ICML 55.2 - guideline for the optimized lubrication of mechanical physical assets:
ICML 55.2 is part of a series of standards documents that represent the ICML 55ʼ International Lubrication Standard. ICML 55.2 is designed to take an in-depth look at the twelve Lubrication Management Plans/Auditable Elements outlined in ICML 55.1, to illustrate the value of each element (the Why?),...
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| Main Author: | |
|---|---|
| Format: | Electronic eBook |
| Language: | English |
| Published: |
Gistrup, Denmark
River Publishers
[2023]
|
| Series: | ICML 55 series
|
| Subjects: | |
| Online Access: | FHI01 Volltext |
| Summary: | ICML 55.2 is part of a series of standards documents that represent the ICML 55ʼ International Lubrication Standard. ICML 55.2 is designed to take an in-depth look at the twelve Lubrication Management Plans/Auditable Elements outlined in ICML 55.1, to illustrate the value of each element (the Why?), and provide the reader with many ⁰́₋how to⁰́₊ examples. Included are many ⁰́₋punch lists⁰́₊ of typical requirements an auditor would look for to prove compliance readiness for certification purposes. Even if certification is not the goal, ICML 55.2 can be used as a practical ⁰́₋blueprint⁰́₊ manual for implementing a best practice lubrication management program, as well as a reference and study guide for many of the individual certifications offered by the ICML. ICML 55.2 is intended for use in association with ICML 55.0, Optimized Lubrication of Mechanical Physical Assets Overview, ICML 55.1, Requirements for the Optimized Lubrication of Mechanical Physical Assets, and ICML 55.3, Auditors⁰́₉ Standard Practice and Policies Manual |
| Physical Description: | 1 Online-Ressource (xxv, 248 Seiten) |
| ISBN: | 9788770040372 8770040370 |
Staff View
MARC
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| 100 | 1 | |a Bannister, Kenneth E. |d 1955- |e Verfasser |4 aut | |
| 245 | 1 | 0 | |a ICML 55.2 - guideline for the optimized lubrication of mechanical physical assets |c Kenneth E. Bannister |
| 264 | 1 | |a Gistrup, Denmark |b River Publishers |c [2023] | |
| 300 | |a 1 Online-Ressource (xxv, 248 Seiten) | ||
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| 490 | 0 | |a ICML 55 series | |
| 505 | 8 | |a Foreword xiii Acknowledgments xvii List of Figures xix List of Tables xxi List of Abbreviations xxiii 1 Job Task Skills, | |
| 505 | 8 | |a Training and Competency 1 1.1 Delivering Effective and Appropriate Training 2 1.2 Selecting a Training Partner 6 1.3 Strata and Content for Lubrication Technicians/Trainees 8 1.4 Providing Content for Knowledge Development 9 2 Machine Lubrication and Condition Monitoring Readiness 13 2.1 Machine Lubrication 14 2.2 Condition Monitoring Readiness 16 2.2.1 Preparing for and building a condition monitoring (CM) program 17 2.2.2 Benefitting from your CM program 20 3 Lubrication System Design and Selection 23 3.1 Lubrication System Design 24 3.1.1 Gauging machine health 24 3.1.2 Correct oil sampling 25 3.1.3 Facilitating inspection 25 3.1.4 Facilitating lubrication tasks 25 3.1.5 Facilitating condition monitoring 26 3.1.6 Designing for contamination control 26 3.1.7 Designing for reliabilty 27 3.1.8 Lubricant fill quantity 27 3.1.9 Storage and handling practice 28 3.1.10 Facilitating routine lubrication 28 3.1.11 Identifying lubricants 29 3.1.12 Facilitating lubricant identification 29 | |
| 505 | 8 | |a 3.1.13 Real-time monitoring 30 3.1.14 Leak prevention 30 3.2 Supplier Selection 31 3.2.1 The range and quality of lubricants offered 31 3.2.2 Lubricant test capability offered, to include condition monitoring service 32 3.2.3 The ability and willingness to provide certification of conformity 32 3.2.4 Having up-to-date SDS or other safety information and providing this information in a timely manner when changes occur 32 3.2.5 Willingness or ability to concurrently supply other chemical or hydrocarbon fluids including fuel, heat transfer fluids, coolants, solvents, and pastes 33 3.2.6 Bulk and package volume and related options 33 3.2.7 Availability to supply accessible and competent technical support 33 3.2.8 Provide timely information when lubricants are no longer manufactured 34 3.2.9 Capability to provide compatible replacement lubricants when obsolescence is identified 34 3.2.10 Geographic coverage or service area (especially important for multi-plant operations, linear assets, | |
| 505 | 8 | |a mobile equipment, etc.) 34 3.2.11 Willingness or ability to supply and deliver any specialty lubricants that are required but are marketed under another brand name 34 3.2.12 Willingness to guarantee the performance of their lubricants 35 3.2.13 Lubricant cost 35 3.2.14 Lead time of lubricant deliveries and willingness to maintain an inventory of critical lubricants, in proximity, | |
| 505 | 8 | |a to minimize delay in emergency situations 35 3.2.15 Avoid selecting and procuring lubricants as a commodity item 36 4 Planned and Corrective Maintenance Lubrication Tasks 37 4.1 Health and Safety 41 4.1.1 Safety regulations 43 4.1.2 North American environmental regulations 44 4.1.3 European environmental regulations 45 4.2 Planned Maintenance Task Elements 46 4.3 Corrective Maintenance Task Elements 50 4.3.1 Comparison of planned and corrective lubricant maintenance task elements 53 4.3.2 Guidance for planned and corrective lubricant maintenance programs 58 References 60 5 Lubrication Support Facilities and Tools 63 5.1 Lubricant and Lubrication Support Facilities and Infrastructure 64 5.1.1 Lubrication room that provides sufficient space and control of ambient conditions to maintain the lubricant assets in optimal condition 64 5.1.2 Management and dispensation of lubricants, lubrication tools, filters, breathers, | |
| 505 | 8 | |a and other lubrication accessories 66 5.1.3 Restricted access to the population that can obtain lubricants, to reduce the risk of poor lubricant management 68 5.1.4 Satellite storage areas, which may be created for large facilities by placing smaller/additional storage areas throughout the facility Satellite storage facilities include tanks, piping systems, and mobile units (mining, construction, etc.) Also, satellite facilities need to comply with the same requirements as the primary lubricant storage area 69 5.1.5 Lubricant containers that are properly sized and of acceptable quality to support program requirements 69 5.1.6 A staging area that allows for support of lubrication tasks 70 5.1.7 Clear identification of lubricant types on each permanent or portable lubricant container 72 5.1.8 Methods to receive and inspect new lubricants that minimize the risk of spillage and contaminant ingestion 72 5.1.9 Methods for lubricant stock rotation (e.g., first in, | |
| 505 | 8 | |a first out) 74 5.1.10 A process to ensure that lubricants are not stored for extended periods prior to use 74 5.1.11 A process to determine if new lubricants meet specification requirements 75 5.1.12 A process to decontaminate or reject lubricants deemed to be unacceptable upon receipt 76 5.1.13 Sample points that provide for effective, efficient, and safe access for the sampling of stored lubricants 76 5.1.14 A sampling process of stored lubricants that minimizes the risk of contaminant ingestion 77 5.1.15 A process to manage lubricant samples for testing 77 5.1.16 Effective, efficient, and safe access to allow periodic filtration and/or conditioning when required 78 5.1.17 Containment areas to collect incidentally spilled or leaked lubricants to avoid safety and/or environmental risks 78 5.1.18 Separation of new and used lubricants When kept in near proximity, | |
