Consolidation
Storage, dispensing
Contamination control
Diagnostics
Oil sampling
Training
Registration
One qualified person or group is responsible for performing lubrication tasks. These individuals receive annual lubrication training delivered by a third party.
One qualified person or group is responsible for performing lubrication tasks.
There is no independent lubrication expert; the appointed employee performs lubrication tasks in parallel with other activities.
Operators (e.g. machine operators) perform lubrication and maintenance tasks based on well-established practices.
An external service provider performs lubrication tasks.
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We use lubricants recommended for any given machine in its operating handbook.
We use lubricants recommended by our suppliers.
The employee appointed to be responsible for lubrication, supported by our lubricant suppliers, defines optimal sets of criteria in line with manufacturers’ requirements. He will, as far as possible, standardise lubricants to be used and maintain an up-to-date database.
Our primary criterion is the price of lubricants; we buy the cheapest lubricants.
We use lubricants that belong to the same viscosity category of each oil grade (gear, hydraulics, motor oil, etc.).
We maintain up-to-date lubricant tables registering the lubricant to be used for any given machine. Lubricants are displayed in daily lubrication instructions and we use labels with colour codes for any given machine.
The lubricant type to be used (e.g. ISO VG 32) is painted on critical machinery.
The lubrication point of every machine is marked with a label using colour codes, clearly showing the name and viscosity grade of the relevant lubricants.
The expert performing lubrication tasks knows which oil should be used for which machine.
We maintain a wall board in the plant showing all the machines and the lubricants used for them.
There is no relevant best practice.
Selection of lubricants for critical machines is the primary criterion; these lubricants are also used for other machines.
We define the minimum technical requirements for each lubricant type based on viscosity, performance and manufacturers’ requirements.
Using expert help from our lubricant suppliers, broken down by each lubricant type, we define optimum requirement levels based viscosity analyses, performance levels, manufacturers’ requirements and maintenance costs.
We only use lubricants with the highest performance levels.
Our procurement officer invites bids from several lubricant distribution companies and selects the cheapest supplier.
In addition to lubricant prices, terms of payment and supply, we also consider other key criteria: an on-site lubricants service that supports machinery reliability, oil diagnostics to check machinery and lubricating oil condition and the availability of expert consultation and training.
Maintenance workers prepare lists of lubricants required in their work areas and send them to procurement who then invite bids. We select the best bidder based on financial and technical aspects.
We select lubricants based on prices, terms of payment and supply.
There is no one single selected supplier but we work with several lubricant suppliers because machinery handbooks propose products offered by different oil companies.
Lubricants are stored outdoors in their original drums and containers, exposed to the effects of weather.
Lubricants are stored indoors in their original drums and containers or outdoors in a protected area.
Lubricants are stored in a heated lubricant warehouse in storage systems marked with colour codes and equipped with drip trays and pumps with adequate air filters and oil filters.
Lubricants are stored in the production area in original drums and containers, equipped with drip trays and adequate air filters and oil filters.
Lubricants are stored in original drums and containers in the production area.
Lube oils and lubricating greases in 20 litre or smaller packages are stored in a lubricants warehouse in designated cabinets.
Lubricating greases are stored on open shelves in original ex-factory packaging, while cans are stored on the floor.
We do not use small package lubricants.
Our lubrication expert has a handcart for storing small packages of oils and greases.
There is a designated handcart equipped with lockable cabinets in the production area where 20 litre cans and grease cartridges can be stored.
We use a bucket with a funnel for filling-up at oil inlet or venting port.
Our machines have lubrication points equipped with quick connectors. The lube oil tank is filled from drums transported to the machine on a handcart by pumping or pneumatic pumping with direct connections and without filtering.
Machines and oil dispensing tanks have quick connectors and are marked with colour codes. Lube oil is filled in a closed system from a dedicated handcart equipped with air and oil filters without opening up the machine or the oil dispensing tank. Precise filling is obtained by using a filling nozzle equipped with a mass flowmeter. For minor quantities, we use closed cans.
Oil is poured into machinery directly from the original disposable 10 or 20 litre ex-factory can through the filling inlet using a funnel.
We use closed oil filling cans, marked with colour codes (labels), through the filling inlet.
We use a manual greasing tool and the grease pumped as long as fresh grease shows up at the seals.
Lubricants are fed in the exact quantity at the right frequency using a manual greasing tool equipped with a mass flowmeter or using a central system.
Re-lubrication is performed based on diagnostic results and the lubrication expert specifies the fill-up quantities.
