Organizations and systems for lubrication management

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Organizations and systems for lubrication management. I. Organizational forms of enterprise lubrication management. Organizations responsible for equipment lubrication generally adopt two forms: centralized management and hierarchical management. 1. Centralized management of lubrication: For equipment in small enterprises, centralized management is suitable for lubrication purposes. The equipment department has dedicated lubrication technicians and lubrication stations, along with a certain number of lubrication workers, who are responsible for lubricating all of the company’s equipment. The inspection of lubricating materials can be carried out by the central physical and chemical laboratory, or by the lubrication station. The lubricant material inventory can be managed by the supply department or assigned to the lubrication station. 2. Hierarchical management approach for lubrication: Large and medium-sized enterprises generally adopt a hierarchical management approach for equipment lubrication. The enterprise’s equipment department shall assign engineering and technical personnel in charge of lubrication, and establish a lubrication station (main station). Lubrication sub-stations shall be established in each branch factory (workshop). II. Division of responsibilities for lubrication management 1. The division of responsibilities is determined based on the corporate organizational structure and other factors; the tasks and requirements related to equipment lubrication management are assigned to the relevant departments, and these are implemented in accordance with the company’s policies. 2. Organization of the lubrication station 2.1 Establishment of the lubrication station (main station) 2.1.1 Enterprises should establish a lubrication station. The lubrication station is responsible for the incoming inspection, warehousing, storage, distribution of lubricants, and the management of waste oil recovery. Responsible for the inspection and supervision of equipment for oil change under different conditions. 2.1.2 Large and medium-sized enterprises should assign a chief engineer in the equipment management department to be responsible for lubrication management. 2.1.3 The staff at the lubrication station include lubricant testers, lubrication technicians, fitters, and warehouse managers. A lubrication technician is a skilled professional who, in addition to having knowledge of lubricants and lubrication management, must also possess a variety of skills related to equipment lubrication tasks. The work of the aforementioned personnel can be fully overseen by a lubrication laboratory technician possessing skills in grease testing. 2.1.4 Large and medium-sized enterprises should establish lubricant testing laboratories to be responsible for the inspection of lubricants upon purchase and the identification of lubricating oils in use. 2.1.5 Enterprises should establish a lubricant storage facility, which generally should be capable of storing 1/5 to 1/3 of the annual lubricating oil consumption. The warehouse building must be well-ventilated, protected from light, and shielded from rain and dust. It must also meet safety and fire prevention requirements. 3. Setup of lubrication stations: Lubrication stations are the points for lubrication management in each factory (workshop). The lubrication station should have full-time lubrication workers responsible for managing the lubrication of the equipment in that factory (workshop). III. Implementation of lubrication management The main tasks of lubrication management include: the \"five fixed principles\" for lubrication, cleaning and oil changing of equipment, monitoring of the lubrication status of equipment, as well as planning and statistics related to lubrication. Under the organization and coordination of the chief lubrication engineer, all equipment managers, operators, lubrication workers, and maintenance workers at all levels must fulfill their respective duties to ensure proper equipment lubrication. The “five fixings” for equipment lubrication refer to the scientific management of lubrication tasks, which involves fixing the location, quality, timing, quantity, and responsible person. Its contents are as follows: 1. Fixed points. “Fixed points” refers to first identifying the lubrication points for each piece of equipment; this is a basic requirement in equipment lubrication management. “The requirements for “fixed-point” maintenance are as follows: 1.1 All types of equipment must have lubricant added to and replaced at the locations and points specified in the lubrication charts. 1.2 The operators and lubrication workers of the equipment must be familiar with the lubrication areas and points of the relevant equipment. 