| 505 | 8 | |a clearly marked containers for storing used oil to avoid reuse 78 5.1.19 A disposal plan to ensure proper handling and management of waste per the organization⁰́₉s safety and environmental compliance standards and requirements 79 5.1.20 Safety provisions such as appropriately positioned eyewash stations and ventilation Ready access to SDS/MDS sheets 80 5.1.21 Local and national environmental regulations available for use. | |
| 505 | 8 | |a 80 5.2 Tools, Instrumentation (Automation), and Consumables 80 6 Machine and Lubricant Inspection 83 6.1 Inspection Plan 85 6.1.1 Multiple disciplines 86 6.1.2 Common goals 86 6.1.3 Alignment with ranked failure modes 87 6.1.4 Inspecting across the five operating states 88 6.1.5 Machine inspection ownership 92 6.1.6 Inspection points 94 6.1.7 Inspection tasks and methods 96 6.1.8 Inspector skills, training, | |
| 505 | 8 | |a and qualifications 100 6.1.9 Tools and machine modifications needed 100 6.1.10 Inspection findings and data collection 103 6.1.11 Inspection routes 104 6.1.12 Health and safety issues 105 6.1.13 Metrics and compliance 105 6.1.14 Audits of the inspection plan 107 6.2 Practical Implementation of the Inspection Plan 107 7 Condition Monitoring and Lubricant Analysis 109 7.1 Lubricant Analysis Information 111 7.1.1 Lubricant baseline signature data 111 7.1.2 Lubricant remaining useful life 113 7.1.3 Failure indicators 114 7.1.4 Wear metal analysis 114 7.1.5 Contamination control device failure 114 7.2 Assuring Effective Execution of Lubricant Analysis 115 7.2.1 Test slate example for compressors 117 7.2.2 Test slate example for pumps 118 7.3 Analytical Ferrography 119 7.3.1 Test slate example for gearboxes 120 7.3.2 Test slate example for hydraulic systems 121 7.3.3 Test slate example for bearings 122 7.3.4 The P-F interval 124 7.3.5 Machine criticality 124 7.3.6 Failure risk profile and | |
| 505 | 8 | |a analytics 125 7.3.7 Regulatory and insurance requirements 126 7.4 Lubricant Sampling 127 7.4.1 Sampling frequency 127 7.4.2 Optimize data density 128 7.4.3 Sample bottles 129 7.4.4 Sampling tools and retrofitting 130 7.4.5 Sample bottle labeling 131 7.4.6 Setting alarm limits ⁰́₃ determining optimal, cautionary, and critical limits 133 7.4.7 Using cause failure analysis to set alarms 134 7.4.8 Variation between machines and applications 134 7.4.9 Data trending techniques 135 7.4.10 Instrumentation 137 7.4.11 Selection of test methods 138 7.4.12 Typical internal test slate 139 7.4.13 Hardware, materials, and workspace 141 7.4.14 Training 141 7.4.15 Standardized procedures: ASTM, ISO, | |
| 505 | 8 | |a and internal SOPs 143 7.4.16 Instrument calibration/maintenance 144 7.4.17 Data collection and management methods 145 7.4.18 Health and safety precautions 146 7.4.19 Waste disposal 147 7.4.20 Selecting the right laboratory 148 7.4.21 Test selection 149 7.4.22 Offsite testing capabilities 150 7.4.23 Wear testing 150 7.4.24 Ferrous debris 150 7.4.25 Elemental analysis 150 7.4.26 Microscopic analysis 151 7.4.27 Contamination testing 151 7.4.28 Physical properties testing 152 7.4.29 Grease analysis 152 8 Fault/Failure Troubleshooting and Root Cause Analysis 157 8.1 Fault Analysis 159 8.1.1 Implementing a fault analysis system 159 8.1.2 Failure analysis process 162 8.1.3 Output of failure analysis and risk mitigation 163 8.1.4 Measurement performance and effectiveness of the failure analysis system 165 8.2 Troubleshooting 166 8.2.1 The troubleshooting plan 166 8.2.2 The criteria and properties of the troubleshooting plan 166 8.2.3 Objective of the troubleshooting process 166 8.2.4 The | |
| 505 | 8 | |a troubleshooting process 167 8.2.5 The review process of the troubleshooting plan 167 8.3 Root Cause Analysis (RCA) 168 8.3.1 Objective(s) of the RCA process 169 8.3.2 Benefits of performing RCA 169 8.3.3 Selection methodology for faults and defects investigated using RCA 170 8.3.4 The five-step RCA process 170 8.3.5 Root cause analysis methodology 173 9 Lubricant Waste Handling and Management 175 9.1 Lubricant Specifications 176 9.2 Waste Management Consumables 176 9.3 Waste Reduction Strategy 177 9.4 What Constitutes Waste Oil 177 9.5 Classifying and Managing Waste Oil 179 9.6 Managing Used and Waste Oils 179 References 181 10 Energy Conservation and Environmental Impact 183 10.1 Energy Conservation 184 10.1.1 Choosing the right lubricant 184 10.1.2 Contamination control 188 10.1.3 Fluid volume 189 10.1.4 Measuring lubricant health 189 10.1.5 Energy reduction measurement 190 10.2 Environmental Impact 190 10.2.1 Choosing a more environment-friendly lubricant (EFL) 191 10.2.2 Ensuring | |
| 505 | 8 | |a your environmen ... | |
| 520 | 3 | |a ICML 55.2 is part of a series of standards documents that represent the ICML 55ʼ International Lubrication Standard. ICML 55.2 is designed to take an in-depth look at the twelve Lubrication Management Plans/Auditable Elements outlined in ICML 55.1, to illustrate the value of each element (the Why?), and provide the reader with many ⁰́₋how to⁰́₊ examples. Included are many ⁰́₋punch lists⁰́₊ of typical requirements an auditor would look for to prove compliance readiness for certification purposes. Even if certification is not the goal, ICML 55.2 can be used as a practical ⁰́₋blueprint⁰́₊ manual for implementing a best practice lubrication management program, as well as a reference and study guide for many of the individual certifications offered by the ICML. ICML 55.2 is intended for use in association with ICML 55.0, Optimized Lubrication of Mechanical Physical Assets Overview, ICML 55.1, Requirements for the Optimized Lubrication of Mechanical Physical Assets, and ICML 55.3, Auditors⁰́₉ Standard Practice and Policies Manual | |
| 653 | 0 | |a Lubrication and lubricants / Standards | |
| 653 | 0 | |a Lubrication systems / Standards | |
| 653 | 0 | |a Graissage / Normes | |
| 776 | 0 | 8 | |i Erscheint auch als |n Druck-Ausgabe |z 9788770040372 |z 8770223513 |
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| 999 | |a oai:aleph.bib-bvb.de:BVB01-034839861 | ||
| 966 | e | |u https://ieeexplore.ieee.org/book/10196675 |l FHI01 |p ZDB-37-RPEB |x Verlag |3 Volltext | |
Record in the Search Index
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| author | Bannister, Kenneth E. 1955- |
| author_facet | Bannister, Kenneth E. 1955- |
