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ENVIRONMENTAL
TECHNOLOGY
BEST PRACTICE
PROGRAMME
GG227GUIDE
COST-EFFECTIVEMANAGEMENT OFLUBRICATING ANDHYDRAULIC OILS
GOOD PRACTICE: Proven technology and techniques for profitable environmental improvement
© Crown copyright. First printed December 1999.
This material may be freely reproduced in its original form except for sale or advertising purposes.
Printed on paper containing 75% post-consumer waste.
COST-EFFECTIVEMANAGEMENT OFLUBRICATING ANDHYDRAULIC OILSThis Good Practice Guide was produced by the
Environmental Technology Best Practice Programme
Prepared with assistance from:
Entec UK Limited
Hydraulic and lubricating oils are vital commodities used by the engineering industry to ensure thesmooth running of machinery and to maintain production. Industry spends millions of pounds eachyear on oil products, but the efficiency of oil use is often poor. Lubricants are vital, yet oftenoverlooked, resources for the engineering industry. They play an important role in keeping plantrunning, thus making production possible.
With good control, oil use can be minimised and considerable savings made. The benefits of havinga good management system extend well beyond these initial savings because there are manyproduction and maintenance benefits. Identification of high oil use can help to identify plantproblems which, if left unchecked, could lead to machine failures and lost production time.
Companies that have embarked on improvement projects have found that they can reduce use byaround 10% using basic measures. It is estimated that the engineering sector would save around£7.5 million/year if it reduced use by 10%. With comprehensive management, some companieshave identified savings of more than 40% - a considerable reduction that no company can affordto overlook. Industry Examples show how some of these savings have been achieved.
The Guide follows the same structured approach to the implementation of an oil managementsystem as for any waste minimisation programme. By following the advice in this Guide, you willachieve reductions and improvements in costs, waste arisings and environmental impact. The flowchart opposite, Fig 1, illustrates the content of this Guide and highlights the importance ofminimising oil usage at source before tackling the issue of waste oil.
The benefits of managing oils effectively include:
■ cost benefits from reduced consumption;
■ using fewer oils leading to simpler management;
■ less time spent applying lubricants;
■ fewer mistakes from incorrect use of oils or running out of oil;
■ lower maintenance costs and less production downtime through improved control ofconsumption and early identification of problems;
■ reduced environmental risk;
■ improved housekeeping.
S U M M A R Y
Introduction
Selecting the right oils
Rationalising oil usage
Minimise atsource anyoil usage
Re-useoil wherepossible
Recyclingand disposaloptions
Implementing an oil management system
Oil storage and handling
Off-site recycling and disposal of waste oil
On-site recovery of waste oil
Section 1
Section 2
Section 3
Section 4
Section 5
Section 6
Section 7
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Fig 1 Flow chart to show the structure of this Guide and key issues
Section Page
1 Introduction 11.1 Purpose of this Guide 11.2 Why reduce oil use? 21.3 Cutting the cost of oil 2
2 Selecting the right oils for your needs 42.1 Why oils are needed 42.2 Mineral and synthetic oils 42.3 Oil viscosity 42.4 Identifying oil properties 62.5 Use-by dates 6
3 Rationalise your oil use 73.1 A step-by-step approach 73.2 A worked example 93.3 Implementing the changes 10
4 Implementing an effective oil management system 114.1 Responsibility for oils 114.2 Procurement of oils 114.3 Stock control 124.4 Measuring to manage 134.5 Lubricating procedures 134.6 Condition monitoring 144.7 Oil management services offered by oil suppliers 15
5 Good practice for oil storage and handling 175.1 The oil store 175.2 Handling oil containers 195.3 Leakage and spill control 20
6 On-site recovery of waste oil 256.1 Reclamation of used oils 256.2 Re-using oil for its initial purpose 256.3 Re-using oil as a lower grade lubricant 256.4 Recovering oil from water 26
7 Off-site recycling and disposal of waste oil 277.1 Off-site reclamation (laundering) 277.2 Off-site recycling (re-refining) 277.3 Disposal of waste oils 28
8 Action Plan 29
C O N T E N T S
1.1 PURPOSE OF THIS GUIDE
This Guide is produced by the Environmental Technology Best Practice Programme to helpengineering companies improve their management of hydraulic and lubricating oils. The Guidedemonstrates how improved management will reduce the cost of oil purchase, bring cost benefitsthrough better maintenance routines, reduce production downtime, and lower environmental risk.
The efficiency of oil use is often poor and there are many ways in which oil is wasted. For example,small amounts are left in containers and part drums of fresh oil are filled with waste oil. Companiesthat have embarked on improvement projects have found that they can reduce use by around 10%using basic measures. With comprehensive management, some companies have identified savingsof more than 40%. In cost terms, this represents a considerable saving for UK industry. A 10%reduction in lubricating and hydraulic oil usage could save the engineering industry around £7.5 million/year.
Oil use must be understood before it can be controlled. This Guide will help any engineeringcompany to gain better understanding of how oil is used in its processes and how to improve theefficiency with which it is used.
Taking a systematic approach is most effective for reducing the use of hydraulic and lubricating oils,because an ongoing programme of systematic measurement and reassessment will lead tocontinuous improvement. Once cost savings and benefits start to be made and quantified, feedingback the results can make it easier to gain commitment for continuing and making further changesand savings.
In order to implement an improved oil management programme along the lines outlined in thisGuide and to start saving money, you may first need to win the commitment of senior managementand colleagues. Start by contacting the Environment and Energy Helpline on 0800 585794 foradvice. Ask about the free support material produced by the Environmental Technology BestPractice Programme. The following publications may be of particular interest:
Good Practice Guide (GG125) Waste Minimisation Pays: Five business reasons forreducing waste.
Good Practice Guide (GG199) Optimising the Use of Metalworking Fluids.
Good Practice Guide (GG205) Environmental Management Systems Workbook forEngineering Manufacturers.
Environmental Performance Guide (EG179) Benchmarking the Consumption of Metal CuttingFluids.
Waste can be dealt with in a number of ways, but the most effective is by following the ‘wasteminimisation hierarchy’ - eliminate, reduce, re-use and recycle, in that order. Elimination is at thetop of this ranking because it is best for the environment. If feasible, it will also generate the largestcost savings. The next best option is to minimise waste and production at source. Below this comesthe option to re-use, but if this is not practicable then waste should be recycled in-house, sold forreprocessing, or incinerated for energy recovery. The last and generally least beneficial option forthe environment is disposal of waste to landfill.
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1.2 WHY REDUCE OIL USE?
Hydraulic and lubricating oils are vital commodities used by the engineering industry to ensure thesmooth running of machinery and to maintain production. Industry spends millions of pounds eachyear on oil products, but the efficiency of oil use is often poor. Lubricants are vital, yet oftenoverlooked, resources for the engineering industry that play an important role in keeping plantrunning, thus making production possible.
With good control, oil use can be minimised and considerable savings made. The benefits of havinga good management system extend well beyond these initial savings because there are many otherproduction and maintenance benefits. Identification of high oil usage can help to establish plantproblems which, if left unchecked, could lead to machine failures and lost production time.
Improving the use of hydraulic and lubricating oils will help companies to:
■ save money on oil purchase and disposal costs;
■ use fewer oils leading to simpler management;
■ save time spent applying lubricants;
■ make fewer mistakes from incorrect oil use or running out of oil;
■ save on maintenance costs and production downtime through improved control ofconsumption and early identification of problems;
■ improve environmental performance and reduce environmental risk;
■ improve health and safety in the workshop;
■ improve housekeeping.
This Guide demonstrates how to improve the efficiency of your oil system to achieve cost savings.Good practice details are given for the management, storage and handling of oils as well as theoptions for dealing with spent oil, including re-use, recovery and recycling.
Problems with oil selection, supply, storage or application can all lead to difficulties that can increaseplant downtime and reduce output. This Guide outlines the good practice techniques required toprovide an efficient oil management system for lubricating and hydraulic oils. Industry Examplesappear throughout the Guide to demonstrate good practice in action. A number of checklists andforms are included in the pocket at the back of this Guide for photocopying and reference, alongwith two further Industry Examples.
Many of the benefits will be difficult to quantify accurately as they will be avoided costs, such as theavoidance of downtime caused by machinery breakdown through incorrect oil use. A more efficientoil system will lower the risk of plant problems in general. For this reason, in many of the IndustryExamples used, the companies found it difficult to quantify accurate financial savings, although allare aware of substantial benefits from the actions taken.
