Machinery Lubrication's 2013 Lube

Room Challenge
Achieving Lubrication Excellence





Tags: lubricant storage and handling

Machinery Lubrication recently asked readers to participate in its annual Lube Room
Challenge by submitting exceptional lube rooms that incorporate best-practice
features. Several readers met the challenge with evidence of how their lubricant
storage and dispensing methods have been transformed. The following entries
showcase how designing a proper lube room is one of the first steps to achieving
lubrication excellence.
Calumet
The Calumet refinery in Superior, Wis., processes 35,000 barrels of sweet and sour
crude oil from Canada and the Dakotas. Approximately 160 employees work at this
site, where the finished products include a variety of specialty fuels and asphalts.
With eight different lubricant suppliers, including one that was less than a mile from
the facility, the refinery took a hard look at its lubrication program in order to
reduce the number of oils purchased and determine how the entire system could be
simplified.

Before improvements were made, the Calumet lube room was unorganized with
drums,
cans, pumps, buckets and funnels. The new lube room incorporates stackable poly
tanks
and color-coded, labeled and contained dispensers.
The lube room was unorganized with drums, cans, pumps, buckets and funnels.
Labeling for the type of lubricant wasnt clear, which created numerous errors of
the wrong lubricant being placed in machines. Pumps were pulled from one drum
and placed into another, while containers were interchanged without labels or lids.
In taking steps to consolidate and organize, the refinery switched from buckets and
funnels to color-coded, labeled and contained dispensers. Other improvements
were made using stackable poly tanks, breathers, vent lines, bulls-eye sight
glasses, oil level indicators, dedicated lubrication systems and lube oil metering
systems. Calumet also purchased a number of metal safety cabinets to store
needed lubricants near the machinery. The cabinets are steam-heated and kept
clean and organized. The right lube is now handy when its needed.
As part of the changes, Calumet provided best-practices awareness training for
maintenance and operations personnel. Many superintendents and managers
attended the classes as well. Following the training, an equipment and reliability
lubrication technician position was created. The pump mechanic who was promoted
into this position became responsible for closely monitoring equipment for the
correct lubrication, expanding the current preventative maintenance program,
coordinating the oil analysis program, working closely with the vibration analysis
contractor, maintaining the oil storage facility, monitoring inventories and
developing a close working relationship with operators.
The operations and maintenance departments have appreciated all of these
changes. Mistakes have greatly decreased, and the wrong lubricant is no longer put
into compressors, pumps or gearboxes. While it hasnt yet achieved world-class
lubrication, the Calumet Superior refinery knows its on the right path.
Cloud Peak Energy

Cloud Peak Energys Spring Creek mine
converted an old electrical
motor-control-center trailer
into a lube room.
The lube room at Cloud Peak Energys Spring Creek mine near Decker, Mont.,
began as an old electrical motor-control-center trailer. Although the trailer was
well-insulated and sealed, a location had to be chosen that would be centrally
located yet separate from washdown and processing. Once the old electrical
components were removed, the lube room was equipped with a fire-suppression
system and a new heating/air-conditioning unit for climate control. The floor was
then painted with a chemical-resistant, anti-slip coating. Sealed hazardous
environment lighting and a new door with a window were also added.
Concrete was poured around the lube room, and concrete heating was installed on
the loading dock. The completed loading dock features a handrail and a jib crane
that allows lubricants to be loaded and unloaded in and out of the lube room.
Portable oil totes were modified so lubricants could be moved to remote locations
via overhead/vehicle-mounted cranes.

After consolidating to eight lubricating
oils, the mine purchased eight 65-gallon
containers for makeup oil reservoirs.
Additional 65-gallon containers are used
for larger lubricant requirements. There
is also a portable cart for each oil type.
An audit of the mines lubricants determined that it could consolidate down to eight
separate lubricants. Eight 65-gallon containers were then purchased to be utilized
as makeup oil reservoirs. Additional 65-gallon containers are used for larger
lubricant requirements. A portable cart is employed for each oil type. Filtration units
were also mounted for all of the mines reservoirs.
The lube dispenser was equipped with a custom stainless-steel drip tray. The
system is designed to continually filter oil in the top makeup oil reservoir.
During the lubrication audit, the number of greases was consolidated to six types.
Containers were purchased to store all grease on hand. Reducing the stock on hand
helps guarantee that grease is circulated more frequently, decreasing bleed and
separation. A work order ensures that grease is restocked weekly.