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| contents | Foreword xiii Acknowledgments xvii List of Figures xix List of Tables xxi List of Abbreviations xxiii 1 Job Task Skills, Training and Competency 1 1.1 Delivering Effective and Appropriate Training 2 1.2 Selecting a Training Partner 6 1.3 Strata and Content for Lubrication Technicians/Trainees 8 1.4 Providing Content for Knowledge Development 9 2 Machine Lubrication and Condition Monitoring Readiness 13 2.1 Machine Lubrication 14 2.2 Condition Monitoring Readiness 16 2.2.1 Preparing for and building a condition monitoring (CM) program 17 2.2.2 Benefitting from your CM program 20 3 Lubrication System Design and Selection 23 3.1 Lubrication System Design 24 3.1.1 Gauging machine health 24 3.1.2 Correct oil sampling 25 3.1.3 Facilitating inspection 25 3.1.4 Facilitating lubrication tasks 25 3.1.5 Facilitating condition monitoring 26 3.1.6 Designing for contamination control 26 3.1.7 Designing for reliabilty 27 3.1.8 Lubricant fill quantity 27 3.1.9 Storage and handling practice 28 3.1.10 Facilitating routine lubrication 28 3.1.11 Identifying lubricants 29 3.1.12 Facilitating lubricant identification 29 3.1.13 Real-time monitoring 30 3.1.14 Leak prevention 30 3.2 Supplier Selection 31 3.2.1 The range and quality of lubricants offered 31 3.2.2 Lubricant test capability offered, to include condition monitoring service 32 3.2.3 The ability and willingness to provide certification of conformity 32 3.2.4 Having up-to-date SDS or other safety information and providing this information in a timely manner when changes occur 32 3.2.5 Willingness or ability to concurrently supply other chemical or hydrocarbon fluids including fuel, heat transfer fluids, coolants, solvents, and pastes 33 3.2.6 Bulk and package volume and related options 33 3.2.7 Availability to supply accessible and competent technical support 33 3.2.8 Provide timely information when lubricants are no longer manufactured 34 3.2.9 Capability to provide compatible replacement lubricants when obsolescence is identified 34 3.2.10 Geographic coverage or service area (especially important for multi-plant operations, linear assets, mobile equipment, etc.) 34 3.2.11 Willingness or ability to supply and deliver any specialty lubricants that are required but are marketed under another brand name 34 3.2.12 Willingness to guarantee the performance of their lubricants 35 3.2.13 Lubricant cost 35 3.2.14 Lead time of lubricant deliveries and willingness to maintain an inventory of critical lubricants, in proximity, to minimize delay in emergency situations 35 3.2.15 Avoid selecting and procuring lubricants as a commodity item 36 4 Planned and Corrective Maintenance Lubrication Tasks 37 4.1 Health and Safety 41 4.1.1 Safety regulations 43 4.1.2 North American environmental regulations 44 4.1.3 European environmental regulations 45 4.2 Planned Maintenance Task Elements 46 4.3 Corrective Maintenance Task Elements 50 4.3.1 Comparison of planned and corrective lubricant maintenance task elements 53 4.3.2 Guidance for planned and corrective lubricant maintenance programs 58 References 60 5 Lubrication Support Facilities and Tools 63 5.1 Lubricant and Lubrication Support Facilities and Infrastructure 64 5.1.1 Lubrication room that provides sufficient space and control of ambient conditions to maintain the lubricant assets in optimal condition 64 5.1.2 Management and dispensation of lubricants, lubrication tools, filters, breathers, and other lubrication accessories 66 5.1.3 Restricted access to the population that can obtain lubricants, to reduce the risk of poor lubricant management 68 5.1.4 Satellite storage areas, which may be created for large facilities by placing smaller/additional storage areas throughout the facility Satellite storage facilities include tanks, piping systems, and mobile units (mining, construction, etc.) Also, satellite facilities need to comply with the same requirements as the primary lubricant storage area 69 5.1.5 Lubricant containers that are properly sized and of acceptable quality to support program requirements 69 5.1.6 A staging area that allows for support of lubrication tasks 70 5.1.7 Clear identification of lubricant types on each permanent or portable lubricant container 72 5.1.8 Methods to receive and inspect new lubricants that minimize the risk of spillage and contaminant ingestion 72 5.1.9 Methods for lubricant stock rotation (e.g., first in, first out) 74 5.1.10 A process to ensure that lubricants are not stored for extended periods prior to use 74 5.1.11 A process to determine if new lubricants meet specification requirements 75 5.1.12 A process to decontaminate or reject lubricants deemed to be unacceptable upon receipt 76 5.1.13 Sample points that provide for effective, efficient, and safe access for the sampling of stored lubricants 76 5.1.14 A sampling process of stored lubricants that minimizes the risk of contaminant ingestion 77 5.1.15 A process to manage lubricant samples for testing 77 5.1.16 Effective, efficient, and safe access to allow periodic filtration and/or conditioning when required 78 5.1.17 Containment areas to collect incidentally spilled or leaked lubricants to avoid safety and/or environmental risks 78 5.1.18 Separation of new and used lubricants When kept in near proximity, clearly marked containers for storing used oil to avoid reuse 78 5.1.19 A disposal plan to ensure proper handling and management of waste per the organization⁰́₉s safety and environmental compliance standards and requirements 79 5.1.20 Safety provisions such as appropriately positioned eyewash stations and ventilation Ready access to SDS/MDS sheets 80 5.1.21 Local and national environmental regulations available for use. 80 5.2 Tools, Instrumentation (Automation), and Consumables 80 6 Machine and Lubricant Inspection 83 6.1 Inspection Plan 85 6.1.1 Multiple disciplines 86 6.1.2 Common goals 86 6.1.3 Alignment with ranked failure modes 87 6.1.4 Inspecting across the five operating states 88 6.1.5 Machine inspection ownership 92 6.1.6 Inspection points 94 6.1.7 Inspection tasks and methods 96 6.1.8 Inspector skills, training, and qualifications 100 6.1.9 Tools and machine modifications needed 100 6.1.10 Inspection findings and data collection 103 6.1.11 Inspection routes 104 6.1.12 Health and safety issues 105 6.1.13 Metrics and compliance 105 6.1.14 Audits of the inspection plan 107 6.2 Practical Implementation of the Inspection Plan 107 7 Condition Monitoring and Lubricant Analysis 109 7.1 Lubricant Analysis Information 111 7.1.1 Lubricant baseline signature data 111 7.1.2 Lubricant remaining useful life 113 7.1.3 Failure indicators 114 7.1.4 Wear metal analysis 114 7.1.5 Contamination control device failure 114 7.2 Assuring Effective Execution of Lubricant Analysis 115 7.2.1 Test slate example for compressors 117 7.2.2 Test slate example for pumps 118 7.3 Analytical Ferrography 119 7.3.1 Test slate example for gearboxes 120 7.3.2 Test slate example for hydraulic systems 121 7.3.3 Test slate example for bearings 122 7.3.4 The P-F interval 124 7.3.5 Machine criticality 124 7.3.6 Failure risk profile and analytics 125 7.3.7 Regulatory and insurance requirements 126 7.4 Lubricant Sampling 127 7.4.1 Sampling frequency 127 7.4.2 Optimize data density 128 7.4.3 Sample bottles 129 7.4.4 Sampling tools and retrofitting 130 7.4.5 Sample bottle labeling 131 7.4.6 Setting alarm limits ⁰́₃ determining optimal, cautionary, and critical limits 133 7.4.7 Using cause failure analysis to set alarms 134 7.4.8 Variation between machines and applications 134 7.4.9 Data trending techniques 135 7.4.10 Instrumentation 137 7.4.11 Selection of test methods 138 7.4.12 Typical internal test slate 139 7.4.13 Hardware, materials, and workspace 141 7.4.14 Training 141 7.4.15 Standardized procedures: ASTM, ISO, and internal SOPs 143 7.4.16 Instrument calibration/maintenance 144 7.4.17 Data collection and management methods 145 7.4.18 Health and safety precautions 146 7.4.19 Waste disposal 147 7.4.20 Selecting the right laboratory 148 7.4.21 Test selection 149 7.4.22 Offsite testing capabilities 150 7.4.23 Wear testing 150 7.4.24 Ferrous debris 150 7.4.25 Elemental analysis 150 7.4.26 Microscopic analysis 151 7.4.27 Contamination testing 151 7.4.28 Physical properties testing 152 7.4.29 Grease analysis 152 8 Fault/Failure Troubleshooting and Root Cause Analysis 157 8.1 Fault Analysis 159 8.1.1 Implementing a fault analysis system 159 8.1.2 Failure analysis process 162 8.1.3 Output of failure analysis and risk mitigation 163 