2. Qualitative control: “Qualitative control” refers to ensuring the variety and quality of lubricant materials. It is a prerequisite for ensuring the lubrication of equipment. Add or replace with high-quality lubricating materials as required by the lubrication card or lubrication chart. “The “quality assurance” requirement stipulates that: 2.1 The type and grade of lubricants must be added or replaced in accordance with those specified in the lubrication cards and diagrams. 2.2 When adding or replacing lubricating materials, clean tools must be used to prevent contamination. 2.3 A requirement of “three filtrations” for lubricating oil is implemented to ensure its cleanliness. “\"Three filters\" refer to: inbound filter, distribution filter, and refueling filter. 3. Scheduled (regular) “Scheduled” means that oil should be added and changed according to the times specified in the lubrication cards and charts, and samples should be taken from large oil reservoirs on a periodic basis for inspection. The requirements regarding timing are as follows: 3.1 Before the equipment starts operating, the operator must check the equipment’s lubrication system in accordance with the lubrication requirements, and fill in the lubrication points that require regular oiling. 3.2 The refueling and oil changes of equipment must be inspected and replenished at specified times, and cleaning and oil changes must be carried out as planned. 3.3 For large oil tanks, a sampling and testing plan should be formulated based on time intervals. 3.4 For key equipment, oil samples shall be taken and analyzed according to the monitoring cycle. 4. Quantification “Quantification” refers to adding oil, replenishing oil, or performing an oil change in accordance with a specified quantity. The quantitative requirement is as follows: 4.1 At regular refueling points, fuel should be added in accordance with the established daily refueling quotas, so as to ensure proper lubrication while avoiding waste. 4.2 Replenish as required according to the oil level and quantity in the oil sump. 4.3 When changing the oil, it is necessary to consider the capacity of the oil tank; the circulation system should be turned on, and once it is confirmed that the oil level is no longer dropping, the oil should be added until the proper level is reached. 5. Assigning responsibilities: “Assigning responsibilities” means clarifying the duties that the relevant personnel must undertake regarding equipment lubrication. Requirements for the personnel: 5.1 The operators on duty are responsible for conducting daily inspections of the equipment’s lubrication system; the equipment may only be operated after it has been confirmed to be properly lubricated. 5.2 The on-duty operators are responsible for applying oil and lubricant to the equipment’s regular lubrication points before and during shifts. 5.3 The operators are responsible for checking the oil level in the lubricating oil tank, and topping it up promptly when it is low. 5.4 Under the responsibility of the lubricator and with the participation of operators, the equipment oil pools shall be cleaned and refilled with oil as scheduled. 5.5 The maintenance fitter is responsible for conducting regular inspections of the equipment’s lubrication system and addressing oil leaks. 5.6 The maintenance electrician is responsible for regularly inspecting the lubrication of the motor bearings and replacing the grease in a timely manner. IV. Management of equipment cleaning and oil replacement: During use, lubricating oil undergoes physical and chemical changes due to various internal and external factors, which causes it to degrade. Continued use will cause corrosion or wear of the components. Therefore, substandard lubricating oil should be replaced promptly. 1. Two methods of oil change 1.1 Regular oil change: Changing the oil at the intervals specified in the equipment’s lubrication schedule is known as regular oil change. Regular oil changes are generally scheduled based on the actual operating time, while for various vehicles, the oil change interval is determined by the distance traveled. Regular oil change is convenient to manage, but it will undoubtedly replace some lubricant that is still usable ahead of time. The regular oil change method is generally used for small devices with a high operation rate and an oil tank capacity of 25 kg or less. 1.2 Oil change based on quality: Changing the oil after assessing its quality is known as oil change based on quality. Oil replacement based on quality is generally applicable to large oil tanks of 100 liters or more. First, regularly take samples of the lubricating oil for testing, and determine whether to change the oil immediately or continue using it based on its actual condition. Changing oil based on its quality is a scientific management method for using oil efficiently and avoiding waste. 1.2.1 Sampling cycle: Sampling is generally scheduled 50 to 100 hours in advance of the oil change cycle specified by the equipment. 