January 28, 2015

???
Maintenance Department
Lafarge Republic Bulacan Plant
Minuyan, Bulacan
TECHNICAL REPORT: REVIEW OFOIL CONDITION AND MILL LUBRICATION SYSTEMS

Dear Sir:

We have completed our review of your needs concerning dirt and water contamination of your
in-service oils and are pleased to submit the enclosed technical report. We trust that the
recommendations in the report will bring about significant reduction of equipment and
component wear and tear through more reliable lubrication.

We appreciate your time and assistance in the preparation of this report. All information will be
kept in confidence until you authorize otherwise.

We thank you for this opportunity to be of assistance.

Sincerely,

???

TECHNICAL SERVICES REPORT

FOR
LAFARGE REPUBLIC BULACAN PLANT
MINUYAN, BULACAN

ANALYSIS OF
OIL CONDITION AND REVIEW OF OIL LUBRICATION
SYSTEMS AT CEMENT PLANT

PLANT NAME: Lafarge Republic Bulacan Plant

LOCATION:
Minuyan, Bulacan
BACKGROUND:
Machinery Reliability Systems, Inc. visited Lafarge Republic Bulacan Plant last
August 12, 2014 to conduct visual inspection of all central lubrication and
hydraulic systems at the mill to validate oil sample test results indicating
severe oil contamination and high rate of equipment wear.

OBJECTIVE:
Study and check the oil condition of central lubrication and hydraulic
system.
Inspect lubrication systems operation.
Check contamination control systems.
Recommend methods to improve and maintain oil cleanliness to
prevent premature equipment and component failures

METHOD:
Ocular inspection in Central Lubrication system and hydraulic system
components.
On site oil analysis and cleanliness testing using patch test method.
Oil sample Laboratory Analysis

DATA AND RESULTS:

1.

Visual Appearance of Oil Passed through a Sample Patch:

CLEAN

DIRTY

In a Patch Test Analysis, sample oil is passed through a 1.2 micron

patch leaving behind contaminants in the oil such as common

dirt, dust, rust, wear metals and oil oxidation by-products.

Contamination leads to accelerated equipment wear.
2.

Visual Appearance and Patch Test of Oil taken from Horomill

central Lube and hydraulic system. And also lube system for
VRM planetary gear.

3. Conventional Breathers/Filters /accumulator

DISCUSSION:
Oil samples taken from Lube Center and hydraulic system of Horomill, lube system of planetary gear of
VRM and Triple Gate hydraulic system indicate severely contaminated systems (dirt, road dust, wear
metals etc.) that would naturally lead to premature equipment and component wear. Wear debris from
machine components are clearly visible in the oil sample patches under a microscope (100X
Magnification).
Most of the particles in the oil sample patches come from road dirt/dust. Typical road dust is composed of
silica and alumina oxide- the same material used in sand paper, and these elements are harder than steel
alloys. In other words, these particle contaminants are severely abrasive to roller bearings, pumps, and
control valves.
Most common entry point of dirt of hydraulic and lube circulation systems is through the breathers vents.
Lube Oil Reservoirs and Hydraulic System Oil Tanks suck in dirty/humid atmospheric air through the
breather vents as fluid levels and temperatures fluctuate during equipment operation. It sucks in air as the
fluid level goes down; and as operating temperature goes down especially during shutdowns and cold
weather operation. Entry of fine dirt and moisture through unprotected breather vents is a major problem
at Steel Asia resulting to oil contamination. It is estimated that with the current contamination levels of the
lube centers, 136 50lb bags of sand/abrasives passes through pump and bearings in one (1) year.
Likewise, moisture from incoming air through the breather vents is also a problem since it condenses and
forms water droplets on the inside surfaces of the reservoir. These water droplets would eventually group
together and contaminate the oil leading to rust and corrosion. Moreover, water significantly reduces the
oil film thickness resulting to metal-metal contact on machine components. 1000-ppm (.10%) water
content in the oil is enough to reduce the life of the bearing by 80% (Timken Bearing Company). A typical
bearing lasting only about one (1) year because of water-contaminated oil can be extended to at least five
(5) years with water-free oil.
Other entry points of contaminants, both water/dirt are as follows: (1) Worn-out Hydraulic Cylinder Wiper
Seals (2) Cylinder Rods with dings and dents. (3) Poor Oil handling/Dispensing (4) Open Manholes/Covers in oil reservoirs.
FINANCIAL: Significant savings in oil change and parts replacement costs especially bearings can be
achieved by Lafarge Bulacan by addressing the contamination issues at this stage. Bearings at the
Gearboxes are expected to last beyond five (5) years if contamination levels are brought to acceptable
levels for Lube systems. Likewise, no hydraulic component failures are expected in the next five (5) years
also in Hydraulic Centers system if contamination levels are controlled.
STATUS: High particle count levels are the main problem in the hydraulic centers and lube centers. This
is mainly due to an inadequate filtration system, and high rate of dirt entry through the breathers and
openings in oil reservoirs.
Water also needs to be removed also from all lube and hydraulic centers, and once dehydrated, desiccant
breather/filters of the right size should be installed on the oil reservoir to prevent water condensation
problems. The procedure should be done also for other lube/hydraulic center experiencing high water
content above 500 ppm.