1.3 CUTTING THECOST OF OIL
The total sale of oil products in theUK last year was between 800 000and 900 000 tonnes, with industryaccounting for approximately halfof the sales. The breakdown of oilsales within the industrial sector isshown in Fig 2.
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Fig 2 UK oil sales
Hydraulic30%
Others20%
Metalworking8%
Transformer8% Process
20%
Gear/compressor/turbine oils
14%
This Guide is concerned with the use of hydraulic, gear, compressor and turbine oils. These accountfor 44% of the oils used by UK industry.
Where oil management has been reviewed in the engineering sector, the reduction in consumptionhas been significant and rewarding.
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1Tip
If the industrial sector reduced its oil consumption by just 10% as a direct result of the bestpractice outlined in this Guide, it would save at least 18 700 tonnes/year of oil. Based on averageoil prices, this represents a saving of around £7.5 million/year for UK industry as a whole. (Thisis based on the use of hydraulic, gear, compressor and turbine oils.)
Improved oil management brings oil use savings
Ford’s Dagenham plant uses a large amount of oil and the potential for reducing the amountand rationalising the grades of oil used was investigated. Ford took several measures to improveoil management, with the staff responsible for distributing the oils encouraged to identifypotential savings. The initial savings helped to secure investment in better facilities and evenfurther improvements. Controlling oil use has helped Ford with its Total PreventativeMaintenance (TPM) programme and has helped the Company to understand plant problems.
Benefits to date include:
■ a 20% reduction in oil use, representing a 200 000 litres/year reduction of oil;
■ reduced plant downtime;
■ reduced risk of oil filling mistakes through plant labelling and fewer oil errors throughimproved management procedures;
■ condition monitoring has been used to reduce unplanned maintenance.
The following improvements have been made so far:
■ the oil storage areas have better handling equipment and air pumps;
■ vehicles have been produced specifically for the transportation and dispensing of oil;
■ Ford’s internal web site is used to record and monitor plant performance with a dedicatedsection on oils, and allows comparison of use for similar plant items;
■ the installation of meters in hydraulic lines has helped to monitor use;
■ all plant items have a small diagram posted next to the filling point to inform staff of theoil type and filling requirements.
Each area is charged for the amount of oil used. This allows comparison between similar areasand helps to identify sudden changes. It also introduces some competition between theproduction lines which will help to drive down oil usage as staff take pride in their work area.
Since starting the condition monitoring and TPM programme with oils, Ford hasreduced unscheduled machine stoppages for lubrication by 80%. The savingsassociated with this reduction will far outweigh the cost of the monitoring.
Future improvements
Ford has undertaken a rationalisation survey and established the potential for reducing thedifferent grades of oil from the current number of 24 down to just 13. This will further improvethe system and make management easier.
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This Section provides the information that will enable you to select the right oils for yourrequirements. An understanding of oils and their properties is crucial if a rationalisation process isto be undertaken effectively.
The correct selection of lubrication and hydraulic oils can maintain the smooth running of machinery.This avoids maintenance problems and the associated costs to the engineering industry. Using theincorrect oil will result in frequent oil changes, high maintenance costs and a low productionefficiency.
2.1 WHY OILS ARE NEEDED
Lubrication and hydraulic oils are used to reduce wear and prevent overheating in machinery wherea number of surfaces come into contact. Lubricants work between surfaces to reduce friction andto minimise the heat build-up resulting from this. Modern lubricants can protect, clean and sealmechanical devices and ensure that they run smoothly.
2.2 MINERAL AND SYNTHETIC OILS
Mineral oils are manufactured from crude oil, which is refined to produce various grades of oil andpetroleum products. Distillation processes produce oils of different viscosities which are thenblended before the addition of additives to produce the final lubricant.
Synthetic oils are manufactured from chemicals and are stable at high temperatures whilstmaintaining good viscosity at low temperatures. Synthetic oils generally have superior performanceto mineral oils although they are more expensive. High performance lubricants can be a mixture ofmineral and synthetic oils to provide the required properties.
Typically, oils are a blend of several base oils with additives to maintain the oils’ properties when inuse. Additives are used for a variety of reasons, for example, to maintain oil properties under hightemperatures or pressures, and reduce oxidation and corrosion.
2.3 OIL VISCOSITY
Viscosity is the most important property of an oil and refers to its resistance to flow eg:
■ low viscosity oils flow easily;
■ high viscosity oils flow very slowly.
Manufacturers will specify the oil viscosity that is required for their machinery. If movingcomponents need oil to flow quickly then a low viscosity oil will be used. Where maximumprotection is required, a high viscosity oil will be specified. All oils thin with increasing temperature,ie the viscosity decreases, which is an important consideration when selecting products.
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2.3.1 Viscosity classifications
There are two viscosity classifications used by oil suppliers:
■ the International Standards Organisation (ISO);
■ the Society of Automotive Engineers (SAE).
ISO classifications are most commonly used in industry and the numbers specify the nominalkinematic viscosity at 40°C. There are 18 viscosity grades ranging from 2 to 1 500, increasing inincrements of approximately 50%:
2 3 5 7 10 15 22 32 46 68 100 150 220 320 460 680 1 000 1 500
The SAE classification is used mainly for the automotive industry but can be applied in otherindustries. SAE classifications can be for gears or engines and there are around 10 SAE enginegrades. The SAE viscosity numbers define viscosity ranges at 100°C and some have a W suffixindicating winter service for applications in low temperatures. A multigrade oil is one that bridgesat least two SAE classifications, for example, SAE 10W/30 has the SAE 10W specification at 0°F andthe SAE 30 specification at 210°F.
Oil viscosity comparison charts can be used to compare different oils. The charts should be used asa rough guide to establish the similarity of oils that appear to be very different. There is a loose-leafcopy of this chart in the back pocket of this Guide.
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Understanding which oils you use is an essential first step to minimising oil consumption. Oils withdifferent names and numbers may be identical. Use a comparison chart (Fig 3) to obtain an initialestimate of how many different oils you actually need. Further guidance is given in Section 3.
Fig 3 Viscosity comparison chart
22
75W 80W 85W 90 140 250
32 46 68 100 150 220 320 460 680
ISO viscositygrades
SAE gearviscositynumbers
0W5W 10W
15W20W20
30 40 50
SAE engineviscositynumbers
Low viscosity High viscosity
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2.4 IDENTIFYING OIL PROPERTIES
In order to gain an understanding of the oils that may be used on your site, it is important to be ableto identify their properties from the name of the oil. The most important benefit of this informationis that the oils you use can then be rationalised. This means you have fewer oil products on-sitewhich will help to reduce waste. Also, if staff understand the properties of the oils used they willbe able to use the correct oil in cases of emergency, eg when one grade runs out and another isrequired. For example, if a machine must be kept running, it may be wise to select the closest oilrather than risk mechanical failure due to lack of lubrication. Selecting the most appropriate oilinvolves matching the closest product in terms of viscosity and other properties (see Fig 4).
The viscosity comparison chart (Fig 3) can be used to highlight the similar viscosity of the exampleabove. The oil from Company A, Type C E30, has an SAE engine viscosity number of 30. The oilfrom Company Z, Type G T100, has an ISO viscosity of 100. Using the chart, read across the SAEengine column, and find the block for 30. Read upwards and you will see that it aligns with the ISOviscosity of 100.
2.5 USE-BY DATES
All oils and greases have a use-by date, normally in the form of a code provided by the manufacturer.To ensure that the oil performs exactly to its specification, the product should be used before thisdate. Your oil supplier will be able to inform you of its date code system so that you can avoidproblems associated with out-of-date products.
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Ask your oil supplier(s) for a list of products with definitions so that you and your employeesunderstand the products being used.
Fig 4 Identifying sample oils
Oil company trade name T68
A trade name to identify the oil type.In this case, it could be a highly refinedturbine oil with anti-wear properties.
The T indicates a turbine oil.68 is the ISO viscosity code.
Company A Type C E30
Company Z Type G T100
Although these two oils have differentnames and codes, they are identical. The companies are different and the trade names will be different but the viscosity codes are, in fact, equivalent. E30 is a classification relating to SAE grades and T100 is a classification relating to the ISO system.
