Contributing Re.engineer Partner: Noria Corporation (www.noria.com)
Challenge: A recent study of the motor and pump repairs at the Indiana-Kentucky Electric Corp. (IKEC) Clifty Creek generating station revealed that approximately $2 million dollars was being lost annually due to improper lubrication. This has led to dramatic changes, including Noria training and a greater emphasis on lubrication to ensure the health and reliability of the plant’s equipment.
Solution: Before 2013, overgreasing and undergreasing were common at the station, as was the use of the wrong oil and grease. No oil analysis was being performed, so oil was changed regardless of whether it was needed. Personnel also did not consider the cleanliness of the oil or the plant’s oil containers as an issues. The thought “grease was grease” and “oil was oil”. If a little was good, a lot was assumed to be better. As long as grease and oil were running from bearing housings or oil was dripping from the machinery, it was believed that the lubrication was sufficient. Ultimately, the IKEC team partnered with Noria to implement a machinery lubrication training program and the details of the implementation can be found here.
Results: Cost savings of $250,000 by preventing two boiler feed pump failures, lubricant consolidation savings of nearly $150,000, increased equipment uptime and availability, and an improvement of the maintenance culture.
Impact: Cost avoidance of $2 million annually