3. Who Is ICML?
A Non-profit, Vendor-neutral, International
Organization
An Independent, Third-party Certification Body,
with over 6,000 certifications, in 74 countries, offering exams
in 8 different languages
A Standards Development Support organization actively
participating in TC108/SC5 for the development of
lubrication-related international standards
An Awards Body which recognizes excellence in used oil
analysis and machinery lubrication
A community of practitioners that advocates the needs of
lubrication Professionals
A close ally of other maintenance and lubrication
organizations
4. Augustus H. Gill Award For Excellence
in Lubricant Analysis
Augustus H. Gill
Born Canton Mass Aug 1 1864
Degree MIT 1884 at age of 20
PhD Leipzig University 1890
Full Professor MIT 1909, Emeritus 1934
Honorary Degree Rhode Island College
SC.D
Founding Member ASTM
Published “A Short Handbook on Oil
Analysis”, “Gas and Fuel Analysis for
Engineers” and “Engine Room Chemistry”
Prof. Gill, Emeritus
Professor – MIT
“Father of Modern Oil
Analysis”
1864 - 1946
5. Augustus H. Gill Award For Excellence
in Lubricant Analysis
Professor Gill’s Laboratory - MIT
Gill Award Criteria
Commitment to Education
Maintenance Culture and
Management Support
Performance Measurements
Used
Proactive/Predictive
Maintenance
Use of Standardized
Procedures
Technology Integration
Contamination Control
Lubrication Management
Oil Analysis Methods and
Strategies
Use of Information Technology
Continuous Improvement
6. Awardees
2001 Palo Verde Nuclear Generating
Station (Arizona Public Service)
2002 Smoky Canyon Mine (J.R.Simplot
Company)
2003 Georgia Power Company (Southern
Company)
2004 Kennecott Energy Company (Rio
Tinto)
2005 No award presented
2006 Clopay Plastics (Augusta Ky. Plant)
2007 Coal Creek Station (North Dakota)
2008 Energizer (Maryville, Mo.)
2009 No award presented
7. Commitment to Education
Sites use in house
developed training
Professional Training
providers
Oil Labs
Lubricant Suppliers
Training is extensive and
often includes operators
8. Maintenance Culture and
Management Support
Management has buy in
Sees excellence as a competitive
advantage
Champions and Sponsors emerge
Technicians receive training
Buy in comes after a time
Generally involves a culture change
Winners stay with it good times and bad
9. Performance
Measurements Used
% Reduction in Lubricant Used
% Cost Reduction in Lubricants
Cleanliness targets achieved
% Lubricant Used vs. % Lubricant
Disposed
Lubricant Used per Unit
Produced
10. Use of Standardized
Procedures
Use of detailed instructions
Lots of visuals
Standard Operating Procedures
Calibrated containers and grease
dispensing equipment
Lube consolidations and
specifications
11. Technology Integration
Sites report using
Oil Analysis'
Vibration Analysis
Thermography
Motor Circuit Evaluation
Acoustic Emission
NDT
Generally the technologies are
integrated and in some cases
the same technicians are
trained in multiple technologies
13. What does Dusted mean ?
50 mg/l x 170 liter sump capacity
= 8.5 grams of Silica in the oil.
Around 2 micron or less in size
Note: caution level set at 15 mg/l
A teaspoon of sand weighs about 8
grams
14. The Story
An oil sample was returned with a
high silica reading-the OEM lab
made the call
OEM immediately voided warranty
since the engine was “dusted”
OEM was happy to let the engine
run to failure-since total cost of
rebuild would be on the end user
“ Collecting on a warranty is a failure-
no one wins in the end”
19. By performing filter analysis no large
particles were observed
Induction leaks were found and sealed
Changed one turbo and the oil
Subsequent filter analysis showed
clean filter-keep running
Savings was over $300,000
Results
25. Lower Viscosity = Lower
Temperature
Ther
m o t
ekn i
x TV S-700 9:33:02 PM 9/10/2004 e : 0.95 Bg : 78.4°F
-11.2
311.0
95.2
149.8
Fahrenheit
100.0
105.0
110.0
115.0
120.0
125.0
130.0
135.0
140.0
145.0
122.2
DL A rea 1
Min. A v g. Max.
99.0 134.0 141.1
A rea 2
Min. A v g. Max.
98.1 119.3 139.2
An ISO 1000 wt. gear oil was being
used in this drag line gearbox in an
effort to control heat. Maximum
bearing surface temperature was
141 degrees f.
An improved EP package was
developed and a ISO 460 wt. gear oil
substituted. The maximum
temperature of the bearings dropped
by about 20 degrees
26. Proactive Predictive Maintenance
Gear Tooth Case Study
Swing Gearbox
time wave form data
Normal time wave form
for a swing transmission
One impact per
revolution generally
associated with a gear
condition
28. Detroit 16V4000
2330 HP Engine in a 240 ton haul truck
Normal on time change out would have been
18,500 hr
Changed crank bearings at 21,000 hours (design
change
No in frame- but
Ran 39,144 hours
Burned 911,000 gallons of fuel
Taken out of service due to a coolant leak
Detected under the oil analysis program
Over $5 per hour operating cost savings
Like getting a new engine for free!
29. Intrusive Inspection at 35353 hours
805,537 gallons of fuel
22.79 gallons per hour
Profile I Haul
Thanks to Craig Softley, Antelope Coal
35. ICML Awards For Excellence in
Lubricant Analysis and Machinery
Lubrication
Recognize End Users
Criteria created to serve
as roadmap to excellence
in oil analysis &
lubrication
Open to Companies
World Wide
No Cost to Nominees
Nominations Directly
From Industry Only
36. Conclusions
ICML serves as a rallying point for machinery lubrication
practitioners – creating a community
ICML bridges the gap between research and application
ICML merges the disciplines of lubrication engineering and
reliability engineering to serve the interests of industry
(safety, environment, profit)
The Gill and Battle Awards criteria serve as a roadmap for
achieving excellence in used oil analysis and machinery
lubrication
ICML certification accurately reflects common roles in
industry and is vital to industry for progressive skill
management programs