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This Section explains how you can reduce the number of oils you handle on site, resulting in asimplified system. Duplication of similar grades over a number of years has left many engineeringcompanies with many more grades of oil than they actually need, often leading to waste.
3.1 A STEP-BY-STEP APPROACH
Rationalisation can reduce the number of oils used on your site through a process of identifying youroil requirements and assessing the suitability of products. Reducing the number of oils used willmake your oil system easier to operate, reduce the chances of mistakes being made through thewrong oil use, and reduce the waste of oil.
A project flow chart can be seen in Fig 5overleaf. It outlines the five key stages in therationalisation process. The time spent on thisexercise should reflect the number of plantitems and oils used.
Step 1 involves a survey to gather informationabout all the oils currently used on-site. Ablank survey form is included in the pocket inthe back of this Guide. You can photocopyand use this to record the necessaryinformation.
Once these basic details on oil types andconsumption have been gathered, Step 2 is toconsider other issues that could affect therationalisation. For example, are any machinescovered by a warranty that will be invalidatedif a specific oil is not used?
Step 3 outlines the process involved inassessing the potential for rationalisation. Inmost cases, to complete Step 3 you will needthe assistance of an oil supplier to assess thefull potential for rationalisation.
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3National Power, Aberthaw, reduced the number of oil products it uses from 36 to 18. Thisresulted in a simplified oil schedule and helped achieve a 15% reduction in oil use. For moredetails see Industry Example 2 in the pocket in the back of this Guide.
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R AT I O N A L I S E Y O U R O I L U S E3
Waste oil container at National Power, Aberthaw.The picture shows the chart on the wall with the
rationalisation system.
To decide on the best option, Step 4, a number of considerations should be made:
What is the reduction in the number of oils used?
■ Fewer grades of oil will result in a system which is easier to use and manage.
■ There is less margin for error when fewer products are used on-site.
Can larger containers be used? Larger containers of oil:
■ are normally cheaper to purchase than smaller ones;
■ reduce the waste which occurs in the bottom of containers after oil is dispensed;
■ can transport oil around the site with fewer trips;
■ reduce the amount of small containers left next to plant items.
What is the overall cost benefit?
■ How do current prices compare to the future prices quoted by suppliers? (This is best achievedby roughly calculating the costs and quantities of oil purchased over a year and comparingthem to the new stock list and expected usage and costs.)
■ Ensure that the products suggested are suitable for their application.
■ Check that no plant items will use excessive amounts of the proposed oil product as a resultof the change.
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Fig 5 Rationalisation flow chart
Step 1
Photocopy and use the oil survey form in the back pocket of this Guide to carry out an audit of oils on site. Cover all items of plant and include all oils, even those that have a small usage.
Identify the current oils used
Step 2
■ Are any machines covered by a warranty?■ Are different sized oil containers currently
used?■ Do any machines have difficult filling points
or restricted access that require certain containers or dispensing systems?
All these details should be included in your plant survey.
Consider other issues
Step 3
This is best done by contacting oil suppliers andproviding them with the full results of yoursurvey. They can then provide a rationalisedlist of products based on their product range.It is important to seek assurance that the oilsproposed will be suitable for the applications.
Assess the potential for rationalisation
Step 4
Based on the results from oil suppliers, adecision can be made on the way forward.Refer to Section 4 for details of setting up an oil management system that uses a reducednumber of suppliers or, ideally, a single supplier.
Decide on the best option
Step 5
Inform all staff of the changes via training andsigns placed in key areas around the site. Signsor leaflets should show all of the old oils alongwith the new equivalents and, ideally, the plant items where each oil is used.
Inform staff and implement changes
A special oil survey form can be found in the back pocket of this Guide.Copy this as many times asrequired to help completeyour survey.
Help
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3.2 A WORKED EXAMPLE
An engineering company had a manufacturing site with a high use of oils. The management of thecompany decided that improving the oil supply system and managing use would both save moneyand reduce engineering problems affecting production. The company could not afford majorexpenditure on the changes but were keen to make savings where possible.
The company used the oil survey form (included for you to photocopy in the pocket in the back ofthis Guide) to establish the current situation and gather information for an oil supplier. An exampleextract of survey information is seen in Fig 6. The use of oils is shown in the Pareto analysis graph,Fig 7, which helped the company understand which oils were used in great quantity.
Once the information was gathered, the company approached a number of suppliers andestablished the potential for rationalising the 19 grades of oil that they were using. After severalcompanies had been consulted, the company agreed to set up a contract with one supplier thatproposed to reduce the number of oils to just 11. The company reduced the number of oils withseveral observations, including:
■ Oil Type R was the same viscosity as Type B. Type R was eliminated as Type B would do thesame job. Type R had been purchased in 205-litre drums from which only a few litres weredispensed. The waste from drums being purchased unnecessarily, or where the oil becamecontaminated, was estimated at five drums/year (at a cost of £400/year).
■ Oil Types A, B and C are now supplied in intermediate bulk containers (IBCs) because thesehold 1 000 litres and save time in transporting oils around site. Purchase costs were reducedby 10%, saving an estimated £500/year.
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Fig 6 Oil survey example
Form 3 of 6
Plant item Press 03
Location Shop floor – Area 3
Oil currently used Company A – Type E80
Size of oil bath 325 litres
Estimated annual consumption 3 250 litres (approx. 10 changes in 1998)
Filling point Height 1.23 m – adjacent to west wall
Notes Good access. Filling point is small and could be madelarger.
Completed by: HSE Co-ordinator Date: 12/4/99
Fig 7 Oil survey results
4 0003 5003 0002 5002 0001 5001 000
5000
A B C D E F G H I J K L M N O P Q R S
Oil type
Oil
use
(lit
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year
)
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The company reduced oil use by 20% as a result of the new system. Based on the annual use of29 000 litres of oil, the company reduced use by 5 800 litres/year, an estimated saving of£2 200/year.
3.3 IMPLEMENTING THE CHANGES
Once the best option has been identified, Step 5 is to implement the changes. If an oil store hasbeen renovated or rearranged, this is the best opportunity to implement the main changes. Staffwill need to be informed of the proposed changes and made aware that oil grades will be changing.
Arrange the oil store so that all oils are grouped according to the results of the rationalisation. Thismay mean that different oils are stored next to each other until the replacement grade is ordered.The confusion can be minimised if all drums are marked up as the new oil and all old names areignored. Over a few months the old grades will slowly be used and the new grades will beintroduced.
The most effective way of communicating the new system to the relevant staff is to hold brieftraining sessions that can be included at the start of existing meetings or group workshops.Information, in the form of signs and/or pocket references about the changes, can be easilyproduced and distributed (see Fig 8).
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Fig 8 Example of rationalisation sign or flyer
Old lubricant New lubricant Plant items
Company A Type B E90 Press in cell 1Company C Type R 220 Company C Type B 220 All presses in production area 1Company B Type X 220 Gearbox on VSD air coolers
Company B Type V 100 Company C Type A 100 Hydraulic systems in production area 1
Company C Type A E80 All spiral bevel gearsCompany A Type U 100 Company C Type A EP80
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Don’t forget to measure existing levels of use to get a base-line figure from which to chartprogress. It will be more difficult to prove results if you don’t know your starting point.
Tip
In order to undertake the rationalisation process, first obtain commitment from all levels. Taketime to complete all the steps of the rationalisation process shown in Fig 5. Accurate data willproduce better results. The decision process involves an evaluation of benefits and costs.Consider all of the benefits, including the time and labour issues. When launching a newsystem, communicate the changes to staff as early as possible to ensure a smooth transition.
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This Section gives guidance on the key elements of an effective oil management system to minimisecosts. By taking a structured approach and setting up a basic system, it should be possible toimprove the management of oil supply and use, and ensure that waste is minimised. Themanagement system is the vital factor in the control of oil movements and should allow easymonitoring of both oil and plant items.
4.1 RESPONSIBILITY FOR OILS
Before stock control can be tackled it is important to establish who has responsibility for oil withinyour organisation. The number and identity of those responsible will depend on the size of yourcompany, the number of staff employed and the quantity of oils used each year. For effectivemanagement, oil stock and use must be controlled, and everyone must be clear about who hasresponsibility.
Several approaches can be used, including:
■ control of the oil store is given to a small number of staff with site-wide responsibility;
■ responsibility for the application of oils is given to a site team;
■ individual manufacturing cells are given responsibility for oil application.