1.2.2 Oil quality inspection (1) For the routine inspection of lubricant quality, the parameters to be checked include the viscosity of the lubricant, water content, acid value, mechanical impurities, and water-soluble acids or bases. (2) Use oil quality rapid analysis instruments. There are currently many types of oil quality analyzers available on the market, some of which enable rapid on-site analysis of the main physical and chemical parameters ； There are methods that utilize the principle of light transmission to determine the degree of oil pollution ； As well as using changes in the dielectric constant of the oil to determine its condition. (3) Oil change standards **There are many oil change standards available in standards and industry guidelines. Enterprises can formulate their own oil change standards by taking into account the characteristics of their equipment and by adopting or referring to relevant standards. (4) Extended use: The extended usage period for lubricant is generally 300–500 hours. For lubricants whose service life has been extended, the sampling time should be adjusted to be earlier. 2. Implementation of equipment cleaning and oil change 2.1 Division of labor for equipment oil change The oil change for equipment in companies with centralized lubrication management is handled by the lubrication station. Generally, oil is delivered to the machine according to the plan, and with the assistance of the equipment operators, the machine is cleaned and its oil is changed. In companies that practice hierarchical lubrication management, the scheduling of equipment oil changes is generally prepared by the equipment department. 2.2 Process for cleaning and changing oil in equipment 2.2.1 General process for cleaning and changing oil in equipment a. Turn off the power supply ； b．Drain the oil tank ； c. Clean the residual oil, dirt, and impurities at the bottom of the oil tank, and wipe all parts of the tank with cotton cloth or sponge ； d. Wipe the oil window and dipstick, clean the oil filter and strainer ； e. Rinse the oil tank with clean kerosene ； f. Add new oil to the specified level through the refueling port in the appropriate type and quantity ； s. Start the lubrication system by supplying power; if the oil level in the oil tank does not drop, top up the oil to the normal level ； h. Inspection and acceptance: Fill out the completion acceptance form for equipment cleaning and oil change; the management department then fills out the oil change record card or enters the data into the computer for management. 2.2.2 Oil change process for extra-large oil tanks Extra-large oil tanks generally refer to lubrication or hydraulic oil tanks with a capacity of 2000L or more. It needs to be completed with the joint participation of lubrication workers, operators, and maintenance workers, under the unified supervision of the workshop mechanic. a. Pre-construction preparations. Prepare new oil according to the type of fuel to be used; if substitute oil is employed, compatibility tests must be conducted to ensure that it has no adverse effects on the equipment (it should not be corrosive to the components of the pump, and seals should be tested using a small sample by immersing it for 15 days – no deformation, swelling, or increase in weight should occur) ； b. Develop the cleaning and oil change procedure, and implement it after approval by the equipment supervisor. V. Equipment lubrication condition management 1. Inspection of equipment lubrication condition The inspection of equipment lubrication condition is divided into daily inspections and regular inspections. 1.1 Routine inspections 1.1.1 Operators carry out routine inspections. Before starting work, check the equipment’s oil gauges and oil levels, and perform routine refueling. Activate the lubrication system and verify that it is functioning properly, with unobstructed oil passages, clearly visible oil level indicators, and pressure within the specified range. Constantly check the lubrication status of the equipment in the class, as well as whether an oil film has formed on the equipment’s guide rails and sliding surfaces. 1.1.2 Daily inspections carried out by lubrication workers. Do operators of key equipment perform proper daily lubrication on the equipment? Is the oil reservoir for critical equipment at the proper oil level? If not, replenish it in a timely manner. 1.1.3 Daily inspections carried out by regional charter aircraft maintenance workers. Check whether the lubrication system of the key equipment is functioning properly and whether the pressure is within the specified range. 1.2 Regular inspections: Comprehensive inspections of equipment conducted at specified intervals, with the participation of workshop mechanics, maintenance workers, and lubrication technicians. Generally, it is carried out in conjunction with the regular inspection of equipment. Items for regular inspection: Check whether the lubrication of the sliding surfaces of the equipment is adequate, and look for any signs of scuffing or wear ； Check whether the lubrication system and hydraulic system are functioning properly ； Are all the lubrication components in each part present and in good condition? ； The motor bearing area is well-lubricated (using a bearing inspector). 