Moreover, in-line filters on lube centers and Hydraulic Centers are not delivering the required cleanliness
levels required as indicated by the dirty sample oil patches. Filters need to be upgraded to ISO Standard
quality filters: 12 microns Beta 1000 rating for Lube Centers system and 6 microns Beta 1000 rating for
the Hydraulic system. In addition, a filter change-out should be initiated when filter-clogging indicators
show a red color or when oil analysis indicates an increase in contamination levels.
NOTE: Filter Rating Specifications based on ISO Cleanliness Codes Requirement for Gearboxes and
Hydraulic Systems.
ACTION:
To take the necessary corrective actions to address the increasing contaminant levels while
further damage to equipment and lubricant can still be prevented.
It is highly recommended that the following corrective actions be carried out:
1. To prevent damage to equipment, the oil just needs to be removed of contaminants at the following
Lube/Hydraulic Centers:
Equipment
1.
2.
3.
4.

Hydraulic Tank (Triple gate)

Hydraulic Tank (Horomill)
Lube Center (Horomill)
Lube Center (VRM planetary gear)

Required Action to Remove Contaminants

Off-Line Filtration (3-microns)/Water Removal
Off-Line Filtration (3-microns)/Water Removal
Off-line Filtration (3-microns)
Off-Line Filtration (3-microns)/ Water Removal

Oil condition as far as the chemical properties are concerned is still satisfactory and no oil changes are
necessary if the dirt/water contamination is removed. Off-Line Filtration/Flushing would ensure that in-line
filters once installed will not clog up quickly since there will be minimal dirt circulating after the
filtration/flushing. These in-line filters will keep the system clean for extended periods.
Note:

Off-Line Filtration- particulates removal.

a.
b.

Target ISO Cleanliness Lube Centers: ISO 1716/13

Target ISO Cleanliness for Hydraulic Systems: ISO 17/15/12

Water removal
Target: 300-ppm moisture content (.03% vol.)
2. Ensure that oil for top-up is pre-filtered. New oil is not necessarily clean.
3. Check adequate sealing of manhole covers, seals, fluid return lines on oil reservoirs. Rectify openings
4. Install ISO Standard filters on in-line filter housings of all Lube and Hydraulic Centers. Twelve (12)
micron rating required for Lube Centers and six (6) microns for hydraulic centers.
5. Upgrade the Conventional breathers to Desiccant type Breather. Dirty air entering through the
conventional breather contributes significantly to the increase in contaminant levels including moisture in
the Lube Centers.

6. Protective Covers if installed on Hydraulic Cylinder Rods will help prevent dirt/water entry through the
wiper seals
7.

Periodic on-site oil analysis must at least be carried out every two months to check on cleanliness
levels and moisture content. If cleanliness levels and moisture content can be maintained within
limits, significant improvement in equipment and component life and more reliable equipment
operation will be attained.