8.1.4 Measurement performance and effectiveness of the failure analysis system 165 8.2 Troubleshooting 166 8.2.1 The troubleshooting plan 166 8.2.2 The criteria and properties of the troubleshooting plan 166 8.2.3 Objective of the troubleshooting process 166 8.2.4 The troubleshooting process 167 8.2.5 The review process of the troubleshooting plan 167 8.3 Root Cause Analysis (RCA) 168 8.3.1 Objective(s) of the RCA process 169 8.3.2 Benefits of performing RCA 169 8.3.3 Selection methodology for faults and defects investigated using RCA 170 8.3.4 The five-step RCA process 170 8.3.5 Root cause analysis methodology 173 9 Lubricant Waste Handling and Management 175 9.1 Lubricant Specifications 176 9.2 Waste Management Consumables 176 9.3 Waste Reduction Strategy 177 9.4 What Constitutes Waste Oil 177 9.5 Classifying and Managing Waste Oil 179 9.6 Managing Used and Waste Oils 179 References 181 10 Energy Conservation and Environmental Impact 183 10.1 Energy Conservation 184 10.1.1 Choosing the right lubricant 184 10.1.2 Contamination control 188 10.1.3 Fluid volume 189 10.1.4 Measuring lubricant health 189 10.1.5 Energy reduction measurement 190 10.2 Environmental Impact 190 10.2.1 Choosing a more environment-friendly lubricant (EFL) 191 10.2.2 Ensuring your environmen ... |
| ctrlnum | (OCoLC)1418691145 (DE-599)BVBBV049494609 |
| format | Electronic eBook |
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</subfield></datafield><datafield tag="505" ind1="8" ind2=" "><subfield code="a">Training and Competency 1 1.1 Delivering Effective and Appropriate Training 2 1.2 Selecting a Training Partner 6 1.3 Strata and Content for Lubrication Technicians/Trainees 8 1.4 Providing Content for Knowledge Development 9 2 Machine Lubrication and Condition Monitoring Readiness 13 2.1 Machine Lubrication 14 2.2 Condition Monitoring Readiness 16 2.2.1 Preparing for and building a condition monitoring (CM) program 17 2.2.2 Benefitting from your CM program 20 3 Lubrication System Design and Selection 23 3.1 Lubrication System Design 24 3.1.1 Gauging machine health 24 3.1.2 Correct oil sampling 25 3.1.3 Facilitating inspection 25 3.1.4 Facilitating lubrication tasks 25 3.1.5 Facilitating condition monitoring 26 3.1.6 Designing for contamination control 26 3.1.7 Designing for reliabilty 27 3.1.8 Lubricant fill quantity 27 3.1.9 Storage and handling practice 28 3.1.10 Facilitating routine lubrication 28 3.1.11 Identifying lubricants 29 3.1.12 Facilitating lubricant identification 29 </subfield></datafield><datafield tag="505" ind1="8" ind2=" "><subfield code="a">3.1.13 Real-time monitoring 30 3.1.14 Leak prevention 30 3.2 Supplier Selection 31 3.2.1 The range and quality of lubricants offered 31 3.2.2 Lubricant test capability offered, to include condition monitoring service 32 3.2.3 The ability and willingness to provide certification of conformity 32 3.2.4 Having up-to-date SDS or other safety information and providing this information in a timely manner when changes occur 32 3.2.5 Willingness or ability to concurrently supply other chemical or hydrocarbon fluids including fuel, heat transfer fluids, coolants, solvents, and pastes 33 3.2.6 Bulk and package volume and related options 33 3.2.7 Availability to supply accessible and competent technical support 33 3.2.8 Provide timely information when lubricants are no longer manufactured 34 3.2.9 Capability to provide compatible replacement lubricants when obsolescence is identified 34 3.2.10 Geographic coverage or service area (especially important for multi-plant operations, linear assets, </subfield></datafield><datafield tag="505" ind1="8" ind2=" "><subfield code="a">mobile equipment, etc.) 34 3.2.11 Willingness or ability to supply and deliver any specialty lubricants that are required but are marketed under another brand name 34 3.2.12 Willingness to guarantee the performance of their lubricants 35 3.2.13 Lubricant cost 35 3.2.14 Lead time of lubricant deliveries and willingness to maintain an inventory of critical lubricants, in proximity, </subfield></datafield><datafield tag="505" ind1="8" ind2=" "><subfield code="a">to minimize delay in emergency situations 35 3.2.15 Avoid selecting and procuring lubricants as a commodity item 36 4 Planned and Corrective Maintenance Lubrication Tasks 37 4.1 Health and Safety 41 4.1.1 Safety regulations 43 4.1.2 North American environmental regulations 44 4.1.3 European environmental regulations 45 4.2 Planned Maintenance Task Elements 46 4.3 Corrective Maintenance Task Elements 50 4.3.1 Comparison of planned and corrective lubricant maintenance task elements 53 4.3.2 Guidance for planned and corrective lubricant maintenance programs 58 References 60 5 Lubrication Support Facilities and Tools 63 5.1 Lubricant and Lubrication Support Facilities and Infrastructure 64 5.1.1 Lubrication room that provides sufficient space and control of ambient conditions to maintain the lubricant assets in optimal condition 64 5.1.2 Management and dispensation of lubricants, lubrication tools, filters, breathers, </subfield></datafield><datafield tag="505" ind1="8" ind2=" "><subfield code="a">and other lubrication accessories 66 5.1.3 Restricted access to the population that can obtain lubricants, to reduce the risk of poor lubricant management 68 5.1.4 Satellite storage areas, which may be created for large facilities by placing smaller/additional storage areas throughout the facility Satellite storage facilities include tanks, piping systems, and mobile units (mining, construction, etc.) Also, satellite facilities need to comply with the same requirements as the primary lubricant storage area 69 5.1.5 Lubricant containers that are properly sized and of acceptable quality to support program requirements 69 5.1.6 A staging area that allows for support of lubrication tasks 70 5.1.7 Clear identification of lubricant types on each permanent or portable lubricant container 72 5.1.8 Methods to receive and inspect new lubricants that minimize the risk of spillage and contaminant ingestion 72 5.1.9 Methods for lubricant stock rotation (e.g., first in, </subfield></datafield><datafield tag="505" ind1="8" ind2=" "><subfield code="a">first out) 74 5.1.10 A process to ensure that lubricants are not stored for extended periods prior to use 74 5.1.11 A process to determine if new lubricants meet specification requirements 75 5.1.12 A process to decontaminate or reject lubricants deemed to be unacceptable upon receipt 76 5.1.13 Sample points that provide for effective, efficient, and safe access for the sampling of stored lubricants 76 5.1.14 A sampling process of stored lubricants that minimizes the risk of contaminant ingestion 77 5.1.15 A process to manage lubricant samples for testing 77 5.1.16 Effective, efficient, and safe access to allow periodic filtration and/or conditioning when required 78 5.1.17 Containment areas to collect incidentally spilled or leaked lubricants to avoid safety and/or environmental risks 78 5.1.18 Separation of new and used lubricants When kept in near proximity, </subfield></datafield><datafield tag="505" ind1="8" ind2=" "><subfield code="a">clearly marked containers for storing used oil to avoid reuse 78 5.1.19 A disposal plan to ensure proper handling and management of waste per the organization⁰́₉s safety and environmental compliance standards and requirements 79 5.1.20 Safety provisions such as appropriately positioned eyewash stations and ventilation Ready access to SDS/MDS sheets 80 5.1.21 Local and national environmental