1.3 Standards for good lubrication condition of equipment 1.3.1 Lubricant is present at all lubricated areas and points, with no dry friction occurring. 1.3.2 The components of the lubrication system are complete and in good condition; the oil pipes are intact and the oil flow is unobstructed. 1.3.3 Oil lines and oil felts are complete, clean, and properly positioned. 1.3.4 The oil remains clean throughout its service life. 1.3.5 The oil pressures of all circuits are within the specified range. 1.3.6 No oil leakage. 2. Equipment lubrication condition monitoring technology. Equipment lubrication condition monitoring technology is an important method in equipment failure diagnosis; it involves detecting, assessing, and predicting equipment wear failures through the analysis of lubricant conditions. Monitoring methods include the testing of physical and chemical parameters of lubricating oil and the use of wear debris detection techniques. 2.1 Testing of physical and chemical properties of lubricating oil: The testing of physical and chemical properties can only determine the quality of the oil, but it cannot predict equipment failures. 2.2 Wear debris detection technology: The wear debris detection technology for lubricants is a diagnostic method that enables the prediction of the operating condition of friction pairs and the identification of the locations and extent of wear faults, without the need to disassemble the equipment, by analyzing the shape and quantity of wear debris present in the oil. The instruments mainly include ferrography machines and spectrometers. 2.2.1 Ferrography Ferrography utilizes a high-gradient strong magnetic field to transform the abrasive particles in lubricant samples into ferrographic slides; optical or electronic microscopes are then used to determine the shape, size, quantity, and material composition of these particles or fragments, thereby assessing the wear condition and trends of the equipment. Ferrite spectrometers come in various types, including direct-reading, analytical, dual-type, and rotary models. The advantages are low instrument cost and wide range of applications. It is sensitive to iron-based swarf in the range of 0.1~100 fJm and above, and is widely applicable. 2.2.2 Spectrometers There are two types of spectrometers: atomic absorption spectrometers and atomic emission spectrometers. They analyze the content of chemical elements in the metal particles present in the oil, and by comparing this with the operating time and the rate of increase in metal content in the oil, they can assess the wear level of the friction pairs in the equipment. The spectrometer is characterized by the fact that no pretreatment of the oil sample is required, it offers good repeatability, a high degree of automation, fast analysis speeds, and accurate readings. However, it is difficult to determine the type of wear and predict the location of failures. 2.3 Working procedures for fluid monitoring 2.3.1 Selection of equipment to be monitored Generally, key equipment in terms of production and safety should be selected. Large CNC equipment in machinery manufacturing enterprises, mining lifting and transportation machinery, railway diesel locomotives, ships and vessels, aircraft, and power generation equipment, etc. 2.3.2 Formulating diagnostic criteria: The criteria include standards for lubricant change, as well as the original ferrography and spectrogram data of the oil used in the equipment. Feasible monitoring and diagnostic criteria should be established in light of the actual situation. 2.3.3 Sampling To take samples while the equipment is in operation, equipment that has been shut down must be operated for one hour before sampling can be carried out. Clean tools and containers should be used for sampling, with equal amounts of oil samples taken from the upper, middle, and lower sections of the oil tank and mixed together to form the sample. 2.3.4 Treatment of oil samples: The oil samples should be heated in a water bath before testing. The temperature is set at 65±5°C, the time is 30 minutes, and shaking takes place for 2–3 minutes to ensure uniform mixing of the oil sample before analysis. VI. Planning and statistical work for equipment lubrication management 1. Computer-aided equipment management. Equipment lubrication management is an important part of comprehensive equipment management; the lubrication management subroutines in equipment management software include functions such as maintaining records of equipment lubrication, managing oil changes for equipment, and overseeing the inventory of lubricants. The lubrication database is an important part of the system. The lubrication points of the main production equipment, the oil grade to be used, the amount of oil required, and the oil change interval should all be entered into the lubrication records. 