All plant-wide grease guns were disposed of, and a new grease gun was
designated for each type of grease. These are the only grease guns used in the
plant. A custom holder was fabricated to hold these grease guns, allowing users to
identify which guns are currently in use. Tags were posted at each grease gun
pocket, identifying the grease gun location. Only clear tubes are used to reduce
cross-contamination of greases. Greases that are used for electric motor lubrication
have been equipped with grease-dispensing meters. The other grease guns are
calibrated and equipped with a tag, which includes the volume dispensed per pump
and the date checked.
A desk was dedicated to house all oil analysis equipment and procedures. A large
bulletin board is used for posting all current oil analysis/filter analysis results. This
allows every mechanic to have access to all the results. It also provides a
dashboard for problematic equipment.
Domtar
When Domtars paper mill in Kingsport, Tenn., decided to improve its lubrication
process, the goal was to become world class in managing inventory and dispensing
oils. The mills new process incorporates several best practices such as color-
coding, labels, drum racks, first-in/first-out (FIFO), drum top units for oil filtering,
handheld technology and new systems for transferring and dispensing lubricants.

A new oil storage and dispensing system at Domtars Kingsport mill has
eliminated wasted space, time and labor.
Domtars investment in a new oil storage and dispensing system has eliminated
wasted space, time and labor. Inventory is now properly maintained, and
employees have a much safer and more ergonomic working
environment. Inefficient lubricant transfer is avoided with the new system, while
clean-up from spills, labor costs and absorbent purchases have decreased. The
number of in-process drums and employee downtime have also been reduced. Oil is
now filtered before being dispensed, which has improved the cleanliness level.

Drum racks have improved oil storage in the mills lube room.
New visuals have helped to prevent cross-contamination and ensure that FIFO is
followed. The job aides and work instructions also guarantee that all employees use
the same process.

New oil transfer containers have helped to prevent cross-contamination.
When performing lube routes, the mill utilizes barcoding with a maintenance
management system. This has eliminated cross-contamination when adding oil or
greasing the equipment. The correct lubricant is displayed when the equipment is
scanned during an inspection. The system also tracks usage and records inventory.
Lube routes are uploaded each week with an electronic record of the findings,
including who performed the route, the date and time, the equipment status and
any comments. The user also has the capability to enter a work request in the field
on a handheld device.

FIFO/ISO code labels and work instructions are used to
ensure employees follow best practices.
Monroe County, N.Y.
In 2012, the Monroe County wastewater treatment facility in Rochester, N.Y.,
evaluated the condition of its lube room and found it to be average. Plant
personnel realized there was more to building a lube room than just cleaning up a
space and installing oil dispensing and transferring devices. A lot of research
needed to be done.

Proper inventory tracking of lubricants
and supplies helped transform the lube room
at the Monroe County wastewater
treatment facility.
A wall was knocked down to make the room bigger. However, the first true
transformation occurred when proper inventory tracking of lubricants and supplies
was implemented along with the creation of an oil analysis database.
Other additions to the improved lube room included a non-slip floor, controlled
access, adequate illumination and proper warning and safety signs. An upgraded
heating, ventilation and air-conditioning (HVAC) system was added for a controlled
climate. Most importantly, the room was kept clean to prevent potential
contamination.
The facility also evaluated where and how lubricants were stored. By placing
lubricants in a climate-controlled environment, the plant found it could reduce
chemical degradation and oxidation. Rotating oil supplies and using the first-
in/first-out (FIFO) method also prevented lubricant degradation.

Color-coded lubricant transfer containers (left) ensure accurate delivery
of clean lubricant. The new oil storage and dispensing system (right) incorporates
a breather, filter, suction hose and pump per tank.
The storage area was designed to accommodate cabinets for grease guns, spray
lubricants, level gauges, drain ports, equipment tags, safety equipment, filters, etc.
Desiccant breathers for gearboxes were used to eliminate water-contaminated oil,
while new color-coded lubricant transfer containers helped ensure the accurate
delivery of clean lubricant from bulk storage to the gearboxes.
A base oil cleanliness benchmark was established with the help of a new oil storage
and dispensing system. The system incorporates a breather, filter, suction hose and
pump per tank, as well as safety features such as spill containment, auto shut-off
dispensing faucets and fire-safety hoses and valves.
Above all, the staffs attitude was instrumental in creating a successful lube room,
as personnel were willing to do whatever was needed to accomplish the goal.
Peabody Energy
With 14 miles of conveyor belt operating 24 hours a day, seven days a week,
Peabody Energys North Antelope Rochelle Mine in Wright, Wyo., is the largest coal
producer in North America. When the mine started its journey to improve its
lubrication program, drums were being stored outside and were exposed to the
elements. Lubricant storage also took place in various areas of the plant, including
next to gearboxes, for faster top-off capabilities.

