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Total Fluid Management(TFM) Services

VAS Tribology Solutions

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Total Fluid Management(TFM) Services

  1. 1. 1 Total Fluid Management Services Mr. Praveen Kumar VAS Tribology Solutions India Abstract Total Fluid Management Services increase equipment reliability through the elimination of failures caused by improper lubrication practices. This services provide a highly detailed plan of attack to achieve lubrication excellence.The purpose is to plan and schedule the deployment of lubrication to oil and grease lubricated machinery. While the basis of an effective fluid management services is to provide; the right lubricant, in the right location, in the right amount, at the right time, in the right condition and by the right person .This services assist in the proper practices for storage, handling, dispensing, safety, oil analys is, waste oil disposal, training and PMs. Keywords: Machine Reliability,Lubrication Excellence,Storage & Handling TOTAL FLUID MANAGEMENT SERVICES Many companies' maintenance departments throughout the world have undergone radical changes over the last 50+ years in how they perform maintenance on plant equipment. They have implemeted CMMS system , used oil analysis, spread sheets , condition monitoring, predictive maintenanace , sysnthetic fluid but yet the problems of lubrication remain. It has been determined that inadequate or improper lubrication accounts for as much as 43% of all mechanical failures in industry. A fluid management services should ensure that the correct grade of lubricant is delivered to the right place, in the right quantity, at the right time. The area of fluid management services are lubrication management,coolant management, grease management ,rolling oil management,quenching oil management, transformaer oil management , turbine oil management. Fluid management services define a structured process to help you build a strong fluid management services. The process comprehends six major steps – Plant Audit, Proposal, Implementation, Review, Manage and Innovation. Plant Audit A plant audit of lubricant usage (also known as a lubrication survey or a lubrication chart) is designed to populate the database with a complete set of all oil and grease lubricated equipment in the plant. A database of the oils and greases used in the plant is also required to ensure that the equipment is linked to its appropriate lubricant. This is the first step in the development of a plant fluid management services. Proposal Conclusions of our audit survey will enable us to discuss with customer possible improvements through a full scale and detailed survey led by a qualified engineer. Implementaion Once the proposal is accepted, our team discuss the implementation with customer and share copies of road map and schedule is delivered for each part of the process. During the process of implementation, we keep on update on the project progress for each activities to the key staff through schedule meetings , mails, personal intraction. Review The review meeting enables us to discuss our points of view with customers about the fluid management services and set-up a regular meeting schedule between customers and key members of our team. Manage
  2. 2. 2 With the skilled technician,robust reporting system,latest technology etc we manage the project and perform review on the way our contract is run, We offer customer “Value Added Service”. Innovation Always in search of ever more efficient and innovative solutions, our return of experience enables us to improve continuously on Lubrication enabled reliability, Lubrication excellence,Quality and productivity. Fluid Management Services Include o Create Daily/Weekly/Monthly Lubrication Routes o Inventory Management o Handling & Dispensing o Condition Monitoring o Renewal of fluids o Tank Cleaning o Disposal of used oil o Report Management o In-house training o Measuring the fluid management services Create Daily/Weekly/Monthly Lubrication Routes Once the plant audit has been completed, the entry of scheduled lubrication tasks is carried out. Each lubrication point on a machine train is identified by Lubrication Identification System(LIS) and linked to its appropriate lubricant. With proper analysis,we are enable to generate a lubrication schedule period. Lubrication routes help us to gether day to day activities, task. A properly designed route help us to minimize the amount of time and effort needed to get to all of the lubrication points, and also minimize the amount of lubricant types needed to be used at any one time. This can help ensure that all points are lubricated correctly. Inventory Management Inspection of incoming oil: At the time of delivery ,we take sample and perform required test of incoming new oil in our in-house lab and confirm that the oil ordered is correct by verifying the information on the drum. We request that the oil not be used until the results are back. Lubricant storage: we maintain correct & clear labeling to ensure proper use of the enclosed contents. We consider to prevent the degradation of the physical, chemical and cleanliness requirements of the lubricant throughout the storage and dispensing phase with proper stock rotation and storage methods. Maintain FIFO system: we dedicatedly maintain the FIFO or First In First Out system where the lubricant which Enters the system first & exists the system first. Handling & Dispensing We have focused team to ensure the health and the cleanliness of the lubricant which meets the specifications required by the equipment. The best practices are implemented to eliminate the opportunities for contamination like Pre-filtering of all lubricants, LIS system, S&R containers etc. Scheduled reports for all Preventive Maintenance activities involving oil drains, top ups, sweetening, flushing or reclaiming is recorded and forwarded to the individual responsible for the oil analysis program group in a timely manner. Proper record keeping of any activity involving lubricant consumption, lubricant replacement and/or lubricant top- ups performed is dedicatedly maintained. Our team is trained in visual management techniques to ensure the correct lubricant is being used for each lubrication point which avoid cross contamination. Condition Monitoring On-site testing facility is set up to our customer’s sites and the most of the oil analysis is