regulations available for use. </subfield></datafield><datafield tag="505" ind1="8" ind2=" "><subfield code="a">80 5.2 Tools, Instrumentation (Automation), and Consumables 80 6 Machine and Lubricant Inspection 83 6.1 Inspection Plan 85 6.1.1 Multiple disciplines 86 6.1.2 Common goals 86 6.1.3 Alignment with ranked failure modes 87 6.1.4 Inspecting across the five operating states 88 6.1.5 Machine inspection ownership 92 6.1.6 Inspection points 94 6.1.7 Inspection tasks and methods 96 6.1.8 Inspector skills, training, </subfield></datafield><datafield tag="505" ind1="8" ind2=" "><subfield code="a">and qualifications 100 6.1.9 Tools and machine modifications needed 100 6.1.10 Inspection findings and data collection 103 6.1.11 Inspection routes 104 6.1.12 Health and safety issues 105 6.1.13 Metrics and compliance 105 6.1.14 Audits of the inspection plan 107 6.2 Practical Implementation of the Inspection Plan 107 7 Condition Monitoring and Lubricant Analysis 109 7.1 Lubricant Analysis Information 111 7.1.1 Lubricant baseline signature data 111 7.1.2 Lubricant remaining useful life 113 7.1.3 Failure indicators 114 7.1.4 Wear metal analysis 114 7.1.5 Contamination control device failure 114 7.2 Assuring Effective Execution of Lubricant Analysis 115 7.2.1 Test slate example for compressors 117 7.2.2 Test slate example for pumps 118 7.3 Analytical Ferrography 119 7.3.1 Test slate example for gearboxes 120 7.3.2 Test slate example for hydraulic systems 121 7.3.3 Test slate example for bearings 122 7.3.4 The P-F interval 124 7.3.5 Machine criticality 124 7.3.6 Failure risk profile and </subfield></datafield><datafield tag="505" ind1="8" ind2=" "><subfield code="a">analytics 125 7.3.7 Regulatory and insurance requirements 126 7.4 Lubricant Sampling 127 7.4.1 Sampling frequency 127 7.4.2 Optimize data density 128 7.4.3 Sample bottles 129 7.4.4 Sampling tools and retrofitting 130 7.4.5 Sample bottle labeling 131 7.4.6 Setting alarm limits ⁰́₃ determining optimal, cautionary, and critical limits 133 7.4.7 Using cause failure analysis to set alarms 134 7.4.8 Variation between machines and applications 134 7.4.9 Data trending techniques 135 7.4.10 Instrumentation 137 7.4.11 Selection of test methods 138 7.4.12 Typical internal test slate 139 7.4.13 Hardware, materials, and workspace 141 7.4.14 Training 141 7.4.15 Standardized procedures: ASTM, ISO, </subfield></datafield><datafield tag="505" ind1="8" ind2=" "><subfield code="a">and internal SOPs 143 7.4.16 Instrument calibration/maintenance 144 7.4.17 Data collection and management methods 145 7.4.18 Health and safety precautions 146 7.4.19 Waste disposal 147 7.4.20 Selecting the right laboratory 148 7.4.21 Test selection 149 7.4.22 Offsite testing capabilities 150 7.4.23 Wear testing 150 7.4.24 Ferrous debris 150 7.4.25 Elemental analysis 150 7.4.26 Microscopic analysis 151 7.4.27 Contamination testing 151 7.4.28 Physical properties testing 152 7.4.29 Grease analysis 152 8 Fault/Failure Troubleshooting and Root Cause Analysis 157 8.1 Fault Analysis 159 8.1.1 Implementing a fault analysis system 159 8.1.2 Failure analysis process 162 8.1.3 Output of failure analysis and risk mitigation 163 8.1.4 Measurement performance and effectiveness of the failure analysis system 165 8.2 Troubleshooting 166 8.2.1 The troubleshooting plan 166 8.2.2 The criteria and properties of the troubleshooting plan 166 8.2.3 Objective of the troubleshooting process 166 8.2.4 The </subfield></datafield><datafield tag="505" ind1="8" ind2=" "><subfield code="a">troubleshooting process 167 8.2.5 The review process of the troubleshooting plan 167 8.3 Root Cause Analysis (RCA) 168 8.3.1 Objective(s) of the RCA process 169 8.3.2 Benefits of performing RCA 169 8.3.3 Selection methodology for faults and defects investigated using RCA 170 8.3.4 The five-step RCA process 170 8.3.5 Root cause analysis methodology 173 9 Lubricant Waste Handling and Management 175 9.1 Lubricant Specifications 176 9.2 Waste Management Consumables 176 9.3 Waste Reduction Strategy 177 9.4 What Constitutes Waste Oil 177 9.5 Classifying and Managing Waste Oil 179 9.6 Managing Used and Waste Oils 179 References 181 10 Energy Conservation and Environmental Impact 183 10.1 Energy Conservation 184 10.1.1 Choosing the right lubricant 184 10.1.2 Contamination control 188 10.1.3 Fluid volume 189 10.1.4 Measuring lubricant health 189 10.1.5 Energy reduction measurement 190 10.2 Environmental Impact 190 10.2.1 Choosing a more environment-friendly lubricant (EFL) 191 10.2.2 Ensuring </subfield></datafield><datafield tag="505" ind1="8" ind2=" "><subfield code="a">your environmen ...</subfield></datafield><datafield tag="520" ind1="3" ind2=" "><subfield code="a">ICML 55.2 is part of a series of standards documents that represent the ICML 55ʼ International Lubrication Standard. ICML 55.2 is designed to take an in-depth look at the twelve Lubrication Management Plans/Auditable Elements outlined in ICML 55.1, to illustrate the value of each element (the Why?), and provide the reader with many ⁰́₋how to⁰́₊ examples. Included are many ⁰́₋punch lists⁰́₊ of typical requirements an auditor would look for to prove compliance readiness for certification purposes. Even if certification is not the goal, ICML 55.2 can be used as a practical ⁰́₋blueprint⁰́₊ manual for implementing a best practice lubrication management program, as well as a reference and study guide for many of the individual certifications offered by the ICML. ICML 55.2 is intended for use in association with ICML 55.0, Optimized Lubrication of Mechanical Physical Assets Overview, ICML 55.1, Requirements for the Optimized Lubrication of Mechanical Physical Assets, and ICML 55.3, Auditors⁰́₉ Standard Practice and Policies Manual</subfield></datafield><datafield tag="653" ind1=" " ind2="0"><subfield code="a">Lubrication and lubricants / Standards</subfield></datafield><datafield tag="653" ind1=" " ind2="0"><subfield code="a">Lubrication systems / Standards</subfield></datafield><datafield tag="653" ind1=" " ind2="0"><subfield code="a">Graissage / Normes</subfield></datafield><datafield tag="776" ind1="0" ind2="8"><subfield code="i">Erscheint auch als</subfield><subfield code="n">Druck-Ausgabe</subfield><subfield code="z">9788770040372</subfield><subfield code="z">8770223513</subfield></datafield><datafield tag="856" ind1="4" ind2="0"><subfield code="u">https://ieeexplore.ieee.org/book/10196675</subfield><subfield code="x">Aggregator</subfield><subfield code="z">URL des Erstveröffentlichers</subfield><subfield code="3">Volltext</subfield></datafield><datafield tag="912" ind1=" " ind2=" "><subfield code="a">ZDB-37-RPEB</subfield></datafield><datafield tag="999" ind1=" " ind2=" "><subfield code="a">oai:aleph.bib-bvb.de:BVB01-034839861</subfield></datafield><datafield tag="966" ind1="e" ind2=" "><subfield code="u">https://ieeexplore.ieee.org/book/10196675</subfield><subfield code="l">FHI01</subfield><subfield code="p">ZDB-37-RPEB</subfield><subfield code="x">Verlag</subfield><subfield code="3">Volltext</subfield></datafield></record></collection> |
| id | DE-604.BV049494609 |
| illustrated | Not Illustrated |
| index_date | 2024-07-03T23:20:17Z |
| indexdate | 2024-07-10T10:08:52Z |
| institution | BVB |
| isbn | 9788770040372 8770040370 |
| language | English |
| oai_aleph_id | oai:aleph.bib-bvb.de:BVB01-034839861 |
| oclc_num | 1418691145 |
| open_access_boolean | |
| owner | DE-573 |
| owner_facet | DE-573 |
| physical | 1 Online-Ressource (xxv, 248 Seiten) |
| psigel | ZDB-37-RPEB |
