Why You Should Perform a Lubrication Survey at Your Plant Facility

IWHY YOU SHOULD PERFORM A LUBRICATION SURVEY AT YOUR PLANT FACILITY Why you should perform a Lubrication Survey at your plant facility. CONTENTS The confidence gained in knowing that your equipment is running smoothly and efficiently is crucial to the performance of any plant facility. Performing a Lubrication Survey certifies you are going in the right direction in regards to optimal lubricant selection, performance and safety. And a lubricant supplier is an excellent resource for conducting your Lubrication Survey. p.01 DEFINING A LUBRICATION SURVEY p.02 LUBRICATION SURVEY ACTIVITIES: CONVERSATIONS TO CONCLUSIONS p.03 BREAKDOWN OF LUBRICATION SURVEY ACTIVITIES p.04 FOOD GRADE SPECIFIC LUBRICATION SURVEY p.05 LUBRICATION SURVEY BENEFITS p.06 IDENTIFYING THE RIGHT SUPPLIER TO CONDUCT THE SURVEY p.07 TOTAL SPECIALTIES USA, INC. 01WHY YOU SHOULD PERFORM A LUBRICATION SURVEY AT YOUR PLANT FACILITY Identifying and analyzing the following practices allows a plant to focus on proactive procedures versus operating in a reactive manner. And it provides the lubricant supplier conducting the Lubrication Survey specific information for each piece of equipment that leads to educated recommendations based on OEM specifications. • Lubricant storage practices • Lubrication plant maintenance scheduling and compliance • General safety within the plant • Oil sampling practices and analysis To achieve the greatest results, plant facility personnel must participate in the process alongside the lubricant supplier conducting the Lubrication Survey. DEFINING A LUBRICATION SURVEY Conducting a Lubrication Survey at your plant provides an excellent opportunity to identify all equipment lubrication points within a facility and what lubricants should be used. Information that is gathered from the survey is unique to that facility and produces highly applicable recommendations for establishing a proactive lubrication program. Implementing this type of program off of a Lubrication Survey leads to an increase in reliability, lower operating costs, decreased time between failures and less downtime in the facility. Lubrication Surveys are valuable across industries where there is rotating or heavy-duty equipment involved in facility operations. Companies that are experiencing difficulties with operations or are looking to improve their lubrication programs are typically the first to request a lubricant supplier to conduct a survey. DEFINITION Continued reliability issues that lead to increased expenses and cost of goods, reactive operations within facility which decrease planning and scheduling of outages are at risk of occurring if a Lubrication Survey is not conducted. Reasons for conducting a Lubrication Survey Equipment optimization Potential product consolidation Improved reliability Waste and over lubrication reduction Extended drain oils Correct lubricant products in equipment Increased operation efficiency 02WHY YOU SHOULD PERFORM A LUBRICATION SURVEY AT YOUR PLANT FACILITY LUBRICATION SURVEY ACTIVITIES: CONVERSATIONS TO CONCLUSIONS The process for initiating a Lubrication Survey typically arises from discussions around increasing reliability, lowering costs by reducing downtime and making improvements to a facility’s lubrication program. These considerations often take place between plant personnel and their lubricant supplier. ACTIVITIES Once the decision has been made by the plant facility to perform a Lubrication Survey and a supplier has been selected, the timeframe for completion is determined by the size, quantity of equipment and availability of a facility. An average sized facility will normally take 3-5 days to capture all of the information and data points. In order to make comprehensive and effective recommendations, all areas of the facility which have lubrication points must be examined. Field Engineers from the selected lubricant supplier will manage the Lubrication Survey. It is vital to the success of the Lubrication Survey that all facility personnel involved in the reliability of plant equipment participate in the process. Transparency into details like plant maintenance schedules, current lubrication in equipment, frequency of oil samplings, identifying equipment with high failure rate and describing areas of concern enhance the scope of the Lubrication Survey and increase the relevancy of future lubrication programs. Relevant facility personnel include Plant Managers, VP of Operations, Maintenance Managers, Reliability Engineers, Supervisors and Mechanics. After the Lubrication Survey has been completed onsite at the plant facility, it is