Standardised quantities and lubrication cycles are defined for each machine type in the grease lubrication practice (e.g. for electric machines with 35-72kW capacity 3 strokes for each bearing with a 3 month frequency).
Re-filling intervals and required quantities are defined based on experience gained during lubrication.
Waste oil is drained and captured in drums and cans and then stored in the plant and lubricants warehouse.
We drain waste oil into drums clearly marked and store them in a separate place until transport.
We drain waste oil into temporary storage and then transfer it into dual-walled indoor tanks with good ventilation.
We drain waste oil into temporary storage and then transfer it into dual-walled outdoor tanks.
We drain waste oil into temporary storage and then transfer it into special-purpose waste oil tanks, which are not dual-walled and have no ventilation.
We use machines equipped with original air filters (installed by an ex-factory - OEM) and oil filters (if any).
We apply a mobile filter machine to remove solid contaminants when oil sample laboratory test results or visual inspection so require.
Our machines have the correct drain and filling ports (quick connectors, desiccant air breathers). For critical machines, we apply by-pass circuit filtering. In other machines we apply mobile filter units based on laboratory tests.
We close the ventilation port with screws.
Every machine has a desiccant air breaser.
We have a filter cart in the plant (purchased a couple of years ago) but it is rarely used.
We have prepared a self-made mobile filter cart using parts available in the plant and we use this for planned oil tank clean-ups.
We have purchased a filter cart from our filter supplier and we use this for cleaning the oil charge when this is prescribed by oil sample laboratory tests or results of visual inspections.
We have mobile filter machines marked with colour codes for each oil family (e.g. hydraulic, compressor, turbine, gear oil, etc.). Selection criteria: proper flow velocity, filter capacity and required purity levels.
There is no mobile filter machine in the plant.
We perform general oil tests (ppm, water content, acid number, etc.) and we have a filter cart with 20-50 litre/minute capacity for purifying the oil charge.
Ventilation units are equipped with changeable desiccant air breasers. We hold specific tests to monitor oil condition. Large capacity filter machines and separators are available to manage contamination to oil charges.
We purify oil charges in a routine process conducted with pre-defined frequency (e.g. every 3-12 months). We drain the sediment, water and other contaminants through a valve installed at the bottom of the tank and then we fill up the quantity thus consumed.
We only carry out re-filling and oil changes.
We only have lubrication systems with smaller than 2,000 litre charges.
Most gear units are equipped with external fluid level indicators with marks showing the lower (operating) and higher (idle) fluid levels.
External oil level indicators are fitted to some gear units.
Gear units are equipped with original (ex-factory) dip sticks or eye-level plugs.
For the most part, our gearboxes have no means to check oil level.
There is no gear unit in our plant.
Oil and filters are changed in accordance with the scheduled preventative maintenance of machinery.
We have pre-defined oil and filter change intervals for each machine type (e.g. one year for hydraulic oil, six months for gear oil, filter changes in the indicated Dp display, etc.).
We change oil as and when required e.g. After repairs, reconstruction or if it seems that there is a problem with the oil, etc. and change filters when the Dp display shows that a filter is in by-pass.
We rely on the results of on site oil analysis for solid contaminants and water content of the lube oil. Oil and/or filters are changed when oil tests indicate problems.
We decide on maintenance actions based on oil diagnostics. If results indicate pollution, we implement the interventions required (e.g. by-pass circuit filtering, dehydration and air filter and oil filter changes, etc.). We only change oil if it can no longer be treated based on oil tests.
We only implement oil diagnostics in a few machines. We primarily analyse machines with problems.
We implement oil diagnostics in almost every machine in a alternating and rotating operation.
We do not use oil diagnostics.
We only use oil diagnostics in the most critically important machines.
We implement oil diagnostics in machines that are critical to production security, have large charges, cause problems and represent major value.
We take samples from every sampling point every 6 months.
We take samples from every sampling point annually.
We do not conduct oil tests.
We take samples from every sampling point every 3 months but monthly from critical systems.
An individual sampling programme is attached to every sampling point, starting from one monthly sampling to 6-monthly sampling.
Our lubricant suppliers provide necessary tests from time to time.
We purchase this service from an independent, external laboratory. We use the same testing package for all machines.
An oil testing package is attached to every machine type (gear, hydraulic, turbine, compressor, etc.) to capture information necessary to achieving safer operations.
We implement some required oil analyses on-site.