4.2 PROCUREMENT OF OILS
The use of a single supplier for all oils has a number of benefits, including:
■ it helps to minimise waste;
■ it simplifies the control of stock movements;
■ the rationalisation process is far more effective when one supplier is used;
■ if all oil is purchased from one supplier, discounts may be available due to larger orders;
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Improved management of oils will lead to better control, improved quality of output andreduced maintenance.
Internal competition reduces oil use
A study of oil consumption at Royal Ordnance, Crewe, revealed the duplication of many oils, andthat this was resulting in excessive use. Royal Ordnance undertook a project to reduce oilconsumption, move to a single supplier and reduce the environmental risk of handling oils.
‘Production cell’ manufacture means that each individual manufacturing area is responsible forits own oil use, and high oil use will result in a greater burden on each budget. Comparison ofsimilar cells promotes competition to reduce oil use.
Monitoring of oil use also means that if a problem with machinery arises suddenly it is identifiedeasily. Action can be taken and plant shutdowns and expensive breakdowns are avoided.
Royal Ordnance has seen reductions of up to 50% in the consumption of some oils.
■ with a larger order, oil companies are more likely to provide technical support and assistance;
■ you will have a single point of contact;
■ the procurement process is easier to administer, reducing the supply chain costs.
If a contract is going to be set up with a single supplier it is important to take the time to ensurethat the contract meets your requirements. Obtain details of what several suppliers can offer andthen evaluate each in terms of the oil supplied, delivery details, technical support and the variousterms and conditions of the contract.
4.3 STOCK CONTROL
Effective stock control will enable you to produce a balance of the oil dispensed and the waste oilgenerated. If records are kept of quantities of oil dispensed, the time and date and the location ofthe oil use, the system can be used to monitor plant performance and assist in maintenance planning.
For effective stock control, ideally all oils should be stored in one location, although this is dependenton the size of your site. Larger sites may require several small oil stores. If oils are stored all overthe site, eg next to the plant items where they will be used, effective stock control becomes almostimpossible.
4.3.1 Oil store stock levels
Within your oil store a minimum stock of oil is required to cover operational requirements. However,unexpected plant problems can lead to a sudden need for large quantities of oils. If this happens,arrangements must be in place with your oil supplier to provide the necessary oil within an agreedtime in order to maintain the running of machines.
The minimum stock levels should be calculated based on your consumption, delivery lead-time andminimum order quantities.
Part of the assessment made during the rationalisation process should involve a survey to identifythe required stock levels of oils. This is normally done by deciding upon a minimum stock level anda reorder quantity to maintain the stock levels.
4.3.2 Logging oil use
When oil is taken from the oil storage area, knowing where the oil goes is a vital part of monitoringits use. Without these data an effective monitoring system cannot be established and problems withcertain plant items may be overlooked.
Data need to be collected for all oil that is taken from the store. As a minimum, data should includethe type of oil and when and how much was taken. Ideally, they should also include the plant areaor machines for which the oil has been dispensed. This information can be used to monitor the oiluse and for comparison with the stock purchases for the oil store.
Once data are collected they should be processed efficiently to identify any problems quickly.Comments from staff are vital in establishing discrepancies with the normal use figures.
The oil issue sheets are best kept in the oil storage area and completion of the sheets should bewritten into any procedure for oil dispensing. Where oils are dispensed into a container andtransported around site for filling plant items, it will be necessary to issue forms to the staff involvedin the management system.
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Tip
Photocopy the oil issue sheet in the pocket in the back of this Guide to help you.
4.3.3 Logging waste oil
The monitoring of waste oil generation can be as important as the monitoring of fresh oil application.In order to understand use of plant items it is very useful to know the quantity of waste oil arisings.
A log book in the oil store or a central control room can be used for waste oil arisings. Anysignificant quantity of waste oil should be recorded, along with basic details of the type andquantity. The combination of the data from the oil dispensed and the waste oil generated will helpyou to understand your oil requirements on-site.
4.4 MEASURING TO MANAGE
When you are producing regular and accurate data for oil movements on-site, anaylsis will allow youto identify trends and this will help you to begin to reduce oil consumption.
The data gathered from the stock control system can be used to set some targets for the reductionof oils, to cut down on waste and benefit from savings. Reliable data are a vital component ofthis system and it is important to win the confidence of staff.
The basic stages of the monitoring and targeting process are:
■ collection of oil usage and waste oil data;
■ monitoring of oil use;
■ setting targets that your company can achieve with the use of the techniques outlined in thisGuide;
■ using the data to identify problems with machines.
4.5 LUBRICATING PROCEDURES
In order to formalise stock control and a monitoring system, written procedures may need to beintroduced. A written procedure can be included in a management manual as part of a companyquality system to harmonise oil practices. Training of the relevant staff is a task that can be carriedout quickly and efficiently, ensuring staff are aware of the procedures and the oils used.
Your oil procedure should contain the following elements:
■ use of the oil store, including the procedure for gaining access;
■ the operation of dispensing oils;
■ stock control;
■ logging of oil use and waste oil;
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Bar-coding allows easy oil use comparison
Ford’s Dagenham plant is currently installing a bar code system to monitor oil consumption byevery plant item. Although this is a large and complex project, it will allow Ford to monitor alloil use. The oil history of any plant item will be available to identify problems and reduce oil use.A further benefit is that this will allow easy comparison of oil consumption for similar machines.
Tip
Good stock control will eliminate waste by reducing the oil used at source. This is the priorityas it saves on the cost of oil used as well as the disposal and any other costs associated withhandling oils on-site.
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■ health and safety issues, including the procedure for handling oil containers1;
■ how waste oil should be handled and where it should be stored;
■ emergency spill procedure.
4.6 CONDITION MONITORING
Condition monitoring involves the taking and analysing of oil samples from plant items to identifyany problems. The main uses of condition monitoring are to:
■ identify any debris within an oil to highlight problems with wear of machinery andcomponents, eg bearings;
■ establish the performance and suitability of an oil for its application;
■ see if an oil change is required.
The final point is very important as it illustrates how condition monitoring can be included inmaintenance procedures. Oil needs to be changed only when it becomes excessively contaminatedor the additives become depleted and it performs less efficiently.
The benefits of condition monitoring include:
■ cost savings by extending oil life and avoiding costly changes;
■ early warning of machinery breakdown or excessive wear of components;
■ provides a benchmark for comparing identical machines;
■ a better understanding of the suitability of each oil.
Condition monitoring is a further step in minimising oil consumption at source. This also reducesthe waste of resources spent on oil changes.
Condition monitoring is seen as ‘listening’ to plant items so that oil is changed only when necessary.Condition monitoring is proven in industry. It has the potential to reduce oil consumptiondramatically where oil changes are customarily made on a time or plant running hours basis.
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Possible savings from one machine
The following example illustrates the savings possible from condition monitoring on just onemachine, where previously the oil was changed on the basis of plant running hours alone.
Condition monitoring was carried out on a monthly basis on this important production machineat an engineering company:
Cost of oil change £250*
Cost of condition monitoring per sample £12
Number of samples taken 10
The sample from month ten indicated that the oil was still fit for its purpose. The engineeringcompany did not change the oil and saved £250. The monitoring had cost them £120, resultingin a saving of around £130. The company estimates that one ‘all-clear’ result in 20 makesthe condition monitoring worthwhile and cost-effective.
*This is the cost of oil, labour and lost downtime.
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1 Health and Safety in Engineering Workshops, from HSE Books, can be purchased for £9.50 and is available from: HSEBooks, PO Box 1999, Sudbury, Suffolk, CO10 6FS. Tel: 01787 881165, Fax: 01787 313995. See alsowww.open.gov.uk/hse/hsehome.htm or call the HSE infoline 0541 545500.
4.6.1 On-site condition monitoring
Where on-site laboratory facilities are available, condition monitoring can be a part of thelaboratory’s duties. The analysis of oil can be complicated, so it is important to establish the levelof oil analysis required.
4.6.2 Off-site condition monitoring
The majority of engineering companies that carry out condition monitoring use the services offeredby their lubricant suppliers or specialist laboratories. During the consultation process with suppliersto assess the potential for rationalisation it is worth finding out about condition monitoring servicesas part of the contract.
The results from condition monitoring will normally be displayed in a brief report which provides achemical analysis of the oil, highlighting any abnormalities. The report will often be accompaniedby a form which lists various chemical components and their likely source.