| publishDate | 2023 |
| publishDateSearch | 2023 |
| publishDateSort | 2023 |
| publisher | River Publishers |
| record_format | marc |
| series2 | ICML 55 series |
| spelling | Bannister, Kenneth E. 1955- Verfasser aut ICML 55.2 - guideline for the optimized lubrication of mechanical physical assets Kenneth E. Bannister Gistrup, Denmark River Publishers [2023] 1 Online-Ressource (xxv, 248 Seiten) txt rdacontent c rdamedia cr rdacarrier ICML 55 series Foreword xiii Acknowledgments xvii List of Figures xix List of Tables xxi List of Abbreviations xxiii 1 Job Task Skills, Training and Competency 1 1.1 Delivering Effective and Appropriate Training 2 1.2 Selecting a Training Partner 6 1.3 Strata and Content for Lubrication Technicians/Trainees 8 1.4 Providing Content for Knowledge Development 9 2 Machine Lubrication and Condition Monitoring Readiness 13 2.1 Machine Lubrication 14 2.2 Condition Monitoring Readiness 16 2.2.1 Preparing for and building a condition monitoring (CM) program 17 2.2.2 Benefitting from your CM program 20 3 Lubrication System Design and Selection 23 3.1 Lubrication System Design 24 3.1.1 Gauging machine health 24 3.1.2 Correct oil sampling 25 3.1.3 Facilitating inspection 25 3.1.4 Facilitating lubrication tasks 25 3.1.5 Facilitating condition monitoring 26 3.1.6 Designing for contamination control 26 3.1.7 Designing for reliabilty 27 3.1.8 Lubricant fill quantity 27 3.1.9 Storage and handling practice 28 3.1.10 Facilitating routine lubrication 28 3.1.11 Identifying lubricants 29 3.1.12 Facilitating lubricant identification 29 3.1.13 Real-time monitoring 30 3.1.14 Leak prevention 30 3.2 Supplier Selection 31 3.2.1 The range and quality of lubricants offered 31 3.2.2 Lubricant test capability offered, to include condition monitoring service 32 3.2.3 The ability and willingness to provide certification of conformity 32 3.2.4 Having up-to-date SDS or other safety information and providing this information in a timely manner when changes occur 32 3.2.5 Willingness or ability to concurrently supply other chemical or hydrocarbon fluids including fuel, heat transfer fluids, coolants, solvents, and pastes 33 3.2.6 Bulk and package volume and related options 33 3.2.7 Availability to supply accessible and competent technical support 33 3.2.8 Provide timely information when lubricants are no longer manufactured 34 3.2.9 Capability to provide compatible replacement lubricants when obsolescence is identified 34 3.2.10 Geographic coverage or service area (especially important for multi-plant operations, linear assets, mobile equipment, etc.) 34 3.2.11 Willingness or ability to supply and deliver any specialty lubricants that are required but are marketed under another brand name 34 3.2.12 Willingness to guarantee the performance of their lubricants 35 3.2.13 Lubricant cost 35 3.2.14 Lead time of lubricant deliveries and willingness to maintain an inventory of critical lubricants, in proximity, to minimize delay in emergency situations 35 3.2.15 Avoid selecting and procuring lubricants as a commodity item 36 4 Planned and Corrective Maintenance Lubrication Tasks 37 4.1 Health and Safety 41 4.1.1 Safety regulations 43 4.1.2 North American environmental regulations 44 4.1.3 European environmental regulations 45 4.2 Planned Maintenance Task Elements 46 4.3 Corrective Maintenance Task Elements 50 4.3.1 Comparison of planned and corrective lubricant maintenance task elements 53 4.3.2 Guidance for planned and corrective lubricant maintenance programs 58 References 60 5 Lubrication Support Facilities and Tools 63 5.1 Lubricant and Lubrication Support Facilities and Infrastructure 64 5.1.1 Lubrication room that provides sufficient space and control of ambient conditions to maintain the lubricant assets in optimal condition 64 5.1.2 Management and dispensation of lubricants, lubrication tools, filters, breathers, and other lubrication accessories 66 5.1.3 Restricted access to the population that can obtain lubricants, to reduce the risk of poor lubricant management 68 5.1.4 Satellite storage areas, which may be created for large facilities by placing smaller/additional storage areas throughout the facility Satellite storage facilities include tanks, piping systems, and mobile units (mining, construction, etc.) Also, satellite facilities need to comply with the same requirements as the primary lubricant storage area 69 5.1.5 Lubricant containers that are properly sized and of acceptable quality to support program requirements 69 5.1.6 A staging area that allows for support of lubrication tasks 70 5.1.7 Clear identification of lubricant types on each permanent or portable lubricant container 72 5.1.8 Methods to receive and inspect new lubricants that minimize the risk of spillage and contaminant ingestion 72 5.1.9 Methods for lubricant stock rotation (e.g., first in, first out) 74 5.1.10 A process to ensure that lubricants are not stored for extended periods prior to use 74 5.1.11 A process to determine if new lubricants meet specification requirements 75 5.1.12 A process to decontaminate or reject lubricants deemed to be unacceptable upon receipt 76 5.1.13 Sample points that provide for effective, efficient, and safe access for the sampling of stored lubricants 76 5.1.14 A sampling process of stored lubricants that minimizes the risk of contaminant ingestion 77 5.1.15 A process to manage lubricant samples for testing 77 5.1.16 Effective, efficient, and safe access to allow periodic filtration and/or conditioning when required 78 5.1.17 Containment areas to collect incidentally spilled or leaked lubricants to avoid safety and/or environmental risks 78 5.1.18 Separation of new and used lubricants When kept in near proximity, clearly marked containers for storing used oil to avoid reuse 78 5.1.19 A disposal plan to ensure proper handling and management of waste per the organization⁰́₉s safety and environmental compliance standards and requirements 79 5.1.20 Safety provisions such as appropriately positioned eyewash stations and ventilation Ready access to SDS/MDS sheets 80 5.1.21 Local and national environmental regulations available for use. 80 5.2 Tools, Instrumentation (Automation), and Consumables 80 6 Machine and Lubricant Inspection 83 6.1 Inspection Plan 85 6.1.1 Multiple disciplines 86 6.1.2 Common goals 86 6.1.3 Alignment with ranked failure modes 87 6.1.4 Inspecting across the five operating states 88 6.1.5 Machine inspection ownership 92 6.1.6 Inspection points 94 6.1.7 Inspection tasks and methods 96 6.1.8 Inspector skills, training, and qualifications 100 6.1.9 Tools and machine modifications needed 100 6.1.10 Inspection findings and data collection 103 6.1.11 Inspection routes 104 6.1.12 Health and safety issues 105 6.1.13 Metrics and compliance 105 6.1.14 Audits of the inspection plan 107 6.2 Practical Implementation of the Inspection Plan 107 7 Condition Monitoring and Lubricant Analysis 109 7.1 Lubricant Analysis Information 111 7.1.1 Lubricant baseline signature data 111 7.1.2 Lubricant remaining useful life 113 7.1.3 Failure indicators 114 7.1.4 Wear metal analysis 114 7.1.5 Contamination control device failure 114 7.2 Assuring Effective Execution of Lubricant Analysis 115 7.2.1 Test slate example for compressors 117 7.2.2 Test slate example for pumps 118 7.3 Analytical Ferrography 119 7.3.1 Test slate example for gearboxes 120 7.3.2 Test slate example for hydraulic systems 121 7.3.3 Test slate example for bearings 122 7.3.4 The P-F interval 124 7.3.5 Machine criticality 124 7.3.6 Failure risk