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Cogeneration: optimizing pump performance at Thermal Power Plant 27 (TPP-27), Mosenergo

In this Pump Engineer magazine: Watershed management at DeKalb County Casing vibration in cavitation assessment Association interview: SSPMA Case Study : Ghost in the machine?
Volume 5, July 2013

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Case Study

Ghost in the machine? Oil behavior in vacuum pumps

Stacy Heston

Described by colleagues as an extremely professional engineer in a male dominated maintenance environment, Stacy Heston in her role as Lubrication Subject Matter Expert at Allied Reliability has faced some interesting challenges in her career. I dont know if this qualies as an interesting project, but it was denitely an interesting and possibly life threatening experience. Stacy talks to Pump Engineer about the case, one she can now look back on and laugh.
Recently, while conducting a lubrication benchmarking exercise, I was assessing a set of vacuum pumps, began Stacy. Due to the function of these pumps, oil and the vacuum air will mix. Oils for these types of pumps are designed for this operation and typically have air release capabilities to reduce risk of oxidation. In this particular instance, I noticed the oil in the pump was a clear red in color, but none of the available oils matched this description. The required oil is clear yellow in color and would typically darken to a brownish color while in use. Additionally, the oil had started to oxidize and create a thick sludge that settled to the bottom of the components oil reservoir. It looked very much like coagulated blood, and being as this is a medical vacuum pump, I was very concerned about what may have gotten into the system. The lubrication technician veried that he was using the appropriate lubricant, so a phone call was placed to the local distributor for information on what may be causing this. His response was he had never seen the oil turn like that, and was thinking the same thing I was concerning medical waste getting into the component. The site began to look for the system separator to ensure proper function. As a Lubrication SME, key tasks of Stacys job include performing Lubrication Program benchmarking exercises to ensure all elements of the Lubrication Program are optimally designed and managed. This can include providing lubricant reviews, lubrication task intervals

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I noticed the oil in the pump was a clear red in color

and lubricant application amounts, and storage and handling practices. Other tasks might include coaching and mentoring for a customer and various levels of lubrication training. This job is ever changing and an average day just doesnt exist. One day could be a training day, another out in the eld evaluating equipment, or handling the documentation pieces. Dierent companies have dierent needs and wants with each having a dierent set of parameters that must be worked within.

Solution
Meanwhile, I put in another call, this time to the manufacturer, and was very relieved to learn that the oil will turn a shade of red to purple as the antioxidant additive is consumed. The lubrication technician reported that the oil always turned red within 5 minutes of operation after an oil change. This helped pinpoint an issue with the overall oil change practices. First, a

component ush was not being performed, which meant any sludge buildup or oxidation residue was being left behind. Second, as soon as the new oil was added, it went to work to neutralize the residues and deplete the antioxidant additives. Finally, once the antioxidants were consumed, the oil would begin/continue to oxidize and the viscosity would thicken. Lubricant viscosity is a key component during the lubricant selection process. Too thick a viscosity can lead to heat generation within the component, increased wear rates, and increased energy consumption. A full system ush to remove the varnish and sludge buildup was recommended. Stacy doesnt sit behind a desk all day, but does a combination of directing people and practical work, depending on the customer and their needs. In cases where there is a coaching and mentoring requirement, those days might include hands-on training, performing re-greasing tasks or oil sample collection, or developing

It looked very much like coagulated blood

Pump Engineer, July 2013

as this is a medical vacuum pump, I was very concerned

can allow for general lubrication tasks to be performed without shutting the pump down, thus reducing preventive maintenance related downtime. The criticality and sump volume of the pump would dictate the modications selected. In some cases, none of the modications may be possible and in others all would be advisable to monitor the health of the component and lubricant while minimizing the downtime. Modications can also promote a standardized approach to maintaining the pumps so that each pump can be addressed with similar approaches and procedures. When asked what tips can shecould give to others to help them improve pump performance, Stacy replied: Ensure that the lubricants you are using are appropriate for the application. Review the viscosity and additives requirements to ensure they are comparable to the manufacturer recommended lubricants. If that information is not available, conrm with your local lubricant supplier or look for engineered approaches to make the determinations. For greases, look at the thickener type and make sure you arent mixing greases. There are formulas available to calculate viscosity requirements based on operating speeds, loads, etc. Additionally, make sure your intervals and re-grease volumes are specic with set intervals, such as 7 days and not as needed, and grease volumes, such as 0.55 ounces versus an appropriate amount.

and maintaining a Lubrication Program implementation plan. Her only preference is to be able to do both. The variety of desk and practical work keeps things interesting for her. As a consultant, she works with a variety of customers in dierent industries and they all have pumps. I see a variety of pump types and applications in dierent environments with each having their own particular operating concerns that need to be addressed. When it comes to the lubrication piece, I have numerous discussions with the lubrication technicians responsible for maintaining the equipment. If there are additional items to discuss, then the reliability engineer or mechanical engineers could become involved.

Future orientation
I would like to see component and system manufacturers focus a little more on lubrication requirements, especially for systems that may be a little more complex. At a minimum, lubrication specications, such as a base oil requirement, recommended viscosity, and additive package, or maybe a specic product. Sometimes maintenance documents might list Use an appropriate lubricant, which can lead to shortened component life if you dont know what is appropriate. Sometimes lubricants can reactive negatively with component parts and metallurgies. The one thing that drives me in all my work is that Im hopefully helping companies function greener and more reliably while consuming less oil and grease.

Work
Generally when I visit with a customer, their primary lubrication issue is having an improper grease for the grease lubricated pumps or general contamination issues for oils that are in use. Proper lubricant selection and cleanliness can extend component life in some cases 9 times over. One key task to help pumps run more safely and reduce shutdown requirements is to re-grease while grease lubricated pumps are running. This will allow for a more even distribution of grease thorough the bearing. It also allows for technologies such as ultrasonic greasing to be utilized, where the lubrication technician listens to the noise levels of the bearing in order to determine the appropriate amount of grease required based on the condition of the pump. For oil lubricated pumps, modifying pumps with hardware such as visual level gauges, desiccant breathers, quick connect ttings, and sample valves

About Allied Reliability

Stacy Heston CLS, PMP, CMRP, OMA works at Allied Reliability, a member of Allied Reliability Group, a global family of companies comprised of maintenance, reliability, and operational consulting and services, training, stang, and integrated software solutions servicing the industrial and manufacturing sector.

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