performed in-house. Lab instruments, including the particle counter, digital viscometer, Refractometer , Ph meter, TAN/TBN kit is used. Onsite tests are performed like concentration,Ph test,Bacterial & Fungus test,Hardness, foaming test,viscosity,moisture content,dirt content,TAN and TBN etc. If a problem is found in the in-house lab and we need more information, we request a second sample be taken and sent to our off-site lab for a detailed report.We also display the oil / coolant testing chart to each & every machine. Renewal of fluids We use a variety of filtration machine for renewal of contaminated oil and coolant at the customer’s site. A common misunderstanding is that oil needs to be changed after a fixed time, miles or hours in operation. We do condition-based maintenance (CBM), which means only changing the oil when an oil analysis report shows that life period of oil has been used and can not be carried further. We fit a good-quality offline filtration machine to remove dust, wear particles, water . Tank Cleaning After years of use, a layer of sludge will accumulate at the bottom of most oil and coolant reservoirs and bulk tanks. In order to obtain optimal performance from filtration equipment, we remove that layer of sludge and internally clean the reservoir. We maintain the all document and checkilist related to cleaning activities. We use wire brushes, shop-vacs, squeegees, and lint-free rags, as required. Disposal of used oil When the life of oil & coolant is over , we dispose it in the correct storage container for same type of lubricant with proper marked and labeled. We classify the lubricant for
  3. 3. 3 the respective disposal and remove from the area without delay. As long storage times allow for the introduction of contaminants (e.g. water) and other fluids, and could result in re-classification. Report Management We manage several types of reports covering all parameters related to fluid maangement services.These reports include list of overdue lubrication tasks, list of machines or components that are using an excessive amount, lubricant inventory level reports, tank cleaning , tramp oil ,disposal of used oil etc.We share daily/weekly/monthly report on TFM activities. In-house training In our fluid management services ,we provide In-house training for supervisor, oil filler, operators and also customer’s senior management. The operators and oil filler /lube technician that are directly responsible for lubrication is properly trained, and individuals that are indirectly involved in the lubrication program also have at least a basic awareness of the program's goals, primary benefits, and its procedural requirements. In order for the organization as a whole to increase equipment reliability through lubrication excellence, it's vital that a lubrication skill development program be put in place to meet the needs of all individuals who have responsibility for lubrication tasks, or that may have input into the lube program. Measuring the fluid management services Our primary goal during the early development of the fluid management services is the identification of overall program needs and the development of roles and responsibilities. Our secondary goal is to move from the development process to more proactive measurements. These includes refining lubrication limits and alarm levels, determining root causes of lubricant-related equipment failures, extending or eliminating lubrication PM tasks, improving the lubrication consolation process and reducing oil consumption. The following is a simplified list of potential key indicators that is used as the lubrication program matures: o Reduce Lubricant Costs o Improve Compliance to Scheduled Lubrication PM Tasks o Improve Equipment Reliability o Improve Oil Cleanliness Levels o Tracking and Trending Lubricant Disposal Costs Fluid Management Services: Benefits Automobile Industry Four years ago, An automobiile company implemented fluid management services and helped them to transform the plant’s lubrication procedures on all critical assets. Now machinery breaks down less often, and maintenance issues are better anticipated. But the real story is how the company went from standard operating procedure for lubrication to world- class with fluid management services. Oil sampling and testing for predictive maintenance was another area in which they was deficient. Know-how on lubrication and experties were lacking. They were also lacking in tank cleaning process , housekeeping, handling & dispensing and documentation and reporting system. While lubrication was not a strong focus at plant, it became a core strength with the implementation of Fluid Management Services. We established an onsite testing facility and made a standard procedures for oil sampling & testing. It started with a plant-wide,top-to-bottom analysis of all plant system that required lubrication.This was followed up with recommendations down to the component level. Fluid Management services also supplied company with detailed, step-by-step intructions for sampling and Overview Challenge o Disorganized lubrication procedure o Equipment failure and downtime o Status quo opposed to change o Product quality o Testing facility o Unplanned tank cleaning o Discard oil & coolant Solution Fluid Management Services Result o Best practices for lubrication o Fewer breakdown, less downtime o Culture change o Improve product quality o Set up onsite testing facility o Sheduled tank cleaning activity o Less dispose oil & coolant o In-house training programe
  4. 4. 4 analysis. Additionally, VAS Tribo consulted them on buildling a world-class lubrication storage room and oil analysis laboratory. This services has also provided the In-house training programe to their site engineer,supervisor,operator. By all account,the operator training has had a lasting impact that has created a best-practices culture at the plant. After implemention of fluid management services, lubricant costs has reduced,improve oil cleanlines levels, tracking and trending their lubricant disposal costs. This services has also helped the company be smarter about purchasing oil for lubrication. Previously, they used 20 different types of oil. That number was reduced 13 after transition to best practices. As result, they gained negotiating ability with oil suppliers because fewer oil types are needed at the plant, and they know exact specification to request. Cutting Oil Consumption Trend