VAS Tribology Solutions

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Total Fluid Management Services
Mr. Praveen Kumar
VAS Tribology Solutions
India
Abstract
Total Fluid Management Services increase equipment reliability through the elimination of failures caused
by improper lubrication practices. This services provide a highly detailed plan of attack to achieve lubrication
excellence.The purpose is to plan and schedule the deployment of lubrication to oil and grease lubricated
machinery. While the basis of an effective fluid management services is to provide; the right lubricant, in the
right location, in the right amount, at the right time, in the right condition and by the right person .This services
assist in the proper practices for storage, handling, dispensing, safety, oil analys is, waste oil disposal,
training and PMs.
Keywords:
Machine Reliability,Lubrication Excellence,Storage & Handling
TOTAL FLUID MANAGEMENT SERVICES
Many companies' maintenance departments throughout
the world have undergone radical changes over the last
50+ years in how they perform maintenance on plant
equipment. They have implemeted CMMS system , used
oil analysis, spread sheets , condition monitoring,
predictive maintenanace , sysnthetic fluid but yet the
problems of lubrication remain.
It has been determined that inadequate or improper
lubrication accounts for as much as 43% of all
mechanical failures in industry. A fluid management
services should ensure that the correct grade of
lubricant is delivered to the right place, in the right
quantity, at the right time.
The area of fluid management services are lubrication
management,coolant management, grease
management ,rolling oil management,quenching oil
management, transformaer oil management , turbine oil
management.
Fluid management services define a structured process
to help you build a strong fluid management services.
The process comprehends six major steps – Plant
Audit, Proposal, Implementation, Review, Manage and
Innovation.
Plant Audit
A plant audit of lubricant usage (also known as a
lubrication survey or a lubrication chart) is designed to
populate the database with a complete set of all oil and
grease lubricated equipment in the plant. A database of
the oils and greases used in the plant is also required to
ensure that the equipment is linked to its appropriate
lubricant. This is the first step in the development of a
plant fluid management services.
Proposal
Conclusions of our audit survey will enable us to
discuss with customer possible improvements through
a full scale and detailed survey led by a qualified
engineer.
Implementaion
Once the proposal is accepted, our team discuss the
implementation with customer and share copies of road
map and schedule is delivered for each part of the
process. During the process of implementation, we keep
on update on the project progress for each activities to
the key staff through schedule meetings , mails,
personal intraction.
Review
The review meeting enables us to discuss our points of
view with customers about the fluid management
services and set-up a regular meeting schedule
between customers and key members of our team.
Manage

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With the skilled technician,robust reporting system,latest
technology etc we manage the project and perform
review on the way our contract is run, We offer customer
“Value Added Service”.
Innovation
Always in search of ever more efficient and innovative
solutions, our return of experience enables us to
improve continuously on Lubrication enabled reliability,
Lubrication excellence,Quality and productivity.
Fluid Management Services Include
o Create Daily/Weekly/Monthly Lubrication Routes
o Inventory Management
o Handling & Dispensing
o Condition Monitoring
o Renewal of fluids
o Tank Cleaning
o Disposal of used oil
o Report Management
o In-house training
o Measuring the fluid management services
Create Daily/Weekly/Monthly Lubrication Routes
Once the plant audit has been completed, the entry of
scheduled lubrication tasks is carried out. Each
lubrication point on a machine train is identified by
Lubrication Identification System(LIS) and linked to its
appropriate lubricant. With proper analysis,we are
enable to generate a lubrication schedule period.
Lubrication routes help us to gether day to day activities,
task. A properly designed route help us to minimize the
amount of time and effort needed to get to all of the
lubrication points, and also minimize the amount of
lubricant types needed to be used at any one time. This
can help ensure that all points are lubricated correctly.
Inventory Management
Inspection of incoming oil: At the time of delivery ,we take
sample and perform required test of incoming new oil in
our in-house lab and confirm that the oil ordered is
correct by verifying the information on the drum. We
request that the oil not be used until the results are
back.
Lubricant storage: we maintain correct & clear labeling
to ensure proper use of the enclosed contents. We
consider to prevent the degradation of the physical,
chemical and cleanliness requirements of the lubricant
throughout the storage and dispensing phase with
proper stock rotation and storage methods.
Maintain FIFO system: we dedicatedly maintain the FIFO
or First In First Out system where the lubricant which
Enters the system first & exists the system first.
Handling & Dispensing
We have focused team to ensure the health and the
cleanliness of the lubricant which meets the
specifications required by the equipment. The best
practices are implemented to eliminate the opportunities
for contamination like Pre-filtering of all lubricants, LIS
system, S&R containers etc. Scheduled reports for all
Preventive Maintenance activities involving oil drains, top
ups, sweetening, flushing or reclaiming is recorded and
forwarded to the individual responsible for the oil
analysis program group in a timely manner. Proper
record keeping of any activity involving lubricant
consumption, lubricant replacement and/or lubricant top-
ups performed is dedicatedly maintained. Our team is
trained in visual management techniques to ensure the
correct lubricant is being used for each lubrication point
which avoid cross contamination.
Condition Monitoring
On-site testing facility is set up to our customer’s sites
and the most of the oil analysis is performed in-house.
Lab instruments, including the particle counter, digital
viscometer, Refractometer , Ph meter, TAN/TBN kit is
used.
Onsite tests are performed like concentration,Ph
test,Bacterial & Fungus test,Hardness, foaming
test,viscosity,moisture content,dirt content,TAN and TBN
etc.
If a problem is found in the in-house lab and we need
more information, we request a second sample be taken
and sent to our off-site lab for a detailed report.We also
display the oil / coolant testing chart to each & every
machine.
Renewal of fluids
We use a variety of filtration machine for renewal of
contaminated oil and coolant at the customer’s site. A
common misunderstanding is that oil needs to be
changed after a fixed time, miles or hours in operation.
We do condition-based maintenance (CBM), which
means only changing the oil when an oil analysis report
shows that life period of oil has been used and can not
be carried further. We fit a good-quality offline filtration
machine to remove dust, wear particles, water .
Tank Cleaning
After years of use, a layer of sludge will accumulate at
the bottom of most oil and coolant reservoirs and bulk
tanks. In order to obtain optimal performance from
filtration equipment, we remove that layer of sludge and
internally clean the reservoir.
We maintain the all document and checkilist related to
cleaning activities. We use wire brushes, shop-vacs,
squeegees, and lint-free rags, as required.
Disposal of used oil
When the life of oil & coolant is over , we dispose it in the
correct storage container for same type of lubricant with
proper marked and labeled. We classify the lubricant for