The procedure for taking a sample should be followed closely to avoid any contamination of the oilafter it has left its point of use. This could lead to false levels of contaminants. It is important tolabel each sample and state clearly the oil type and the plant item from which it has come.
4.6.3 The cost benefits of condition monitoring
The services offered for condition monitoring normally cost around £10 - £15 per sample. Theresults can lead to several outcomes:
■ the oil may need changing if contamination is high or depletion of additives has occurred;
■ the oil may be satisfactory to leave in place but with a requirement for increased monitoringof parameters that could lead to problems in the future;
■ the oil may be in good condition and thus not need changing.
The effectiveness of the programme will depend on the actions taken as a result of the reports. Ifoil is changed when it could have been left then the scheme will not be cost-effective. Similarly,changing oil without investigating the reasons for the degradation can overlook and ignore possibleplant problems.
4.7 OIL MANAGEMENT SERVICES OFFERED BY OIL SUPPLIERS
An oil management package is available as part of the services offered by many oil suppliers. Thisis best applied to sites that have a considerable use of oil which needs to be well managed. In manycases, the oil supplier will have an employee on-site to look after the oil store, distribute oils aroundthe site and keep the monitoring programme up-to-date.
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Tip
Work out how much is saved when the report from a sample recommends leaving the oil in placewithout a change. Include all costs in this calculation, including labour. Compare this saving tothe cost of the sampling. In most cases, if the true costs of an oil change are compared with thecost of the monitoring, they will be higher. Condition monitoring will usually pay for itself if it savesjust one oil change in ten.
Morgan Matroc’s Rugby Division uses condition monitoring as part of its Total PreventativeMaintenance programme. The Division changes oil based on the reports received from the oilanalysis. Just one report in 30 that recommends leaving the oil in place, when previously it wouldhave been changed, will pay for all of the samples. For more details see Industry Example 1 inthe pocket in the back of this Guide.
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Although at first this may seem an expensive option, many engineering companies find that they arespending a lot of time and resources on managing lubricants. When all costs are considered, it isoften possible to justify employing the services of a lubricant company which has added benefits:
■ reordering is done directly from the oil store to the lubricant supplier;
■ technical support will be readily available;
■ staff do not have to worry about maintaining the oil store as this will be done by the lubricantsupplier;
■ the lubricant supplier will often use a computer package which can readily producemonitoring data as part of your management system.
The strength of computer packages for oil systems is that they allow scheduling of lubricating tasksso that full control of all plant items is achieved. Each day, the system will produce the lubricatingtasks for that day. If missed, the system will continue to generate work orders, ensuring that plantitems receive attention and lubrication is not ignored. The packages can be used to produce dataon consumption by machines as part of the monitoring system detailed in Section 4.6.
Consult your oil supplier about computer packages and investigate the:
■ features of the software;
■ cost of installation and back-up;
■ assistance that the software will provide with the overall oil management;
■ benefits of using a computer package to assist in procurement of oils;
■ compatibility of their system with your company.
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Simplified oil management ensures high quality products
Rolls-Royce’s Ansty site makes and repairs engine parts for aero, power generation and marineengines. It employs 2 400 staff. There are very different production and maintenance processesin different areas of the site, so a system that results in the effective management of oils withoutcompromising the quality of products, is vital.
Rolls-Royce has introduced a computer package to schedule maintenance of plant items. TheCompany is aiming for ISO 14001 certification and has made several improvements to its oilmanagement procedures, including:
■ the use of a range of equipment to facilitate the safe handling and storage of oils on-site*;
■ the use of spill kits around the site, located in key areas and stocked with the necessaryequipment to deal with most spills;
■ the use of a single supplier, where possible, to simplify the procurement of oils.
The main benefits are:
■ a minimal risk to the environment from oil spillage;
■ simple handling of oil containers with the correct equipment;
■ safe storage of oil drums both inside and out;
■ fewer plant problems as a result of the maintenance planning;
■ the ability to contain and clean-up any oil spills effectively.
* Further details on good practice for oil storage and handling can be found in Section 5.
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The correct storage and handling of oils will avoid waste resulting from either damage to orcontamination of the product within its container, or from a leak or spill of the product. Thefollowing Sections outline how to avoid waste from poor handling and storage.
5.1 THE OIL STORE
Ideally, oils should be stored inside or, at least, under cover from the elements. Where drums of oilare stored in their vertical position and exposed to the elements, there is a high chance ofcontamination, particularly from rainwater. This leads to defective oil which will not adequatelyprotect the machine it is used in.
If water accumulates on the top of a drum, particularly during the warmer summer months, it cancause contamination. As the contents of the drum warm up and expand during the day, a smallamount of air from the drum will be forced out. As the drum contents cool later, a vacuum iscreated and the water on the drum will be sucked in. If this occurs with insulating oil there is a riskof failure of the insulating properties of the product.
Oils are susceptible to extremes of temperature. Oils can be affected by low temperatures andextreme cold should be avoided. Similarly, high temperatures, such as may be found close to boilersor steam pipes, can be detrimental to the oils’ properties. The location of the oil store is ideally acentral one in order to minimise the transportation of oils around the site. This reduces the labourinput, makes oils more accessible and reduces the risks associated with transporting oils.
5.1.1 Storage of drums
Drums are ideally stored in their horizontal position, on racking away from any possible surfacewater. Where drums cannot be stored off the ground on racks, pallets will help to keep them awayfrom standing water. Where drums are stored in their vertical position, ensure the label is visibleand that stock is still rotated.
The fitting of taps can allow the dispensing of oils into smaller containers in a controlled manner.Drip trays will be required under each tap to collect the small amounts of oil that will inevitably dripafter dispensing. Bunding should be in place and intact around racking, or in doorways.
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G O O D P R A C T I C E F O R O I LS T O R A G E A N D H A N D L I N G
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Good practice example of an oil store at Morgan Matroc - note the bunded pallet system with ramps onto it.
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5.1.2 Stock control within the store
Stock rotation is important and is best tackled by adopting a ‘first-in-first-out’ system to avoid oilsbeing left to go out of date.
Using the data from the oil use survey (see Section 3), it is important to understand which oils areused frequently. The high use oils should be positioned so that they can be reached easily and areless likely to be hidden away at the back of the store.
5.1.3 Waste oil
Waste oil should be stored in separate, clearly labelled containers to avoid any mistakes that couldlead to waste oil being used instead of fresh oil. Within the store, a container should be clearlylabelled and used for waste oil only. The quantities of waste oil removed from the store should belogged as part of the overall management system to account for oil movements. Further details aregiven in Section 6.
5.1.4 Labelling oils
It is important to ensure that all containers are clearly labelled so that staff can easily identify the oilthey require. As oil is moved around it is important to ensure that the contents labels are left in avisible position. Signs next to rows or columns of oil will help you to organise the oil store.
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Photocopy the oil store checklist in the pocket in the back of this Guide to help you.
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Horizontal storage at National Power, Aberthaw. The drums are arranged in bays, three deep, for each type ofoil. The lower drum is used first so that stock rotation takes place. Stock checking is very easy as stock check
sheets are arranged in the same order as the drums.
5.2 HANDLING OIL CONTAINERS
A range of devices exist for the handling of drums that allow simple movement. Devices are alsoavailable for manoeuvring drums through 90° from their horizontal position to their vertical positionor vice versa.
Intermediate bulk containers (IBCs) can hold 1 000 litres and are easily transported around the site.They can be manoeuvred by a forklift truck although, due to their construction, they must not becarried from above.
Once dispensed from larger containers, oil will often be transferred into plant items via a jug orsimilar container. It is vital to use clean containers to avoid contamination of fresh oil. Ideally, tryto use the same jug for one type of oil and avoid any contact with waste oil.
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Tip
When selecting devices to handle oils, it is important to establish the requirements of all staffwho handle oils. Poor handling leads to many spills that waste oil and require expensive clean-ups. Good handling practices, with the appropriate equipment, will reduce the cost of spills.
Tip
Table 1 in Section 5.3 will help you with the selection of oil containers for handling and storage.
Move to IBCs saves time and money
Adtranz, a rail vehicle and component refurbisher, has saved £1 650/year through improved oilmanagement. The Crewe site employs 1 100 people, has a turnover of £85 million, and uses46 000 litres/year of hydraulic and lubricating oils.