expected for the conducting lubricant supplier to take one to two weeks to build out their final report. The final report is a deep dive into the recommendations, based on the survey findings, for establishing a proactive lubrication program that will lower operating costs, decrease time between equipment failures, provide a better understanding of plant equipment and reduce facility downtime. Lubrication Surveys are not a one-time service provided to a plant facility. After the initial survey is performed, the conducting lubricant supplier maintains continuous contact the facility to ensure corrective actions are performed accurately throughout implementation. Surveys are recommended every 3 to 5 years depending on equipment and personnel changes or if failures begin occurring due to unknown reasons. Symptoms and conditions leading to a Lubrication Survey High failure rates Inexperienced plant staff Frequent staff turnover Desire for improved reliability 03WHY YOU SHOULD PERFORM A LUBRICATION SURVEY AT YOUR PLANT FACILITY BREAKDOWN OF LUBRICATION SURVEY ACTIVITIES Below is a breakdown of the activities that occur after the decision has been made between a plant facility and lubricant supplier to conduct a Lubrication Survey. BREAKDOWN PRIOR TO LUBRICATION SURVEY • Customer requests a Lubrication Survey be conducted at their plant facility • Field Engineers are notified and scheduled • An asset list from the facility is requested by the Field Engineers from the lubricant supplier with names and descriptions of all equipment • Date and time for Lubrication Survey are determined based on plant personnel and Field Engineer availability • Field Engineers review asset list and prepare for survey DURING LUBRICATION SURVEY • Upon arrival Field Engineers discuss potential areas of concern and opportunities which will benefit the facility the most • The survey begins by reviewing each piece of equipment in the facility • Photographs are captured to document findings during the survey and for future reference • Upon completion of full Lubrication Survey, up to 3-5 days, Field Engineers discuss with plant personnel initial findings and immediate options for improvement opportunities before departing the facility POST LUBRICATION SURVEY • Field Engineers review survey findings and compile final report • Final report is reviewed internally with appropriate personnel from the conducting lubricant supplier • Final report is presented to plant personnel inclusive of findings, opportunities and recommendations for establishing a proactive lubrication program • Once recommended plan is adopted by the facility, continuous contact is maintained between lubricant supplier and customer to ensure corrective actions are performed accurately 04WHY YOU SHOULD PERFORM A LUBRICATION SURVEY AT YOUR PLANT FACILITY FOOD GRADE SPECIFIC LUBRICATION SURVEY Within a food processing or manufacturing facility, pollution of lubricants can enter the food through numerous paths including direct contact from over lubricated bearings, equipment leaks, during sealing processes or due to a lack of mechanical knowledge. To combat pollution of food by lubricants, training, equipment tagging, product application guides and a Lubrication Survey are beneficial. FOOD GRADE The National Science Foundation (NSF) is a global independent public health and safety organization that is charged with the responsibility of registering lubricants for their suitability in food environments. FOOD GRADE LUBRICANT CERTIFICATIONS H1 Suitable for incidental food contact (up to 10 PPM) H2 No contact permitted H3 Direct food contact (release agents, ingredients) NSF provides an accredited ISO 21469 certification program that includes third party assessment of product conformity, production facility audits to confirm correct quality procedures and manufacturing practices are followed and analytical testing conducted to verify the integrity of the product composition. VALUE OF ISO 21469 CERTIFICATION • Differentiates products in marketplace • Accepted in global markets with international appeal • Demonstrates commitment to quality • Supports continuous improvement • Strengthens food safety culture Managing food grade lubricants is important in avoiding pollution of food by lubricants. Differentiating between food and non- food grade lubricants is a large component. Often, food grade lubricants are packaged in a different color from other products on the market allowing for visual separation of products. The use of lubrication tags, product application guides and segregation of conventional and food grade products also aid in the management of food grade lubricants. 