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the respective disposal and remove from the area
without delay. As long storage times allow for the
introduction of contaminants (e.g. water) and other
fluids, and could result in re-classification.
Report Management
We manage several types of reports covering all
parameters related to fluid maangement services.These
reports include list of overdue lubrication tasks, list of
machines or components that are using an excessive
amount, lubricant inventory level reports, tank cleaning ,
tramp oil ,disposal of used oil etc.We share
daily/weekly/monthly report on TFM activities.
In-house training
In our fluid management services ,we provide In-house
training for supervisor, oil filler, operators and also
customer’s senior management. The operators and oil
filler /lube technician that are directly responsible for
lubrication is properly trained, and individuals that are
indirectly involved in the lubrication program also have at
least a basic awareness of the program's goals, primary
benefits, and its procedural requirements.
In order for the organization as a whole to increase
equipment reliability through lubrication excellence, it's
vital that a lubrication skill development program be put
in place to meet the needs of all individuals who have
responsibility for lubrication tasks, or that may have input
into the lube program.
Measuring the fluid management services
Our primary goal during the early development of the
fluid management services is the identification of overall
program needs and the development of roles and
responsibilities.
Our secondary goal is to move from the development
process to more proactive measurements. These
includes refining lubrication limits and alarm levels,
determining root causes of lubricant-related equipment
failures, extending or eliminating lubrication PM tasks,
improving the lubrication consolation process and
reducing oil consumption.
The following is a simplified list of potential key
indicators that is used as the lubrication program
matures:
o Reduce Lubricant Costs
o Improve Compliance to Scheduled Lubrication
PM Tasks
o Improve Equipment Reliability
o Improve Oil Cleanliness Levels
o Tracking and Trending Lubricant Disposal
Costs
Fluid Management Services: Benefits
Automobile Industry
Four years ago, An automobiile company implemented
fluid management services and helped them to
transform the plant’s lubrication procedures on all critical
assets. Now machinery breaks down less often, and
maintenance issues are better anticipated.
But the real story is how the company went from
standard operating procedure for lubrication to world-
class with fluid management services.
Oil sampling and testing for predictive maintenance was
another area in which they was deficient. Know-how on
lubrication and experties were lacking. They were also
lacking in tank cleaning process , housekeeping,
handling & dispensing and documentation and reporting
system.
While lubrication was not a strong focus at plant, it
became a core strength with the implementation of Fluid
Management Services.
We established an onsite testing facility and made a
standard procedures for oil sampling & testing.
It started with a plant-wide,top-to-bottom analysis of all
plant system that required lubrication.This was followed
up with recommendations down to the component level.
Fluid Management services also supplied company with
detailed, step-by-step intructions for sampling and
Overview
Challenge
o Disorganized lubrication procedure
o Equipment failure and downtime
o Status quo opposed to change
o Product quality
o Testing facility
o Unplanned tank cleaning
o Discard oil & coolant
Solution
Fluid Management Services
Result
o Best practices for lubrication
o Fewer breakdown, less downtime
o Culture change
o Improve product quality
o Set up onsite testing facility
o Sheduled tank cleaning activity
o Less dispose oil & coolant
o In-house training programe

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analysis. Additionally, VAS Tribo consulted them on
buildling a world-class lubrication storage room and oil
analysis laboratory.
This services has also provided the In-house training
programe to their site engineer,supervisor,operator. By
all account,the operator training has had a lasting
impact that has created a best-practices culture at the
plant.
After implemention of fluid management services,
lubricant costs has reduced,improve oil cleanlines
levels, tracking and trending their lubricant disposal
costs.
This services has also helped the company be smarter
about purchasing oil for lubrication. Previously, they
used 20 different types of oil. That number was reduced
13 after transition to best practices. As result, they
gained negotiating ability with oil suppliers because
fewer oil types are needed at the plant, and they know
exact specification to request.
Cutting Oil Consumption Trend