In relation to water and solid particle content, we follow manufacturers’ requirements and an external oil diagnostics laboratory proposes typical wear and oil condition limits.
We fully rely upon an oil testing laboratory that provides sampling tools, defines alarm limits and helps in interpreting results.
We apply individual limits for every machine and/or machine type where manufacturers’ requirements are available and where there are none, they are based on experience. We send these alarm limits to the oil testing laboratory.
Our current oil testing lab only supplies test results and we interpret its reports.
Our oil testing programme has one person appointed to be responsible. He gives opinions on test reports and issues orders, subject to results.
We also receive test data in electronic format. We load the results into our computerised maintenance system and the engineers responsible get access to them.
The oil diagnostics laboratory secures on-line access to the database that contains test results. In our company, a few appointed persons have the right to access the database.
We file and collect test reports and check machinery in case there is a problem.
After shut down, we deliberately remove draining screws and release oil into sampling bottles.
We take samples from draining pipes and release sufficient oil to gain samples with the correct purity.
Oil samples are sucked into bottles through the loading hole cover lids or after removing air filters through ventilation openings or at dip stick holes using vacuum pumps and plastic hoses or pipes.
We do not conduct oil analysis or take samples from non-pressurized systems.
We have installed representative oil sampling points in our transmission houses and sampling tools can be connected to them. We take samples from the system when operating or directly after shutdown.
We use a sampling tube and take oil samples from operating system measuring points.
We do not use oil diagnostics and we do not take samples for systems operating under pressure.
We install sampling points in the reverse flow lines of the system before the filters and use a pump and a directly connected tube or pipe for sampling. We take samples from the system when operating or directly after shutdown.
We use vacuum sampling pumps and tubes and samples are taken from the oil tanks.
We use sampling tubes and take samples directly from oil filters.
We do not conduct oil analyses.
There is no identification but sampling employees know where the samples were taken from.
Every machine is equipped with sampling connectors and the sampling employees know that these were installed for sampling purposes.
Sampling connectors are installed on all machinery with distinguishing labels and on identify sampling points.
Sampling may be implemented at several points on any given machine; we identify the machine but not the sampling points.
Practical training in sampling techniques is delivered in our plant area.
There is no official training in sampling techniques since employees know exactly how to correctly conduct sampling.
Employees once participated in a training session where proper sampling processes were taught.
We have standardised process descriptions illustrated with diagrams which define the sampling methods for various machine types (e.g. transmission, hydraulic, compressor, etc.). Training session are held in sampling techniques.
The testing laboratory supplies sampling data sheets on which we indicate the machine identification and the sampling date.
The testing laboratory sends sampling data sheets which we fill in for every sample with sampling dates, oil and machine mileage performances (operating hours), oil types and names (if there had been any changes since the last sampling date), dates of oil filter and oil changes.
The testing laboratory already has a database of our machines so we use pre-printed labels and only display sampling dates.
We only write machine identifiers on the caps of sampling devices.
No special requirements are defined.
Lubrication technicians are selected from among experienced employees. From time-to-time they participate in professional training and have vast lubrication technology experience in practice.
Lubrication technicians are selected from among experienced employees. From time-to-time they participate in professional training but have little lubrication technology experience in practice.
Lubrication technicians are trained in the workplace and have many years of lubrication technology experience.
Our lubrication technicians have an excellent technical base and practical experience. External experts provide them with lubrication technology training.
We conduct no annual training.
Minimum 3 days.
2 days
1 day
Half a day
Lubrication technology qualifications are not formal requirements, but practical experience in lubrication technology is expected.
Employees should have adequate experience but lubrication technology qualifications are not a requirement.
The only requirement is basic mechanical engineering practice.
With participation in annual lubrication technology training, there is no special requirement for a pre-qualification.
We have developed our own internal training, qualification and certification system for employees who perform lubrication technology tasks.
The person responsible for the oil test programme has a qualification as a technician and has diagnostics knowledge and practical experience.
The person responsible for the oil test programme is an engineer with up-to-date knowledge in lubrication technology and oil diagnostics.
The plant or maintenance manager is responsible for the oil test programme, but he has not participated in any lubrication technology or oil diagnostics training.
The plant or maintenance manager is responsible for the oil test programme and he has participated in lubrication technology or oil diagnostics training.
We hold weekly meetings at which we often discuss lubrication technology problems and tasks.
A group holds daily meetings if oil tests identify irregularities or the serious status of machinery.
We only hold a meeting if a specific problem arises and then only with the person responsible.
Never
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