2. Forms for lubrication management 2.1 Monthly sampling and inspection plan for large oil sumps. 2. Plan for equipment cleaning and oil change in February. Application plan for lubricant materials in February and March. 2.4 Annual demand plan for lubricant materials. 2. Inventory statistics table for lubricant materials in May. Statistical table for equipment oil change completion in June. 2.7 Quarterly (Annual) Statistics Table for Waste Oil Recovery. VII. Lubrication management system: The lubrication management system that an enterprise should establish and its components 1. Management system for lubricant materials, the main contents of which are: 1.1 The lubrication management engineer is responsible for preparing plans for the procurement of lubricant materials. 1.2 The procurement and supply department is responsible for making purchases based on product type and quantity. 1.3 The Lubrication Station or Central Physical and Chemical Laboratory is responsible for sampling and testing lubricants to be stored. 1.4 The lubricant material warehouse should label the grease that has passed the inspection, sort it by grade, and store it in designated areas. 1.5 For lubricants that have been stored for more than two years, re-sampling and testing must be conducted. 1.6 The stock of lubricant materials should be adjusted to meet the characteristics of the market economy; social channels should be utilized to reduce corporate inventory, thereby avoiding the accumulation and waste of materials. 2. Management systems for the lubrication station and its sub-stations; the main contents are as follows: 2.1 Management system for the lubrication station – The main aspects of the management system for the lubrication station (the main facility) include: 2.1.1 Sampling and testing of lubricating materials that enter the facility. 2.1.2 Responsible for the sampling and inspection of large oil ponds with a capacity of over 100L. 2.1.3 Manage the lubrication materials warehouse (grease warehouse) properly, keeping it clean and tidy. 2.1.4 Ensure proper filtration of lubricating oil upon receipt and before distribution. 2.1.5 Prepare lubricating oil. 2.1.6 Responsible for recycling used oil. Perform fine filtration or regeneration. 2.1.7 Management using oil and cutting coolant. 3. Management system for the lubrication station, the main contents of which are: 3.1 Ensuring proper distribution of daily-use oil for equipment. 3.2 Manage lubrication equipment and supervise equipment lubrication. Where conditions permit, a dual-oil can system for hair oil can be implemented. 3.3 Organize equipment oil change and check the cleaning quality of the oil sump. And supply qualified lubricants and collect used oil in a timely manner. 3.4 Manage cutting oil and coolant properly. 3.5 Carefully fill out the oil change completion report and the branch plant oil change record. 4. Safety and fire prevention regulations for oil storage facilities: The main points are as follows: 4.1 Oil storage facilities must be kept well-ventilated and protected from light. Oil stored outdoors must have measures to protect it from rain and sunlight. 4.2 The lighting and electrical switches inside the warehouse should have an explosion-proof design. 4.3 Fire-fighting equipment must be fully equipped. 4.4 Open flames and smoking are strictly prohibited in the oil storage area. When using an open flame in the warehouse, procedures must be followed as per regulations, and appropriate measures must be taken. 4.5 Gasoline, kerosene and other light oils, as well as other flammable and explosive materials, must not be stored in the oil depot. 5. Procedures for equipment cleaning and oil change, the main contents of which are: 5.1 The mechanics in the branch factory must organize the equipment cleaning and oil change work in accordance with the oil change schedule. 5.2 The lubrication station should prepare cleaning oil, waste oil collection containers, and qualified lubricants in advance. 5.3 Operators must thoroughly clean the equipment oil sumps, filters, and oil filters. 5.4 The personnel at the lubrication station are responsible for checking the cleanliness of the oil reservoir; once it is confirmed to be satisfactory, new oil is added. 5.5 For the oil change of key equipment and complex lubrication and hydraulic systems, the assistance of a maintenance fitter is required. 5.6 After oil change, the operator is responsible for conducting a trial run to check that the lubrication and hydraulic systems are functioning properly before the equipment can be put into official use. 5.7 The personnel at the lubrication station are responsible for filling out the oil change completion form or recording it on the equipment oil change card. 6. Waste oil recycling system, the main contents of which are: 6.1 The lubrication station is responsible for the recycling of waste oil. 6.2 Special containers must be used for the recycling of used oil. Used oil should be stored in separate categories and grades to prevent it from mixing with new oil. 6.3 The lubrication station shall keep accurate records of used oil recovery. 