx - Idx % Water - % L C ont Droplet - Idx C nts >2 - pml C nts >5 - pml C nts >10 - pml C nts >15 - pml C nts >25 - pml C nts >50 - pml C nts >100 - pml IS O >2 - n/a IS O >5 - n/a IS O >15 - n/a NAS 1638 - Idx C hemis try C hemic al Idx - Idx Dielec tric - Idx DV V is c 40C - c S t DV V is c %C hng - % V is c 40C - c S t Wes tar E nergy Oils - S HC - 629 09/16/2002 08/19/2002 268978 213058 S ample T rend - A ll Data Equipment: 201 CC - 201 CASCADE Point: GBX - GEARBOX 05/30/2002 00878224 05/07/2002 25246 Wear 06/26/2002 105408 Jeffrey Energy Center 0 0.0 0 0 85 101.8 1.2722 0 22,847 22,605 21,963 21,151 19,490 14,414 6,092.2 22 22 22 18 0 -2.7 2.21 149.6 -.3 0 0.0 0 0 85 .5 .0059 0 50,242 38,167 6,462 800 88 6 .1 23 22 17 14 0 -2.3 2.21 151.5 1.0 0 0.0 0 0 85 18.4 .2610 0 41,896 39,717 29,503 14,564 449 3 .1 23 22 21 15 0 1.8 2.25 140.1 -6.6 0 0 0.0 0 0 85 63.2 .9003 0 23,859 23,189 21,449 18,927 13,401 2,046 38.4 22 22 21 18 10 6.3 2.30 138.5 -7.7 Contamination Chemistry 25905 Jeffrey Road St. Marys, Kansas 66536 0 26 Chemical Idx - Idx -5 05/07/2002 09/16/2002 112 Contam Idx - Idx 0 0.0 0 05/07/2002 09/16/2002 Oil Analysis Reporting As oil analysis is performed and results reviewed, reports are written for abnormalities concerning the oil and/or equipment (Figure 3). These reports are then e-mailed to the proper plant personnel. These may include, but are not limited to, all PdM personnel, Plant Managers, Directors, Engineers, Supervisors and crews responsible for the equipment. These reports are also attached to the CMMS work request. 33 Ferrous Idx - Idx 0 05/07/2002 09/16/2002 1 % W ater - % 0 05/07/2002 09/16/2002 24 ISO >5 - n/a 0 05/07/2002 09/16/2002 Program Audit Once the oil analysis program was up and running, it was quite evident, based on the problems we were finding, that we needed to address our entire lubrication practice. Contacting our professional lubricant consultant, we scheduled an audit to be done at one of our plant sights, knowing that these problems would be consistent throughout the fleet. The audit identified our strengths and weaknesses in the areas of oil analysis and lubrication management. The consultant found our oil analysis program to be strong as a whole, whereas our lubrication management was found to be weak. This audit proved to be very effective in capturing management’s interest. Immediately after the audit, one plant began work on the implementation of a lubrication team. This team would be responsible for establishing lubrication procedures, PM’s, oil-handling techniques, changing and adding oil to machines and greasing of components. Previously, many different people performed this practice throughout the plant, which made it very difficult to capture detailed lubrication functions that were being performed on any particular piece of equipment. Improvements were made in the oil storage areas to protect lubricants and provide a firstin first-out system, and the purchase of oil 24 ISO >15 - n/a 0 05/07/2002 09/16/2002 This sample indicates a high water content. A crackle test was performed and showed positive for water. Figure 3 - Oil Analysis Report, which is attached to Work Requests. handling containers for better contamination control when delivering lubricant from bulk storage to the machine itself. More Training Once the lubrication team was in place additional training was provided. The lubrication team and other plant personnel attended the professional lubricant consultant’s Oil Analysis I course. Once again, this provided a more detailed education to plant staff on both the importance of lubrication management and what the company was trying to achieve. perform a lubrication audit similar to those performed by the consultant at the other plant sights within the company. Although this audit was not as detailed as the consultant’s audit, it was constructed to identify the basic and most common faults found throughout the fleet. We looked at storage and handling, temporary storage tanks, sampling techniques, contamination control at the machine, procedures and PM’s. These audits stimulated positive changes at the audited sights. Oil Analysis Results Westar Energy has realized many benefits from the improvement in its oil analysis program. Varying anomalies have been detected through the in-house lab, including the discovery of water issues in our Turbine and Boiler Feed Pump lubrication. Having the injune/july 2008 Internal Audit Now that we had a fairly good understanding of oil analysis and lubrication management, the company selected a few individuals to 26

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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