profile and analytics 125 7.3.7 Regulatory and insurance requirements 126 7.4 Lubricant Sampling 127 7.4.1 Sampling frequency 127 7.4.2 Optimize data density 128 7.4.3 Sample bottles 129 7.4.4 Sampling tools and retrofitting 130 7.4.5 Sample bottle labeling 131 7.4.6 Setting alarm limits ⁰́₃ determining optimal, cautionary, and critical limits 133 7.4.7 Using cause failure analysis to set alarms 134 7.4.8 Variation between machines and applications 134 7.4.9 Data trending techniques 135 7.4.10 Instrumentation 137 7.4.11 Selection of test methods 138 7.4.12 Typical internal test slate 139 7.4.13 Hardware, materials, and workspace 141 7.4.14 Training 141 7.4.15 Standardized procedures: ASTM, ISO, and internal SOPs 143 7.4.16 Instrument calibration/maintenance 144 7.4.17 Data collection and management methods 145 7.4.18 Health and safety precautions 146 7.4.19 Waste disposal 147 7.4.20 Selecting the right laboratory 148 7.4.21 Test selection 149 7.4.22 Offsite testing capabilities 150 7.4.23 Wear testing 150 7.4.24 Ferrous debris 150 7.4.25 Elemental analysis 150 7.4.26 Microscopic analysis 151 7.4.27 Contamination testing 151 7.4.28 Physical properties testing 152 7.4.29 Grease analysis 152 8 Fault/Failure Troubleshooting and Root Cause Analysis 157 8.1 Fault Analysis 159 8.1.1 Implementing a fault analysis system 159 8.1.2 Failure analysis process 162 8.1.3 Output of failure analysis and risk mitigation 163 8.1.4 Measurement performance and effectiveness of the failure analysis system 165 8.2 Troubleshooting 166 8.2.1 The troubleshooting plan 166 8.2.2 The criteria and properties of the troubleshooting plan 166 8.2.3 Objective of the troubleshooting process 166 8.2.4 The troubleshooting process 167 8.2.5 The review process of the troubleshooting plan 167 8.3 Root Cause Analysis (RCA) 168 8.3.1 Objective(s) of the RCA process 169 8.3.2 Benefits of performing RCA 169 8.3.3 Selection methodology for faults and defects investigated using RCA 170 8.3.4 The five-step RCA process 170 8.3.5 Root cause analysis methodology 173 9 Lubricant Waste Handling and Management 175 9.1 Lubricant Specifications 176 9.2 Waste Management Consumables 176 9.3 Waste Reduction Strategy 177 9.4 What Constitutes Waste Oil 177 9.5 Classifying and Managing Waste Oil 179 9.6 Managing Used and Waste Oils 179 References 181 10 Energy Conservation and Environmental Impact 183 10.1 Energy Conservation 184 10.1.1 Choosing the right lubricant 184 10.1.2 Contamination control 188 10.1.3 Fluid volume 189 10.1.4 Measuring lubricant health 189 10.1.5 Energy reduction measurement 190 10.2 Environmental Impact 190 10.2.1 Choosing a more environment-friendly lubricant (EFL) 191 10.2.2 Ensuring your environmen ... ICML 55.2 is part of a series of standards documents that represent the ICML 55ʼ International Lubrication Standard. ICML 55.2 is designed to take an in-depth look at the twelve Lubrication Management Plans/Auditable Elements outlined in ICML 55.1, to illustrate the value of each element (the Why?), and provide the reader with many ⁰́₋how to⁰́₊ examples. Included are many ⁰́₋punch lists⁰́₊ of typical requirements an auditor would look for to prove compliance readiness for certification purposes. Even if certification is not the goal, ICML 55.2 can be used as a practical ⁰́₋blueprint⁰́₊ manual for implementing a best practice lubrication management program, as well as a reference and study guide for many of the individual certifications offered by the ICML. ICML 55.2 is intended for use in association with ICML 55.0, Optimized Lubrication of Mechanical Physical Assets Overview, ICML 55.1, Requirements for the Optimized Lubrication of Mechanical Physical Assets, and ICML 55.3, Auditors⁰́₉ Standard Practice and Policies Manual Lubrication and lubricants / Standards Lubrication systems / Standards Graissage / Normes Erscheint auch als Druck-Ausgabe 9788770040372 8770223513 https://ieeexplore.ieee.org/book/10196675 Aggregator URL des Erstveröffentlichers Volltext |
| spellingShingle | Bannister, Kenneth E. 1955- ICML 55.2 - guideline for the optimized lubrication of mechanical physical assets Foreword xiii Acknowledgments xvii List of Figures xix List of Tables xxi List of Abbreviations xxiii 1 Job Task Skills, Training and Competency 1 1.1 Delivering Effective and Appropriate Training 2 1.2 Selecting a Training Partner 6 1.3 Strata and Content for Lubrication Technicians/Trainees 8 1.4 Providing Content for Knowledge Development 9 2 Machine Lubrication and Condition Monitoring Readiness 13 2.1 Machine Lubrication 14 2.2 Condition Monitoring Readiness 16 2.2.1 Preparing for and building a condition monitoring (CM) program 17 2.2.2 Benefitting from your CM program 20 3 Lubrication System Design and Selection 23 3.1 Lubrication System Design 24 3.1.1 Gauging machine health 24 3.1.2 Correct oil sampling 25 3.1.3 Facilitating inspection 25 3.1.4 Facilitating lubrication tasks 25 3.1.5 Facilitating condition monitoring 26 3.1.6 Designing for contamination control 26 3.1.7 Designing for reliabilty 27 3.1.8 Lubricant fill quantity 27 3.1.9 Storage and handling practice 28 3.1.10 Facilitating routine lubrication 28 3.1.11 Identifying lubricants 29 3.1.12 Facilitating lubricant identification 29 3.1.13 Real-time monitoring 30 3.1.14 Leak prevention 30 3.2 Supplier Selection 31 3.2.1 The range and quality of lubricants offered 31 3.2.2 Lubricant test capability offered, to include condition monitoring service 32 3.2.3 The ability and willingness to provide certification of conformity 32 3.2.4 Having up-to-date SDS or other safety information and providing this information in a timely manner when changes occur 32 3.2.5 Willingness or ability to concurrently supply other chemical or hydrocarbon fluids including fuel, heat transfer fluids, coolants, solvents, and pastes 33 3.2.6 Bulk and package volume and related options 33 3.2.7 Availability to supply accessible and competent technical support 33 3.2.8 Provide timely information when lubricants are no longer manufactured 34 3.2.9 Capability to provide compatible replacement lubricants when obsolescence is identified 34 3.2.10 Geographic coverage or service area (especially important for multi-plant operations, linear assets, mobile equipment, etc.) 34 3.2.11 Willingness or ability to supply and deliver any specialty lubricants that are required but are marketed under another brand name 34 3.2.12 Willingness to guarantee the performance of their lubricants 35 3.2.13 Lubricant cost 35 3.2.14 Lead time of lubricant deliveries and willingness to maintain an inventory of critical lubricants, in proximity, to minimize delay in emergency situations 35 3.2.15 Avoid selecting and procuring lubricants as a commodity item 36 4 Planned and Corrective Maintenance Lubrication Tasks 37 4.1 Health and Safety 41 4.1.1 Safety regulations 43 4.1.2 North American environmental regulations 44 4.1.3 European environmental regulations 45 4.2 Planned Maintenance Task Elements 46 4.3 Corrective Maintenance Task Elements 50 4.3.1 Comparison of planned and corrective lubricant maintenance task elements 53 4.3.2 Guidance for planned and corrective lubricant maintenance programs 58 References 60 5 Lubrication Support Facilities and Tools 63 5.1 Lubricant and Lubrication Support Facilities and Infrastructure 64 5.1.1 Lubrication room that provides sufficient space and control of ambient conditions to maintain the lubricant assets in optimal condition 64 5.1.2 Management and dispensation of lubricants, lubrication tools, filters, breathers, and