6.4 Ensure the recycling of used oil. If regeneration is not carried out, the used oil should be delivered to an oil recycling plant promptly. 7. Responsibilities of the Chief Lubrication Engineer, which mainly include: 7.1 Participating in the formulation of systems, procedures, standards for lubrication management, as well as the job responsibilities or work standards for relevant personnel. 7.2 Responsible for lubrication technology tasks, and oversees the lubrication stations and sub-stations in terms of operations. 7.3 Responsible for establishing lubrication records for major production equipment, and compiling equipment lubrication charts and other lubrication-related technical documents. 7.4 Responsible for preparing plans for lubricant materials and consumption quotas. 7.5 Responsible for formulating sampling and inspection plans for large oil tanks, equipment cleaning and oil change plans, as well as the cleaning and oil change procedures for very large oil tanks. 7.6 Responsible for checking and monitoring the lubrication status of key equipment. 7.7 Responsible for addressing equipment oil leaks and modifying lubrication systems. 7.8 Responsible for training and technical assessments of lubrication management personnel at all levels. 7.9 Participate in equipment lubrication accident analysis. 7.10 Conduct theoretical research on friction, wear, and lubrication*, and promote the application of advanced lubrication technologies. 8. Responsibilities of the lubrication worker, mainly including: 8.1 Being familiar with the lubrication points of the equipment in the area under responsibility, as well as the grade and quantity of oil to be used. 8.2 Implement the regulations of “five fixings” and “three filtrations” for equipment lubrication. 8.3 Distribute daily oil promptly for each shift. Conduct inspections of the equipment under one’s responsibility, and urge the operators to carry out regular lubrication of the equipment. 8.4 Conduct inspections of the equipment’s oil reservoirs and top up the oil to the specified level in a timely manner. 8.5 Implement a monthly equipment cleaning and oil change plan, and carry out oil changes in accordance with the specified cleaning and oil change procedures, with the cooperation of equipment operators and maintenance staff. 8.6 Responsible for taking samples from large oil tanks of 100L or more as scheduled for testing. 8.7 Responsible for collecting waste oil and returning it to the lubrication station; 8.8 Responsible for filling out the completion and acceptance form for equipment cleaning and oil change, and then sending it back to the Equipment Department. 8.9 On a quarterly basis, in conjunction with the workshop mechanics and maintenance workers, regular inspections of equipment lubrication are carried out, and actions are taken to address any issues that arise. 8.10 Responsible for preparing cutting oil and coolant. 8.11 Manage lubrication materials properly and keep lubrication equipment clean. 9. Responsibilities of the plant mechanic regarding lubrication work mainly include: 9.1 Being responsible for guiding equipment operators on how to lubricate the equipment correctly. 9.2 Organize the planned cleaning and oil change of the equipment. 9.3 Responsible for formulating measures to address equipment leaks and promptly fixing oil leaks in the equipment. 9.4 Improve the lubrication condition of equipment to prevent equipment accidents caused by poor lubrication. 10. The responsibilities of equipment operators regarding equipment lubrication mainly include: 10.1 Being familiar with the lubrication system of the equipment being operated, as well as the types, grades, and quantities of lubricants used. 10.2 Ensure regular fueling and lubrication of the equipment. 10.3 Check the oil level and quantity, and top up the lubricant in a timely manner. 10.4 Assist the lubrication worker in cleaning and changing the oil of the equipment. 10.5 Always pay attention to the lubrication status of equipment during work. It adjusts the amount of lubricating oil. For any lubrication problems that cannot be ruled out, call a repairman for fixing. VIII. Formulation of the lubrication management system The formulation of the lubrication management system should take into account the division of responsibilities, management procedures, and work requirements of various departments within the enterprise. Ensure that responsibilities between departments are clearly defined, and that personnel responsibilities are assigned to specific positions. Generally, it should be drafted by the chief lubrication engineer, reviewed and approved by the head of the equipment management department, and incorporated into the company’s rules and regulations regarding equipment management.