i got snowed out of the Passenger Vessel Association meeting and wanted to share my presentation on Best Practices on Fluid Maintenance

1. 0
Preventative Maintenance Best
Practices:
Extending Fluid Life and Enhancing
Performance Through an
Effective Oil Analysis Program

2. An Ounce Of Prevention
Is Worth A Pound Of Cure

3. Agenda
• Introduction
• Lubricant Fundamentals
• Value of a Continuous Oil Analysis Program
– ROI, Cost of failure, extended oil life, case studies
• Oil Analysis Metrics
• Interpreting results
• Trend analysis and long terms saving
• How to Implement an Oil Analysis Program
• Conclusions

4. RSC Bio Solutions
• Full array of innovative lubricating and cleaning products and services that deliver
superior performance and systems savings without sacrificing environmental safety
• Leverages the strength and reach of RSC, investing in emerging and advanced
technology and creating new-to-the world solutions
A Separate Connected Platform
Gemtek Products
• Exclusive technology license
• Proprietary biobased
surfactant blends and solvents
Partners and Investments
Sorbent Green
• Exclusive distribution rights
• High performance and safe
absorbent technology
Terresolve Technologies
• Founded in 1996
• Acquired 2012
• Leader in readily biodegradable, high
performance industrial lubricants

5. Introduction to RSC Bio Solutions
Key Markets Served
Waste
Offshore Oil & GasWind Power Marine Construction
Marine Transportation
Utility Fleets
Turf

6. Serving the Marine Industry since 1996

7. We Have Found A Wide Range Of
Maintenance Practices
Predictive. Real-time fluid monitoring
and historic modeling.
Periodic. Monitor fluids at set intervals
to adjust maintenance procedures.
Preventative maintenance on equipment
at set intervals.
Just in time repair of component systems
and fluid replacement.
Crisis management: repair components
when broken.
Top Performers
Strong Performers
The Muddy Middle
Weak Performers
Worst Performers

8. Let’s Focus On Lubricants
or Valuable Asset?
Necessary Evil

9. Lubricants Serve A Variety Of
Functions
• Lubrication
– Reduces friction and wear by introducing a film between moving parts
• Cooling
– Helps dissipate heat away from the critical parts of the equipment
• Cleaning and Suspending
– Facilitates smooth operation of equipment by removing and
suspending products, such as carbon or soot, sludge, and varnish
• Protection
– Prevents metal damage due to oxidation and corrosion

10. Lubricants are Used Throughout
Your Vessel
• Engines
• Thrusters
• Stern Tubes
• Winches
• Gears
• Gates
• Hydraulics

11. Shameless Plug:
There is a growing demand for Environmentally Acceptable
Lubricants (EALs)…
which do have special maintenance requirements.

12. There Are 4 Classifications of EALs
Recognized By EPA and ISO
ISO 6743/4
• Hydraulic Environmental Triglycerides (HETG)
• Hydraulic Environmental Polyalkylene Glycols
(HEPG)
• Hydraulic Environmental Synthetic Esters (HEES)
• Hydraulic Environmental PAO
(polyalphaolefins) and related products
(HEPR)
Particular application factors affect EAL selection.

13. No Shameless Plug:
RSC Bio Solutions does NOT provide oil analysis services - except
as a service to our Customers (using an independent
third party laboratory).

14. All Lubricants Are Happiest
When They Are:
• Clean
• Dry
• Cool

15. In-Service Oil Analysis Can Provide
High ROI
• Shows lubricant performance
– Can predict oil life (extend oil drain)
• Shows system performance
– Can prevent or predict equipment failure

16. Keep Your Equipment in Optimal
Condition
Reduced
MTBM*
Improved Fluid Life
Improved
Lubrication
Reduced Downtime
Improved
Efficiency
* Mean Time Between Maintenance

17. Cost Justification of Oil Analysis
• Identify Costs
– Initial set up (hardware, software, training, consulting support)
– Ongoing costs (testing, advanced support)
• Explain Benefits
– Increased Reliability
– Few dollars spent on repairs
– Improved safety
Before
10% Maintenance
Cost Reduction
40 Percent Sales
Increase
$
Percent of
Sales $
Percent of
Sales $
Percent
of Sales
Sales 200 100 200 100 280 100
Maintenance
Costs 40 20 36 18 56 20
Material, Labor,
G&A, O/H 150 75 150 75 210 75
Profit 10 5 14 7 14 5
A 10% reduction in maintenance
costs in the average plant has the
same bottom line effect equal to a
40% increase in sales.
Dollars made Simple

18. Cost of Failure
Major
Failure
Moderate
Failure
Minor
Failure
Production Losses $500,000 $100,000 $5,000
Maintenance Costs
(Parts/Labor)
$100,000 $10,000 $1,000
Total Cost $600,000 $110,000 $6,000
Probability Factor 10% 20% 70%
Weighted Cost $60,000 $22,000 $4,500
Current Scenario
Weighted cost: $86,500
per failure event

19. Cost of Failure
Major
Failure
Moderate
Failure
Minor
Failure
Production Losses $500,000 $100,000 $5,000
Maintenance Costs
(Parts/Labor)
$100,000 $10,000 $1,000
Total Cost $600,000 $110,000 $6,000
Probability Factor 10% 20% 70%
Weighted Cost $60,000 $22,000 $4,500
Current Scenario
What happens if we can move just 20% of the
Major and Moderate failures into the Minor
category?
Major
Failure
Moderate
Failure
Minor
Failure
Production Losses $500,000 $100,000 $5,000
Maintenance Costs
(Parts/Labor)
$100,000 $10,000 $1,000
Total Cost $600,000 $110,000 $6,000
Probability Factor 8% 18% 76%
Weighted Cost $48,000 $17,600 $4,560
Weighted cost: $86,500
per failure event
Weighted cost: $70,160
per failure event
COST SAVINGS:
$16,340 / FAILURE