A risk assessment was carried out for oil use as part of the Company’s environmentalmanagement system for ISO 14001. This led to improved oil management and the followingbenefits:
■ the change from barrels to IBCs has realised savings of £1 100/year;
■ central collection and selling of waste oil provides revenue;
■ management and operational safety procedures exist for all oils and their use;
■ improved housekeeping reduces health, safety and environmental hazards resulting fromoil leaks and spills.
Adtranz has replaced 200-litre barrels with 1 000-litre IBCs for 40% of oil use. There aresignificant handling and storage benefits. A fork-lift truck can carry only two barrels (400 litres),one IBC holds 1 000 litres. Housekeeping has been improved, with fewer spills and drips. Thesame volume of oil can be stored in far less space. The IBC oil cost is 51 pence/litre, the barreloil cost is 57 pence/litre, a saving of 10% on oil purchase.
Staff training has been fundamental to the success of the oil management improvements. Atailored training programme on how to use spill kits has been developed internally. Training isongoing, so as experienced, skilled operators retire, new operators receive effective training toensure the high standards are maintained.
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5.3 LEAKAGE AND SPILL CONTROL
Preventing leaks from drums within the store will improve housekeeping issues and make the storesafer for staff walking around. Leakage and spill control is achieved with a variety of equipment,depending on the quantity of oil.
When selecting products for leakage and spill control2, it is important to obtain samples from anumber of suppliers and ensure that they are suitable for your needs. Consider the range ofproducts available and select the one that offers good absorbency and is the correct size. It isimportant to consider other issues such as housekeeping and health and safety requirements whenmaking your selection.
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Table 2 will help you with the selection of leak and spill control products.
IBC storage at National Power, Aberthaw
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2 Spill control products are available from a number of suppliers. For further details contact the Environment and EnergyHelpline on 0800 585794.
Table 1 Storage and handling products selection table
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IBCKey:205-litredrum
Small oilcontainer
Decking units can make an oil storage area safe by containing spills and leaks.
280+ Units can be added to cover the floor area required.
Deckingfor oils
Description Indicative price
range (£)
UsesProduct Notes
Storage
Handling
Pallets to hold two or four drums with a sump to contain spills.
250+Sump pallets
Used for transporting and then dispensing a single drum. Fully bunded when in horizontal position.
400+ Good for where oils need to be stored next to their point of use.
Dispensing sump trolley
Racks for the storage of drums, normally in pairs or rows of four.
125+ Plastic or metal racks. Some may be stacked. Some have integral bunds (£275+).
Drum racking
The racking found in most warehouses.
175+ Conventional racking can hold drums horizontally with special chocks.
Conventional racking systems
Basic fork-lift without any attachments. Can be used for simple transporting on standard pallets.
If fork-lift trucks are used for transporting oil, they should have a spill kit onboard.
Fork-lift truck without attachment
Simple trolley to move 205-litre drums. More expensive models have straps or larger wheels.
100+ Good for reducing the manual handling of drums.
Drum trolley
Devices that slide over the forks to increase the capabilities of a fork-lift. Many variations available from twin drum carriers to carriers that wil tip a drum on end.
300 - 2 300 Discuss the devices with staff who handle drums to establish the best option.
Fork-lift attachments
A simple device for safely tipping a drum into the horizontal position.
35+ Reduces manual handling for staff. Reduces the risk of spillage.
Drum- tipping device
Table 2 Leak and spill control products selection table
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DescriptionProduct Minorspills
Majorspills
Leaks
Clay, woodchip or chemical absorbents.
Absorbent granules
• •
Indicative price range (£)
7+ per bag
Notes
Absorbs around 30 litres/bag.
•
Square mats, normally around 0.5 m2.
Absorbent mats
• 50 pence + each
Absorbs 0.5 - 1 litre/mat.•
Absorbent booms with diameters around 7 - 10 cm. Normally between 1 - 6 m long.
Small booms
• 1.50 - 5/m (8 cm diameter)
Absorbency depends on thickness. 8 cm diameter booms absorb around 2 - 2.5 litres/metre of length.
•
Thicker booms of varying lengths.
Large booms
• Around 10/m
Similar to pads and booms but used to lower into interceptor drain or tanks.
Absorbent pillows
• 5+•
Simple, non-absorbent booms to reduce the spread of a spill.
Dikes • • 150+ Ideal for recovery of product.
Trays to put under drums with taps fitted or under small leaks in machines.
Drip trays 3.50+ More expensive types contain absorbent materials.
•
A substance that can be used to plug a rupture in an oil container. A temporary measure to avoid spills.
Drum blocker
• • 5 (per small container)
Useful to include in spill kits carried on fork-lift trucks.
In the event of an emergency these covers will protect surface drains. Best used in conjunction with booms.
Drain covers
• 70 - 400 Low-cost options are resistant mats. High- cost options are steel clamps.
Walls constructed around tanks or storage areas to contain leaks or spills.
Bunds • Varies (depending
on size)
The inside volume of the bund should be at least 1.1 times the volume of the largest tank or container.
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Change in spill management reduces workplace dust
LDV, a Birmingham-based van manufacturer that produces 15 000 vans/year, wanted to improveits environmental performance. The Company decided to improve its oil managementprocedures to minimise the risks associated with handling and storing oils on-site.
For the last few years LDV has used absorbent clay granules to soak up minor oil spills at the endof the production line. Although effective at soaking up oil, the granules tended to produce alarge amount of fine dust, which caused a housekeeping issue and a potential health and safetyproblem due to the possibility of dust inhalation. In order to remove the problem of dust andto avoid the absorbent clay being trodden around the area, a project was set up to find asuitable alternative.
LDV considered several absorbent mats that would eliminate the use of clay granules. However,even these could produce small but significant amounts of fibre from the fibrous material fromwhich they are made. This would cause a great deal of problems in the paint shop and pressshop. The solution was to use absorbent mats and cover them with plastic grid tiles to allowstaff to walk around without oil or oil and clay mixtures underfoot.
LDV will reduce the time spent on general housekeeping cleaning and the risks of personnelinjury as a result of investing in absorbent mats. The savings are not easily quantified but thebenefits demonstrate good practice.
Waste oils were left for collection by a waste contractor and LDV saw the risks of these oils beingused as fresh oil. A labelling system for waste oil containers has eliminated the risk of waste oilbeing used as fresh.
Spillage containment pallets, designed to hold 110% of the contents of the largest barrel, werepurchased to hold any day-to-day spills, or in the worst case, the entire barrel. A drain plug isavailable for easy emptying of the pallets.
The benefits realised so far from the oil management programme include:
■ elimination of the risks associated with waste oil being used as fresh oil;
■ removal of a housekeeping and health and safety problem with the use of appropriateabsorbent materials for spills on the production line;
■ introduction of the formal system which sets a high standard for handling fresh and wasteoils.
The oils at LDV are managed by a facilities management company that ensures stock levels aremaintained. Improvements in the use of oils include:
■ the writing of a procedure for oils which aims to use good practice in all areas;
■ the training of staff in the procedure, and refresher training;
■ the training of track staff to solve minor leaks, and better notification to the maintenancedepartment when leaks occur;
■ improved housekeeping on the production line.
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5.3.1 Emergency spill kits
Spill kits should be available at sites where an environmental hazard would result from a spillage orleak of oil. The contents of a kit should reflect the nature of the spill or leak that could occur.
The kit should contain a number of basic items:
■ absorbent materials;
■ booms to contain pools of oil;
■ gloves for the protection of staff handling oils;
■ bags for waste products;
■ instructions for staff on how to use the equipment effectively and safely.
Kits can be purchased ready-made from most equipment suppliers and generally contain the itemslisted above. Prices for kits vary and it may be more cost-effective to build up your own kits whichare tailored to the needs of your site.
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Following the principles of the waste minimisation hierarchy described in Section 1, introducing re-use or recovery options should only be considered once oil use has been minimised. This Sectioncontains advice on good practice for the re-use of waste oil.
6.1 RECLAMATION OF USED OILS
If oils are to be used again, they must be reclaimed under controlled conditions to avoid any furtherdegradation of their quality. None of the recovery equipment should come in contact with wasteoils for disposal. Pumps and containers for the oil should all be free of any contaminants to maintainthe quality of the oil that is being reclaimed.
