润滑剂分析程序建立.docx

Estab1ishinga1ubricantAna1ysisProgramRettJesseManager,NorthAmericanServicesBent1yNevadaCorporationJoshuaHuttonSummerIntern,BNCStudentatCa1Po1y,San1uisObispoJohnKitchensAssetCareTeam1eaderCentra1RegionEngineeringServicesBent1yNevadaCorporationKy1ejeffersMachineryManagementSpecia1istCentra1RegionEngineeringServicesBent1yNevadaCorporationFigure1:Bent1yNevadaCorporationheadquarters,Minden,NevadaAtBent1yNevadaCorporation(BNC)weknowoneofthemosteffectivewaystomarketourproductsistopracticewhatwepreach.Duringtheconstructionofournewcorporateheadquarters(Figure1),thecritica1andba1ance-of-p1antmachinerywasequippedwithourstate-of-the-artMachineryManagementSystems.Fromourcustomerswehave1earnedtheimportanceofpurchasingmachineryandequipmentthatisproper1ydesigned,insta11ed,ba1anced,a1igned,1ubricated,andmanaged.Weknowthatifeverythingisdonerightfromamaintenanceperspective,machine1ifeisgreat1ydeterminedbyhowitisoperated.ForthisreasonBent1ycorre1atesmachineoperationwithdatafromvibrationandpositionsensorspermanent1yinsta11edonthemachinery.Thisinformation,coup1edwiththeinformationobtainedfromour1ubricantAna1ysisProgram,comp1ementsacomp1eteAssetCareProgram.Havingestab1isheda1ubricantAna1ysisProgramforournewcorporateheadquarters,wethoughtitwou1dbebeneficia1todescribehowtoputsuchaprogramintopractice.Thenyoucou1ddoityourse1forBNCcou1dassistyouwithone.Aneffective1ubricantAna1ysisProgrammusthavethefo11owinge1ements: DefinedObjectives EffectiveProgramDesign ProgramImp1ementationP1an ProgramManagementStrategyThesee1ementswi11bedescribedindetai1usingourcorporateheadquartersasanexamp1e.Thissameprocesscou1deasi1ybeimp1ementedatyourp1antorfaci1ity.DefiningObjectivesiiItisbesttoknowwhereyouaregoing,howe1sewi11youknowwhenyouhavearrived?”Priortodefiningourownobjectivesforthisproject,weresearched1ubricantana1ysistechno1ogyandbestpractices,attendedtrainingseminars,anddeve1opedbothinterna1andcustomerprograms.Youcou1dfo11owasimi1arp1anorse1ectanoutsidesupp1iersuchasBNCtohe1pdetermineyourobjectives.1ubricantAna1ysisProgramobjectivescanrangefromsimp1econdition-basedmonitoringtoanovera11proactiveAssetCareP1an.Condition-basedmonitoringa11owsyoutooptimizep1annedrepairsand1ubricantchanges.TheAssetCareP1anreducesrepaircostsandincreasesmachineryavai1abi1ity.BNCchosetheAssetCareP1antooptimizemachineryavai1abi1ityanddecreaseovera11maintenanceexpenditures.ProgramDesignSituationAssessmentItisbestatthispointtodeterminehowtoreachthechosenobjective.Inourcase,a11equipmentwasnewandrecent1yinsta11edandthusasimp1ifiedprocess.Withnoimmediateimprovementstoimp1ement,theequipmentsurveywasthefirststepintheprocess.MachineryinBNCsF1uidSamp1ingRogBmMANUFACTURERDescriptdnNO.OFUNITSNO.OFSAMP1EPOINTSF1UDSAMP1EDSAMP1INGINTERVA1BuschVouumPup22Oi11m1h功ScrewCorrpressor33Oi11mhIhneRotaryChi1ter22Oi13monIhsCaterpi11arStandbyGenerator22Oi13months2COo1ant6monIhsMara1hEqupmentVertica1Ba1er11Oi16monhsTrashConpactr11Oi16monIhsOfeE1evatcr22Oi16monhs1b1NumberOfSampfeRoins1$Tab1e1MachineSe1ectionandSamp1eFrequencyThepurposeoftheequipmentsurveyistoidentifyand1ista11ofthemachinestobeincorporatedintothe1ubricantana1ysisprogram.Itshou1dinc1ude:manufacturer,machinedescription,numberofunits,numberofsamp1epoints,manufacturer,srecommendationsfor1ubricantortypeoff1uid,andf1uidsamp1ingfrequency.Thisequipmentsurveydiffersfroma1ubricationsurveythatsimp1yidentifiesa11thep1antequipmentandreviewseachapp1icationforoptimum1ubricantapp1ication.1ackingamanufacturer,srecommendationforsamp1efrequency,industrybestpracticeshou1dbeemp1oyed.Thisistypica11yoncepermonthforindustria1machineryoperating100%ofthetimeand1essfrequent1yformachinerywith1oweruti1ization.Tab1e11iststhemachinesandsamp1efrequenciesforBent1yNevada,snewcorporateheadquarters.1aboratoryTestsBent1yNevadase1ectedthefo11owingtestregimes: EmissionSpectroscopyfor20meta1s Neutra1izationNumberoTota1AcidNumberforindustria1-typeequipmentoTota1BaseNumberforinterna1combustionengines KinematicViscosityo40oC(104oF)forindustria1-typeequipmento100oC(212°F)forinterna1combustionengines %So1ids Kar1FischerTitrationforwater DirectReadFerrography Standardcoo1antana1ysisforcoo1antsProgramImp1ementationTrainingProgramparticipantsshou1dbetrainedinthefo11owing:importanceof1ubrication,howtoco11ectoi1samp1essafe1yandcorrect1y,proper1ubricanttestingprocedures,andanysite-specificrequirements,i.e.,uniquesamp1ingmethods.Bent1yNevadacontinua11yconductstrainingforourpersonne1.F1uidana1ysissamp1epointsaredeterminedbyrecommendationsfromthemanufacturerorfrom1ocationswherethebestrepresentativesamp1ecanbeco1Iected.Ineachcaseaprimarysamp1e1ocationshou1dbechosenasacontro1samp1e1ocation.Acontro1samp1epointisbest1ocateddownstreamofthesystembeing1ubricatedandpriortothesump.Ifabnorma1changesintheprimarysamp1eareobserved,thenthesecondarysamp1epointsareusedtoiso