Up Time Magazine- June/July 2008

formation available on-site allowed for a quick response in finding entrainment issues before we experienced any valve or system problems. High ferrous particle counts in some of our gearboxes caused us to investigate and try higher viscosity oil in these components to reduce the wear rate. Non-ferrous materials were also detected that pointed to worn and damaged bearings and gears. Mixed oils were also detected through viscosity, which enabled us to react very quickly, before any damage could be done to these machines. The professional lab support has also been a key element for exception, quarterly and yearly testing. Through TAN, RPVOT, Elemental, FTIR, Demulsibilty and QSA testing, we have acquired a better understanding of our current fleet lubrication condition. The number of work requests based on oil analysis increased, and is indicative of how well the program is addressing oil related issues. This is proving to be extremely beneficial in improving reliability and extending machinery life. port in clearing the path for further budgetary improvements. By investing in the education of the workforce, we have helped to diminish the “oil is oil” myth creating a smooth transition for present and future changes. Bruce Sackman started at Westar Energy in 1990. In 2001, Bruce joined the Predictive Maintenance Department and began developing the Oil Analysis program. Bruce has achieved Level 1 Vibration (Technical Associates), Level 1 Thermography (Westar Energy) and MLA Level 1 (ICML). Mark Mayworm is the Reliability Engineering Manager for Westar Energy’s generation fleet in Kansas. He is responsible for developing and maintaining the Vibration, Thermography, Oil Analysis, Motor/Generator testing, RCM, RCA programs at these facilities. Before joining Westar Energy, he spent 19 years in the Coal Mining Industry in the Powder River Basin located in NE Wyoming. He was responsible for developing predictive maintenance programs for Plant processing and Shovel equipment. VALVES AND TRAPS CAUSING EFFICIENCY LOSSES? Lubrication Management Currently, our lubrication management is in the process of being drastically improved, and management and plant staff are committed to addressing the problems we have identified. Main storage facilities are being addressed through new construction or different locations. Inventory is being reviewed along with a first-in first-out system to prevent old products from being put into service. Containers for lubrication handling are being purchased and properly marked to eliminate contamination issues. PM’s and procedures are being written to address lubrication as a stand-alone task. In early 2007, the company’s fleet of mobile/rolling equipment was also added to the oil analysis program in an effort to detect possible early warning signs of lubrication/wear related failure with components. This effort will also help limit the equipment component rebuilds to only those components deemed to be in rebuild condition, instead of the past practice of time-based component rebuilds. ULTRASONIC VALVE & TRAP LEAK DETECTION IMPROVING PERFORMANCE FOR MORE THAN ✦ Enhance Efficiency ✦ Increase Output ✦ Lower Heat Rate ✦ Reduce Maintenance Costs ✦ Avoid Unnecessary Repairs 25 YEARS Conclusion Westar Energy has made drastic efforts in improving its lubrication and oil analysis program. Since the beginning of the oil analysis program, it has produced very favorable results in addressing machine and lubrication problems. So far, the key element to our success is directly related to education about lubrication management and oil analysis. With plant management having knowledge in lubrication, they have provided further supwww.uptimemagazine.com LDS provides a systematic, time-proven method of improving cycle efficiency. We use our patented ValveAlyzer® System,custom databases, test procedures, physical inspections, ultrasonic testing, and complex thermal analysis to provide significant plant wide savings. For more information, contact us today: 800-345-7157 www.leakdetect.com 27 http://www.leakdetect.com http://www.leakdetect.com 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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