Ideally, reclaimed oil should be of one type, as mixed oils cannot be used for their originalapplications. If oil is to be reclaimed and re-used in the same plant item, it should be kept separatelyfrom all other reclaimed, waste or virgin oils. If oils are reclaimed, they should be available insufficient quantities to make the system cost-effective.
The procedure for reclaiming oil should be written into an oil management system to control the transferand storage processes. Containers may need labelling to avoid confusion with other oils.
6.2 RE-USING OIL FOR ITS INITIAL PURPOSE
If used oil is removed from its machine, cleaned and returned to use, it is important to check thatthe properties of the oil remain adequate for the application. If reclamation opportunities are beinginvestigated, oil condition monitoring may assist in the decision process (see Section 4.6).
Where only basic filtration and water removal is required to launder an oil, on-site recovery may bepossible. Small on-site recovery kits are available on the market to clean up oil for re-use, costingfrom £2 500 upwards.
Standard filtration equipment is too coarse to remove the fine particulate contamination that cancause problems in hydraulic oil and so specialist filtration systems may be required. These can takea small flow of oil from a hydraulic system and pass it through an ultra-fine filtration system thatwill remove particles and water.
6.3 RE-USING OIL AS A LOWER GRADE LUBRICANT
Where oil can be recovered but not used for its original application, there may be opportunities forre-use as a lower grade of oil. This will require some investigation into the condition of the used oiland the requirements of the secondary application will need to be assessed. Failure to investigatethe secondary usage could lead to plant problems.
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Re-
use
O N - S I T E R E C O V E R Y O FW A S T E O I L
6
Tip
A range of filtration devices are available to the engineering industry. These devices cancontinuously clean your oil, reducing the frequency of oil changes. This frees valuableproduction time and allows staff to concentrate on core business activities. Information onfiltration units is available from the Environment and Energy Helpline on 0800 585794.
6.4 RECOVERING OIL FROM WATER
Where oils are used on industrial sites, there will often be oil discharges into the site drainage systemwhich should ideally be removed prior to discharge from the site. Depending on the amount of oiland the details of site operations and infrastructure, a number of options are available.
Belt skimmers are used to remove oil from water in a sump. They are small devices comprising amotor, belt and collection point (see Fig 9). The motor drives the belt so that it passes into the oiland water mixture, adsorbing oil before lifting it out, back towards the drive. The belt then passesthrough rollers which remove the oil and drain it into a collection container under the unit. The beltcan be constructed from rope or other materials such as polypropylene. The removal capacity ofthese units can be up to 6 tonnes/hour.
Variations include systems with two pulleys, one next to the scrapers to drain oil and the other underthe oil and water mixture.
Plate units contain a number of sloping plates that allow water to pass through a unit but trap oilfor removal. Plate units work on a similar principle to the belt skimmers, using the fact that oil floatson top of water.
A number of companies offer interceptor systems that can be built into a drainage system toseparate oil and water. The oil can then be removed by pumping it out. For smaller quantities,absorbent pillows can be purchased with a length of rope to dip into an interceptor drain or tanks.
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Re-
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Tip
The Environment and Energy Helpline on 0800 585794 may be able to assist with a list ofsuppliers of oil recovery systems.
Fig 9 Belt skimmer
Motor drive
Wasteoil drain
Collectiondrum
Belt loweringinto sump
In cases where oil cannot be reclaimed and re-used on-site, off-site recycling or disposal are theremaining options. Recycling of oil is likely to increase in the future, as tighter legislation onincineration increases disposal costs.
7.1 OFF-SITE RECLAMATION (LAUNDERING)
If used oils require treatment in addition to basic filtration and water removal, off-site reclamationmay provide the answer. A number of companies exist that offer a collection, laundering and returnservice. They will normally use a process of filtration, dewatering and then replenishment of theadditives, returning an oil that is of equal quality to the original oil.
Owing to the transportation costs involved, significant quantities of used oil usually need to berecovered to make this a financially viable option. The oil will need to be kept separate from otherused or fresh oils and it should be of a consistent nature.
Gathering accurate data on used oil arisings will assist the specialist waste oil company to offeradvice on the available options.
7.2 OFF-SITE RECYCLING (RE-REFINING)
Re-refining processes use a variety of technologies to recycle waste oil into a base stock oil ready forblending and the addition of additives to make it into a usable product. Consult an oil recyclingcompany and provide it with accurate data of waste oil quantities. Details can be obtained fromthe Environment and Energy Helpline on 0800 585794.
The suitability of a waste oil for re-refining will depend on the:
■ quantity available;
■ nature and degree of contamination;
■ consistency of composition.
If the parameters vary considerably, there may be problems for oil recycling companies to take theoil on a regular basis. These details need to be clarified with the oil recycling companies.
Recycled oils are growing in popularity and some motor vehicle manufacturers have started to userecycled oil in their vehicles. If this trend continues and demand rises, the infrastructure for recyclingoil should develop beyond its current state. In the UK there are relatively few facilities for waste oilrecycling. It is hoped that in the future they will be more widespread and available to morecompanies.
27
section
7
O F F - S I T E R E C Y C L I N G A N DD I S P O S A L O F W A S T E O I L
7
Rec
yclin
g
7.3 DISPOSAL OF WASTE OILS
Waste oils that cannot be re-used or recycled will need to be disposed of in an environmentallyresponsible manner.
7.3.1 Handling waste oils
Waste oil produces environmental and health and safety risks and should be handled and controlledto avoid such risks. Containers that are to be used for waste oil should be clearly identified andlabelled to avoid confusion. Clean drums that have recently had their virgin oil used should not beused for waste oil as this increases the chance of waste oil being used as virgin, with seriousimplications.
7.3.2 Disposal options
Outlined below are the main options for the disposal of waste oils.
Direct burning of waste oils, ie burning waste oil without any pretreatment, is a form of energyrecovery. There are three uses for oil as a direct burn fuel:
■ cement manufacture;
■ space heaters;
■ municipal waste and chemical waste incinerators.
It is estimated that around 30% of waste oil is burnt in space heaters.
Indirect burning of waste oils involves limited reprocessing to allow them to be blended into fueloil for uses including roadstone plants and power station start-up. Roadstone plants combust wasteoil in order to dry limestone prior to sizing and then mixing with bitumen and filler. Roadstoneburning accounts for between 60 - 80% of combusted waste oil.
28
section
7
Tip
Disposal should be the last option for used oils. The methods of minimisation described in thisGuide will offer the greatest savings. Re-use of oil can also provide considerable savings. Whereall options have been considered, disposal will offer a final solution. In all disposal cases, wasteoils must be dealt with responsibly, taking care to avoid any releases into the environment whichcan cause pollution or become a health and safety risk to staff.
Rec
yclin
g
29
A C T I O N P L A N8
section
8
If you would like to improve your management of lubricating andhydraulic oils and save money:
Select the right oils. Investigate which oils you use and which you need.Photocopy the oil survey form in the pocket in the back of this Guide to help you.
Rationalise oil use. Talk to your supplier about reducing the variety of oils used.Reducing the number of oils makes management easier and will reduce waste.
Implement an oil management system. This will ensure the correct products arestocked in the right quantity. Ensure everyone knows who is responsible for useof oils.
Optimise stock control. Photocopy the oil issue sheet in the pocket in the back ofthis Guide to help measure and manage use of oil.
Introduce a system of condition monitoring.
Consider best practice of storage and handling. Photocopy the oil store checklistin the pocket in the back of this Guide to help you reduce waste and make the jobof using lubricants simpler and safer. Use Table 1 to help choose the tools that youneed.
Set up a system for spillage and leak control. Use Table 2 to help you.
When oil use has been minimised, consider on-site recovery of waste oil. On-sitereclamation and re-use may be possible for some oils. This can offset the purchasecost of virgin oil without compromising plant items and production.
When oil use has been optimised, consider using an off-site recycling companybefore disposing of any oil as waste. It may be possible to offset the purchase costof virgin oil.
Where reduction, re-use and recycling is not possible, dispose of waste oil in anenvironmentally responsible way.
Obtain help.The Environment and Energy Helpline (0800 585794) can:
Send you copies of relevant Environmental Technology Best Practice Programmepublications.
Suggest other sources of information.
Provide free, up-to-date information on a wide range of environmental issues,legislation, technology and equipment suppliers.
Arrange for a specialist to visit your company, free of charge, if you employ fewerthan 250 people, at the discretion of the Helpline Manager.