05WHY YOU SHOULD PERFORM A LUBRICATION SURVEY AT YOUR PLANT FACILITY LUBRICATION SURVEY BENEFITS Numerous benefits can be realized from conducting a Lubrication Survey in your plant facility. BENEFITS FINANCIAL Financial gains through lower maintenance budgets and reduced lubricants purchased and wasted. These financial gains are measurable and substantial. EFFICIENCY Improved operational efficiency with greater reliability of equipment and fewer unplanned outages. Areas of potential value for customer Product consolidation Condition monitoring improvements Improved reliability Misapplication corrections Over lubricating and waste reduction Extended oil drains Improved storage and transfer practices of lubricants Improved sampling procedures Training of plant personnel EQUIPMENT LIFE & PRODUCTIVITY Equipment life increases with extended operations and improved MTBF (Mean Time Between Failures) and less downtime means increased operations leading to increased production. 06WHY YOU SHOULD PERFORM A LUBRICATION SURVEY AT YOUR PLANT FACILITY IDENTIFYING THE RIGHT SUPPLIER TO CONDUCT THE SURVEY Identifying the right supplier to conduct a Lubrication Survey of your plant facility positions them as a partner not just a provider. A qualified supplier performing a Lubrication Survey guarantees safety and an additional perspective into a facility’s lubrication activity. The partnership between your facility and the conducting supplier is strengthened through the supplier’s expertise and product knowledge and the facility’s support and transparency. SUPPLIER When identifying the right supplier to perform a Lubrication Survey of your facility, conducting a Snapshot Survey can be very beneficial. Lubricant suppliers regularly require a commitment before performing a full Lubrication Survey of a facility if they are not an existing customer. A Snapshot Lubrication Survey demonstrates the service, quality level and expertise a supplier can provide. Beyond conducting a Lubrication Survey, the right supplier partners with the facility to provide proactive training opportunities, plant maintenance optimization and implementation guidance to ensure continued success. Characteristics of the right lubricant supplier Extensive industry and product knowledge Certified experience with lubricants and plant surveys Approach relationship with facility as a partnership During a Snapshot Lubrication Survey a sampling of 3-5 assets are examined and subsequent recommendations are made by the conducting lubricant supplier. A Snapshot Survey is a great tool for validating the benefits of a comprehensive Lubrication Survey and building credibility in the lubricant supplier’s capability. 07WHY YOU SHOULD PERFORM A LUBRICATION SURVEY AT YOUR PLANT FACILITY TOTAL SPECIALTIES USA, INC. Total Specialties USA, Inc., headquartered in Houston, Texas, is a part of the Americas Division for the Marketing & Services Branch of the Total Group. We are very proud of the rich global heritage of our parent company, Total, the fourth largest oil and gas company in the world. Total Lubricants, a business unit of Total Specialties USA, Inc., offers a comprehensive scope of oils, greases and special products for a range of industries. SUPPLIER Field Engineers for Total Lubricants have extensive knowledge in all industries from Food, Steel, Paper, Refineries, Chemical, Phosphate, Pharmaceutical, Automotive to Heavy Duty. Across all industries, Total Lubricants’ Field Engineers have a robust understanding of product applications with plant facilities. With certifications in various arenas, including STLE, ICMLA and Vibration, Total Lubricants’ Field Engineers have been conducting Lubrication Surveys and assisting customers to improve their reliability programs for over a decade. Total’s line of food grade lubricants, TOTAL NEVASTANE, are ISO 21469, Kosher and Halal certified. TOTAL NEVASTANE Food Grade Lubricants are also GMO (genetically modified organisms) & allergen free which is important when used in today’s food processing marketplace. The category emergence of organic foods has sparked higher demand for lubricants that do not contain any GMOs. Today’s food grade lubricants are formulated to meet the demanding functions of lubrication in equipment. TOTAL NEVASTANE Food Grade Lubricants use the best additive packs and base stocks available to maintain equipment reliability. TOTAL NEVASTANE is applicable to lubricants used for processing in food and beverage, cosmetics, pharmaceuticals, animal feed and tobacco. totalspecialties.com Total Specialties USA, Inc. Total Plaza 1201 Louisiana Street, Ste. 1800 Houston, TX 77002 800.323.3198 totalspecialties.com Au g us t 20 18