GROUP AND INDIVIDUAL ASSIGNMENT BMCG

4833 WEAR DEBRIS AND OIL ANALYSIS

(Date of issuance: 05 04 2018)

Question 1 (15%) GROUP ASSIGNMENT (Two persons per group)

As Lubricant specialist, you are assigned to come up with a lubrication program strategy for your
plant. Choose one of the industries below and propose a comprehensive lubrication program in
the plant. The submission date of the report is 17 May 2018.

Your report shall include

Selection of the industries

1. Automotive plant.
2. Aluminum smelting plant.
3. Aircraft building plant.
4. Power cable plant.
5. Steel manufacturing plant.
6. Quarry and Mining.
7. Drinking water manufacturing plant.
8. Water utility plant.
9. Power plant.
10. Transportation industry
11. Tunnel Boring Machinery
12. Natural Gas manufacturing plant
13. Oil and gas refinery plant
14. Nuclear power plant
15. Milk production plant
16. Rice processing plant
17. Newspaper publishing plant.
18. Hydrogen production plant.
19. Nitrogen production plant
20. Flour manufacturing plant.
Your report shall include

a. Introduction on the industry

i. Process flow diagram
ii. General list of equipment

b. The plant lubrication survey

i. Identify equipment and component parts requiring lubrication.
ii. Obtain similar information for each subcomponent of the machine.
iii. Examine the lubricant recommendations made by the machine or parts
manufacturer.
iv. Determine the lubricants currently used, including quantity, cost, and supply source
v. List the schedules in effect for each lubrication point.
vi. Identify the nature of each lubrication point

c. Establishment of lubrication schedules

i. Review current lubrication schedules, including type and amount of lubricant used
and frequency of application.
ii. Determine if it is the best lubricant for the specific application commensurate with
the proposed lubricant product reduction program and improved performance
requirements.
iii. Analyze each piece of equipment to determine if the present lubrication system is
adequate and if the lubrication points or central reservoirs are readily accessible.
iv. Investigate opportunities to replace inadequate systems, manual systems, and
malfunctioning automatic systems with state-of-the-art automatic systems that can
be justified through reduced labor, increased equipment reliability, and/or reduced
energy costs.
v. Establish lubrication schedules and routings to minimize travel time and
interference with production operations. Determine time required to perform
specific lubrication functions and number of workers required to perform the job.
vi. Establish a check-off or feedback procedure to indicate that the scheduled
lubrication was accomplished with the proper lubricant.
 vii. Record and report the amount and type of lubricant consumed in each area and on
major pieces of equipment.

d. Lubricant analysis
i. Establish the objectives of the analysis program, that is, monitor and track wear and
lubricant quality to detect problems caused by adhesion, friction, and corrosion
before there is major component damage and to determine when lubricant should
be filtered, replaced, and/or fortified with additives.
ii. Select the plant equipment to be included in the analysis program. Equipment
selection is usually based on the importance of the equipment to continuity of plant
operations.
iii. Determine the sampling frequencies for each component.
iv. Design the testing packages to meet the selected objectives
v. Select a lubricant testing laboratory that can accurately test the parameters chosen
and report the results in a comprehensive manner on a timely basis.
vi. Determine the cost of the analysis program.
vii. Develop the sampling procedures and modify equipment as necessary to extract
representative samples while the equipment is in operation.
viii. Establish sampling, testing, and reporting schedules.
ix. Develop procedures and lines of communication to report results and to initiate
actions dictated by the test results.
x. Establish a program review schedule.

e. Fluids management
i. Storage
ii. Receive
iii. Dispensing
iv. Usage
f. Quality assurance,
Question 2 (5%) INDIVIDUAL REPORT
Choose one of the title below, conduct literature review and write an essay for about 1000 words
discussing the topics in detail. Your essay shall include the explanation of the issue and the
remedial approach. Proper paraphrase and citation shall be done if the materials are taken from
any sources. You can choose any of the below title for your short essay.

Titles of essay.

1. How to prevent equipment failures with wear debris analysis.

2. Particles contamination can shorten the life of an equipment.
3. How to verify oil filter efficiency.
4. Why grease cleanliness shall not be overlooked.
5. Lubrication’s effect on the roller bearing reliability.
6. How to make your oil analysis program produce more alerts
7. Troubleshooting hydraulic pumps.
8. The risk of grease mixing
9. Lubrication failure mechanism for rolling element bearings.
10. Selecting lubricants for pharmaceutical facilities.
11. Best practices for lubricating paper machines.
12. How to evaluate a new lubricant.
13. Ways to eliminate hydraulic oil leakage.
14. Overcoming the risks of cold machine starts.
15. Understanding the changing requirement for Food Grade lubrication
16. Volatility vs flash point
17. Ways to reduce hydraulic shock
18. Building a successful maintenance program through oil analysis
19. How to measure effectiveness of condition monitoring
20. Why you should crosscheck you oil analysis lab.
21. How Improving lubricant storage and handling can pay off.
22. Best practices for using oil analysis in lubrication management.
23. Choose the right lubricant to reduce air pollution.
24. Aligning Lubrication with ISO 55000
25. How to mitigate contaminant ingression in hydraulic systems
26. Measuring the financial impact of a successful lubrication program.
27. Contamination control strategies for turbomachinery.
28. Why you should maintain precise oil levels in sumps and reservoirs.
29. Will ISO 55000 change the definition of Lubrication Excellence?
30. Why hydraulic oil changes color.
31. How to interpret oil analysis report.
32. Best ways to combat Oil gelation.
33. What you should know about Lubrication Toxicity.
34. Understanding how engines consume oil.
35. The right way to lubricate worm gears.
36. Selecting lubricants based on specifications.
37. Why communication is key for a successful lubrication program.
38. How to set elemental limit values for motor oils.
39. How to select Machines for oil analysis.
40. Gearbox condition monitoring through oil analysis.