Before improving its lubrication program, Peabody Energys North Antelope Rochelle
Mine stored drums outside and dispensed oil without caps.
In addition, the lubricant handling process was very labor intensive. The plant did
not have the ability to deliver filtered oil from bulk storage to assets. Oil was
dispensed without any caps, and grease types were not identified on the various
grease guns.
Eventually, a centrally located, environmentally controlled lube storage building was
constructed specifically for plant lubrication products. A new fluid storage and
dispensing system was purchased, and each oil type was designated a specific
color. The wire ties on hoses now match the applicable oil.

A centrally located, environmentally controlled lube storage building (left) was
constructed specifically for plant lubrication products. A new fluid storage and
dispensing system (right) was purchased, with each oil type designated a specific
color.
Other upgrades included new grease and filter storage, lubricant transfer containers
with color-coded lids for oil identification, a new barrel handler and dispensing
valves for oils. Each oil is now filtered from bulk storage to lubricant transfer
containers. With these changes, the mine has seen its ISO codes improve from
22/21/13 to 20/15/12.
Sask Power
Sask Powers Poplar River Power Station (PRPS) in Saskatchewan, Canada, recently
launched a project to improve its ability to deliver clean oil to all of its equipment.
With the support of management as well as the plant manager, the process began
with 30 years of grease and oil being cleaned off the floor. The floor and walls were
then painted. Next, lubricant transfer containers and 70-gallon totes were
purchased, along with breathers, filter carts and a pressure washer to clean the
equipment.

Poplar River Power Stations lube room was nothing to be proud of
prior to its project to deliver clean oil to equipment.
Now oil is filtered within the barrel seven to 10 times, then filtered and pumped into
the color-coded totes. It is also understood that oilers do not go home at the end of
the day until the floors are washed and everything is as clean and orderly as it was
in the morning.

The new lube room features a clean and painted floor,
color-coded totes, breathers, filter carts and a pressure washer.
The plant is continuing to add breathers and color-code its equipment. Gearboxes
are also being flushed and washed out as time permits. The goal is to reduce the
number of oils while delivering clean oil to clean equipment with proper seals and
breathers. With the help of the oilers, operators, mechanics and all the staff at
PRPS, the plant is achieving the success for which it had hoped.
Visy Paper

Visy Papers previous lube storage was in a partially open area,
making it difficult to keep lubricant containers clean, cool and dry.
Visy Paper recently completed a lubrication management and cleanliness
improvement initiative across all its paper mills in Australia. As part of the program,
the mills in Sydney now have a new custom-designed and constructed lube
room for best practices in lubricant receiving, conditioning, storage and dispensing.

Inside the lube room are three large tanks,
each with its own pump unit for receiving,
storing, conditioning and delivering
heavy-usage lubricant grades
to system tanks.
The previous lube storage was in a partially open area, which made it difficult to
keep lubricant containers clean, cool and dry. It also had very limited storage for a
large number of oil barrels and grease pails. Although lubricant types and grades
were separated, it was challenging to always keep them in the allocated space.
The newly designed lube room is located inside another large shed with ventilation,
lighting and facilities for cool, clean and dry storage of lubricants and
containers. Color-coded and sign-posted areas along with lubricant transfer
containers for storage and transport of various lubricant types and grades help
avoid the possibility of cross-contamination.
The new lube room incorporates shelves and hangers for storing grease pails,
grease guns, filters and oil samples. It also includes a workbench for small repairs
and oil sample packaging, as well as a fire-extinguisher station, a smoke alarm, a
spill kit and slip-resistant epoxy paint on the floor.

The newly designed lube room has color-coded areas along with lubricant transfer
containers for storage and transport of various lubricant types and grades.
Inside the lube room are three large tanks, each with its own pump unit for
receiving, storing, conditioning and delivering heavy-usage lubricant grades to
system tanks. These storage tanks use piping and cam-locks to receive bulk oil
deliveries from the supplier, and have oil sampling and level monitoring facilities to
ensure oil quality and cleanliness. The pump units are piped to main system tanks
so oil can be delivered easily to individual system tanks without the possibility of
cross-contamination or ingress.
With bulk delivery and storage of heavy-use lubricant grades in new bulk tanks, the
problem of barrel handling and storage has been diminished considerably.