other lubrication accessories 66 5.1.3 Restricted access to the population that can obtain lubricants, to reduce the risk of poor lubricant management 68 5.1.4 Satellite storage areas, which may be created for large facilities by placing smaller/additional storage areas throughout the facility Satellite storage facilities include tanks, piping systems, and mobile units (mining, construction, etc.) Also, satellite facilities need to comply with the same requirements as the primary lubricant storage area 69 5.1.5 Lubricant containers that are properly sized and of acceptable quality to support program requirements 69 5.1.6 A staging area that allows for support of lubrication tasks 70 5.1.7 Clear identification of lubricant types on each permanent or portable lubricant container 72 5.1.8 Methods to receive and inspect new lubricants that minimize the risk of spillage and contaminant ingestion 72 5.1.9 Methods for lubricant stock rotation (e.g., first in, first out) 74 5.1.10 A process to ensure that lubricants are not stored for extended periods prior to use 74 5.1.11 A process to determine if new lubricants meet specification requirements 75 5.1.12 A process to decontaminate or reject lubricants deemed to be unacceptable upon receipt 76 5.1.13 Sample points that provide for effective, efficient, and safe access for the sampling of stored lubricants 76 5.1.14 A sampling process of stored lubricants that minimizes the risk of contaminant ingestion 77 5.1.15 A process to manage lubricant samples for testing 77 5.1.16 Effective, efficient, and safe access to allow periodic filtration and/or conditioning when required 78 5.1.17 Containment areas to collect incidentally spilled or leaked lubricants to avoid safety and/or environmental risks 78 5.1.18 Separation of new and used lubricants When kept in near proximity, clearly marked containers for storing used oil to avoid reuse 78 5.1.19 A disposal plan to ensure proper handling and management of waste per the organization⁰́₉s safety and environmental compliance standards and requirements 79 5.1.20 Safety provisions such as appropriately positioned eyewash stations and ventilation Ready access to SDS/MDS sheets 80 5.1.21 Local and national environmental regulations available for use. 80 5.2 Tools, Instrumentation (Automation), and Consumables 80 6 Machine and Lubricant Inspection 83 6.1 Inspection Plan 85 6.1.1 Multiple disciplines 86 6.1.2 Common goals 86 6.1.3 Alignment with ranked failure modes 87 6.1.4 Inspecting across the five operating states 88 6.1.5 Machine inspection ownership 92 6.1.6 Inspection points 94 6.1.7 Inspection tasks and methods 96 6.1.8 Inspector skills, training, and qualifications 100 6.1.9 Tools and machine modifications needed 100 6.1.10 Inspection findings and data collection 103 6.1.11 Inspection routes 104 6.1.12 Health and safety issues 105 6.1.13 Metrics and compliance 105 6.1.14 Audits of the inspection plan 107 6.2 Practical Implementation of the Inspection Plan 107 7 Condition Monitoring and Lubricant Analysis 109 7.1 Lubricant Analysis Information 111 7.1.1 Lubricant baseline signature data 111 7.1.2 Lubricant remaining useful life 113 7.1.3 Failure indicators 114 7.1.4 Wear metal analysis 114 7.1.5 Contamination control device failure 114 7.2 Assuring Effective Execution of Lubricant Analysis 115 7.2.1 Test slate example for compressors 117 7.2.2 Test slate example for pumps 118 7.3 Analytical Ferrography 119 7.3.1 Test slate example for gearboxes 120 7.3.2 Test slate example for hydraulic systems 121 7.3.3 Test slate example for bearings 122 7.3.4 The P-F interval 124 7.3.5 Machine criticality 124 7.3.6 Failure risk profile and analytics 125 7.3.7 Regulatory and insurance requirements 126 7.4 Lubricant Sampling 127 7.4.1 Sampling frequency 127 7.4.2 Optimize data density 128 7.4.3 Sample bottles 129 7.4.4 Sampling tools and retrofitting 130 7.4.5 Sample bottle labeling 131 7.4.6 Setting alarm limits ⁰́₃ determining optimal, cautionary, and critical limits 133 7.4.7 Using cause failure analysis to set alarms 134 7.4.8 Variation between machines and applications 134 7.4.9 Data trending techniques 135 7.4.10 Instrumentation 137 7.4.11 Selection of test methods 138 7.4.12 Typical internal test slate 139 7.4.13 Hardware, materials, and workspace 141 7.4.14 Training 141 7.4.15 Standardized procedures: ASTM, ISO, and internal SOPs 143 7.4.16 Instrument calibration/maintenance 144 7.4.17 Data collection and management methods 145 7.4.18 Health and safety precautions 146 7.4.19 Waste disposal 147 7.4.20 Selecting the right laboratory 148 7.4.21 Test selection 149 7.4.22 Offsite testing capabilities 150 7.4.23 Wear testing 150 7.4.24 Ferrous debris 150 7.4.25 Elemental analysis 150 7.4.26 Microscopic analysis 151 7.4.27 Contamination testing 151 7.4.28 Physical properties testing 152 7.4.29 Grease analysis 152 8 Fault/Failure Troubleshooting and Root Cause Analysis 157 8.1 Fault Analysis 159 8.1.1 Implementing a fault analysis system 159 8.1.2 Failure analysis process 162 8.1.3 Output of failure analysis and risk mitigation 163 8.1.4 Measurement performance and effectiveness of the failure analysis system 165 8.2 Troubleshooting 166 8.2.1 The troubleshooting plan 166 8.2.2 The criteria and properties of the troubleshooting plan 166 8.2.3 Objective of the troubleshooting process 166 8.2.4 The troubleshooting process 167 8.2.5 The review process of the troubleshooting plan 167 8.3 Root Cause Analysis (RCA) 168 8.3.1 Objective(s) of the RCA process 169 8.3.2 Benefits of performing RCA 169 8.3.3 Selection methodology for faults and defects investigated using RCA 170 8.3.4 The five-step RCA process 170 8.3.5 Root cause analysis methodology 173 9 Lubricant Waste Handling and Management 175 9.1 Lubricant Specifications 176 9.2 Waste Management Consumables 176 9.3 Waste Reduction Strategy 177 9.4 What Constitutes Waste Oil 177 9.5 Classifying and Managing Waste Oil 179 9.6 Managing Used and Waste Oils 179 References 181 10 Energy Conservation and Environmental Impact 183 10.1 Energy Conservation 184 10.1.1 Choosing the right lubricant 184 10.1.2 Contamination control 188 10.1.3 Fluid volume 189 10.1.4 Measuring lubricant health 189 10.1.5 Energy reduction measurement 190 10.2 Environmental Impact 190 10.2.1 Choosing a more environment-friendly lubricant (EFL) 191 10.2.2 Ensuring your environmen ... |
| title | ICML 55.2 - guideline for the optimized lubrication of mechanical physical assets |
| title_auth | ICML 55.2 - guideline for the optimized lubrication of mechanical physical assets |
| title_exact_search | ICML 55.2 - guideline for the optimized lubrication of mechanical physical assets |
| title_exact_search_txtP | ICML 55.2 - guideline for the optimized lubrication of mechanical physical assets |
| title_full | ICML 55.2 - guideline for the optimized lubrication of mechanical physical assets Kenneth E. Bannister |
| title_fullStr | ICML 55.2 - guideline for the optimized lubrication of mechanical physical assets Kenneth E. Bannister |
| title_full_unstemmed | ICML 55.2 - guideline for the optimized lubrication of mechanical physical assets Kenneth E. Bannister |
| title_short | ICML 55.2 - guideline for the optimized lubrication of mechanical physical assets |
| title_sort | icml 55 2 guideline for the optimized lubrication of mechanical physical assets |
| url | https://ieeexplore.ieee.org/book/10196675 |
| work_keys_str_mv | AT bannisterkennethe icml552guidelinefortheoptimizedlubricationofmechanicalphysicalassets |