20. Highlights of Engine Problem Samples Identified Through Routine Oil Analysis
Table 1: BC Ferries Annual Engine Problem Samples Summary
Year
# Engine
Samples
Fuel/Glycol
U or S
% Fuel/Glycol
U or S
Na or K
> 30ppm
% Na or K
> 30ppm
Lead (Pb)
> 8ppm
% Lead
> 8ppm
1991 756 32 4.23% 139 18.39% 40 5.29%
1992 1195 12 1.00% 140 11.72% 37 3.10%
1993 1280 28 2.19% 105 8.20% 36 2.81%
1994 1203 25 2.08% 63 5.24% 20 1.66%
1995 1079 33 3.06% 91 8.43% 29 2.69%
1996 1077 28 2.60% 90 8.36% 36 3.34%
1997 1228 28 2.28% 129 10.50% 32 2.61%
1998 1328 17 1.28% 109 8.21% 49 3.69%
1999 1415 20 1.41% 80 5.65% 12 0.85%
2000 1533 1 0.07% 44 2.87% 32 2.09%
2001 1401 5 0.36% 50 3.57% 39 2.78%
2002 1443 25 1.73% 41 2.84% 24 1.66%
2003 1069 14 1.31% 13 1.22% 8 0.75%
Flagging Codes:
U – Unacceptable level S – Severe level
BC Ferries Case Study

21. Based on the Table 1 data, consider the following
scenario looking at fuel and glycol leaks alone:
1 Probability of Engine Failure
Type Total Cost Probability Total
Major $4,000,0001 0.1% $4,000
Moderate $50,0001 14.9% $7450
Minor $1,0001 85% $850
Estimated Average Cost Per Failure $12,300
1 Failure Cost Estimates courtesy of: Buck Crich, BC Ferries
Engineering Superintendent, Tsawwassen Terminal.
BC Ferries Case Study

22. According to Table 1
data, as well as the
previous example,
the following
conclusion can be
made (based on
conservative figures):
21 x 30% x $12,300
= $77,490
Average Total Annual
Major Fuel/Glycol
Alarms; 1991 – 2003
(13 years)
Percentage of All Major
Problems
(that may have evolved into
failures)
Ave.
Cost per
Failure
Annual Estimated
cost Savings
$77,490 / $32,000
= 2.4
Ave. Annual Cost
of Analysis Ave. Annual
Estimated Return
on Investment
Case Study

23. L&FP Nov., 2000
US Military Case Study

24. Common Contaminants
That Will Cost You Money
Contaminants found by oil analysis:
• Abrasives
• Water
• Acid
• Other Lubricants
If Not Addressed, They Will Shorten Your
Equipment Life AND Your Fluid Life!

25. Key Attributes of an
Effective Oil Analysis Program
2.100a/T1-A1
Machine
Selection
• Criticality- Primary
• Sump Volume- Secondary
Sample
Location
• Primary
• Secondary
Sample
Frequency
• Online/Real time
• Monthly/Quarterly
Test Slate
• Routine
• Exception
• Onsite
• Commercial Lab
Alarms &
Limits
• Targets
• Aging
• Statistical
Action &
Integration
• Other Technologies
• Appropriate Action
KPI Tracking & Continuous
Improvement

26. Test Flow
Routine test slate and
sampling frequency
Have alarms
been
violated?
Is problem
identified?
Execute exception and/or
commercial lab testing
Fix problem and continue
to monitor
YES
NO
NO
Yes

27. Targets & Limits (Alarm Points)
•Particle Count (ISO Code)
•Moisture
•Glycol/Fuel
Targets
(Goal-
Based)
•Viscosity
•AN/BN
•Additives
•Dielectric Constant
Fluid
Aging
Limits
•Elemental Wear metals
•Ferrous Density (DR, PQ)
Statistical
Limits

28. Analysis Metrics
• Oil Viscosity
• Acid Number (AN) formerly Total Acid Number (TAN)
• Water
• Elemental Content
• Particle Count

29. Sampling Technique Is Important
Always:
• Sample hot
• Clean around port
• Use same location
• Use clean tools/tubes
• Inspect filters for debris
• Keep sample jars clean (and closed)

30. Sampling Varies By Application

31. Sample Reports Are Full Of
Valuable Information

32. Sample Reports

33. Sample Reports

34. Sample Reports

35. Improved Mean Time Between
Maintenance
• Longer lifespan→ less overhaul → less downtime
• Improved Lubrication reduce number of failures
– Better wear protection
– Improved lubricity
– No sludge or varnish

36. Trending is Key in Oil Monitoring

37. Water Affects Oils Differently

38. Quantifying Long Term Savings

39. Oil Analysis is a Great Idea!
How do I get started?
• It’s good to partner with a lubricant manufacturer
• Important to use an independent lab
• Request in-depth analysis
• Don’t be afraid to ask about cost
38

40. Conclusions
• Clean – Dry – Cool
An regimented In-Service Oil Analysis program will:
• Prolong the life of your fluids and your equipment
• Allow you to better plan maintenance
• Increase up-time
• Save you money in the longer term

41. Special Thanks to
• Shannon Wittig; RSC Bio Solutions
• Matt Spurlock; AMRRI, Reliability Centered Lubrication
• Fluid Life; Equipment Reliability Services
• Jason Kronlund; Lab One, Inc, An Oil Analysis Lab
• Tyler Kuchta; RSC Bio Solutions
40

42. Thank you
Questions?
Mark Miller
memiller@rscbio.com