REAL-WORLD CASE STUDY
As for the payback from these measures, it was estimated that the plant’s pump repair costs in 2010 were reduced by an average of nearly $600,000. Much of these savings can probably be attributed to use of cleaner oil.
a. Numerous pumps and small gearboxes operating at low temperatures (120-140 F) were using high-priced synthetics. They were switched to mineral oils with no effect on performance at significant savings.
2. Lubricant misapplication/consolidation is now a major consideration. (The former supplier had not provided technical services to ensure that the right lubricants were used.) One of RelaDyne’s first steps was to reduce the number of lube products in the plant, without compromising equipment/process performance. To that end, the number of mineral-oil-based lubricants was reduced by 50%. As an example, blowers had previously been lubricated with mineral oils from ISO 68 to ISO 150. After a Chevron synthetic ISO 150 was specified for all blowers—a move that eliminated three lubricant types—performance improved. The following are other examples of misapplication problems and consolidation strategies at the plant:
b. Many gearboxes using non-EP oils were experiencing problems. This was resolved by using a Chevron EP gear oil, resulting in better gearbox reliability. c. Incorrect oil viscosity was identified as a problem with Bird centrifuges at the plant. Although the bearing OEM had recommended the use of an ISO 68 mineral oil, John Gobert believed that was too low, based on the equipment loading. After further discussions with the OEM, the centrifuges were switched to an ISO 150. During a one-year period from 2009 to 2010, repair and production costs were reduced from over $500,000 to $0.
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MARCH/APRIL 2013
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