The Environmental Technology Best Practice Programme is a Government programme managed by
AEA Technology plc.
The Programme offers free advice and information for UK businesses and promotes
environmental practices that:
■ increase profits for UK industry and commerce;
■ reduce waste and pollution at source.
To find out more about the Programme please call the Environment and Energy Helpline on
freephone 0800 585794. As well as giving information about the Programme, the Helpline has
access to a wide range of environmental information. It offers free advice to UK businesses on
technical matters, environmental legislation, conferences and promotional seminars. For smaller
companies, a free counselling service may be offered at the discretion of the Helpline Manager.
FOR FURTHER INFORMATION, PLEASE CONTACT THE ENVIRONMENT AND ENERGY HELPLINE
0800 585794world wide web: http://www.etbpp.gov.uke-mail address: [email protected]
ENVIRONMENTAL
TECHNOLOGY
BEST PRACTICE
PROGRAMME
INDUSTRY EXAMPLE 1
I M P R O V E D O I LM A N A G E M E N T R E D U C E SP R O D U C T I O N D O W N T I M E
Morgan Matroc’s Rugby Division (a subsidiary of Morgan Crusible Companyplc) produces an extensive range of technical ceramic components for a widerange of industries. These include aerospace, defence, medical andtelecommunications. It employs 170 staff and has a turnover of around £8 million/year.
Improvements in the management of oil at Morgan Matroc has reduced productiondowntime noticeably over a two-year period, saving both money and time.
Reasons for Improving Oil Management
Around three years ago, Morgan Matroc decided to focus on the management of itsoils in order to optimise usage and reduce the risk of spills and leaks. The initiative wasa development of its Total Preventative Maintenance (TPM) programme, and so wonmanagement approval. The overall benefits envisaged were reducing productiondowntime, avoiding costly maintenance activities and reducing the number ofunnecessary, and therefore, costly, oil changes.
GG227GUIDE
Dispensing from a small mobile unit at Morgan Matroc, Rugby Division. This unit holds
three oils and acts as a transfer from the oil store to the point of use.
FOR FURTHER
INFORMATION,
PLEASE CONTACT
THE ENVIRONMENT AND
ENERGY HELPLINE
0800 585794world wide web:
http://www.etbpp.gov.uk
e-mail address:
GG227 © Crown copyright. First printed December 1999.This material may be freely reproduced in its original form except for sale or advertising purposes. Printed on paper containing 75% post-consumer waste.
THE ENVIRONMENTAL TECHNOLOGY BEST PRACTICE PROGRAMME
IS A GOVERNMENT PROGRAMME MANAGED BY AEA TECHNOLOGY PLC
INDUSTRY EXAMPLE 1
Outline of Improvements
The following list summarises the improvements that have been made at MorganMatroc:
■ the oil storage area is now bunded, with oils being stored in rows, each oil havingan air pump for dispensing into smaller containers;
■ the oil store has signs to show the oil type in each row as well as a copy of theprocedure on the wall;
■ Morgan Matroc has just one oil supplier, and this company provides a fullmanagement system, including the provision of a member of staff to manage the oilstore and control the procurement of oil;
■ waste oil materials are labelled and disposed of according to the procedure;
■ spill kits are located in key areas;
■ Morgan Matroc has developed a good understanding of its oil use and can easilyidentify problems.
Benefits of Improvements
The oil store is now a well-controlledarea with bunded decking and spill kitsreadily available. Storing the drumsvertically and using an air pump haveproved effective in reducing spills.
Morgan Matroc has achieved substantialcost savings through reducing its oilconsumption and, more importantly,reducing its production downtime. Theprovision of spill kits has improved theCompany’s overall environmental riskmanagement by ensuring there is only aminimal risk of oil spills or leaksbecoming a threat to the environment.
Problems Overcome
Staff required training in the new procedures and this took some time and effort. Theend result is rewarding as all staff are aware of the full procedure and can implement iteffectively. Staff undergo regular refresher training to keep them up-to-date with anychanges.
Future Improvements
Morgan Matroc is working closely with its oil supplier to achieve further improvementsto the system. Both parties share the common goal of making Morgan Matroc’s oilsystem as efficient as possible, with the least waste and the lowest chance of spillage.Morgan Matroc is planning to introduce a bar-coding system to assist in oilmanagement. The Company takes a proactive approach to oil management and TPMand is keen to review targets and monitor usage to produce continuous savings.
The waste oil product bin is just one example
of good practice at Morgan Matroc
ENVIRONMENTAL
TECHNOLOGY
BEST PRACTICE
PROGRAMME
INDUSTRY EXAMPLE 2
I M P R O V E D O I L M A N A G E M E N T B R I N G SR E D U C T I O N I N O I L U S E
National Power’s Aberthaw Power Station is a 1 500 MW coal-fired plant inSouth Wales. It employs 190 staff and has a turnover of £100 million/year.
Improvements in oil management have reduced oil use by around 15% at the site,saving substantial purchase costs.
Reasons for Improving Oil Management
Aberthaw Power Station uses a large amount of lubricating and hydraulic oils in therunning of its plant. The Power Station wanted to improve its oil management in orderto gain a better understanding of, and achieve a reduction in, oil use, and to monitorthe use of plant items. The management gave its full support to the project.
Outline of Improvements
The following improvements have been made:
■ oils are now purchased from a single supplier;
■ the number of oils used has been reduced from 36 to 18;
GG227GUIDE
View of turbine hall at National Power, Aberthaw
■ the oil store was renovated with new bunds, horizontal storage for all drums andimproved organisation with grades being stacked in a rotation system;
■ the site started using IBCs for bulk oil to avoid handling drums and to avoid thewaste that can occur at the bottom of drums.
Benefits of Improvements
The principal benefits of the improvements made are:
■ a reduction in the quantity of oil used on-site;
■ the introduction of a simple but effective system to control use and distribution;
■ Aberthaw can benefit from the technical support offered by the single supplier;
■ the use of IBCs around the site has ledto a reduction in the waste associatedwith the use of drums and the amountthat tend to get wasted in the bottomafter dispensing;
■ the reduction of the risk associatedwith drums being left around the sitecontaining fresh oil that could becomecontaminated;
■ the reduction of the risk of waste oil inclean drums being used as fresh oil,which would have serious implications;
■ stock control in the oil store is simple asall drums are stored in order with labelsshowing.
IBCs can reduce wastage and maketransportation of oil in bulk a simpleprocess. IBCs are moved with a fork-lift,they can be picked up from any of thefour sides as they all have a pallet-likearrangement for forks to enter.
Problems Overcome
The distribution of oils can be difficult on a large site involving many trips back and forthwith drums of oil. IBCs can transport 1 000 litres safely from the oil store to the pointof use. The introduction of IBCs required some changes in handling techniques as theyneeded to be lowered into the basement area of the Power Station. A special cradlewas fabricated along with some suitable racking for the storage of IBCs. Such itemsmake storage and transportation both safe and efficient.
Future Improvements
National Power, Aberthaw, aims to continue the improvements and believes that furtherreductions can be achieved. A general increase in the awareness of oil use will helpstaff to understand the site’s oil requirements even better and to avoid any unnecessarywaste.
THE ENVIRONMENTAL TECHNOLOGY BEST PRACTICE PROGRAMME
IS A GOVERNMENT PROGRAMME MANAGED BY AEA TECHNOLOGY PLC
INDUSTRY EXAMPLE 2
FOR FURTHER
INFORMATION,
PLEASE CONTACT
THE ENVIRONMENT AND
ENERGY HELPLINE
0800 585794world wide web:
http://www.etbpp.gov.uk
e-mail address:
GG227 © Crown copyright. First printed December 1999.This material may be freely reproduced in its original form except for sale or advertising purposes. Printed on paper containing 75% post-consumer waste.
IBC use at National Power, Aberthaw.
Note the ease of stock checking when it is
possible to read the level in the IBC.
ENVIRONMENTAL TECHNOLOGY BEST PRACTICE PROGRAMME
OIL SURVEY FORM
GG227 published by the Environmental Technology Best Practice Programme. Helpline: 0800 585794
Plant item
Location
Oil currently used
Size of oil bath
Estimated annual consumption
Filling point
Notes
Plant item
Location
Oil currently used
Size of oil bath
Estimated annual consumption
Filling point
Notes
Plant item
Location
Oil currently used
Size of oil bath
Estimated annual consumption
Filling point
Notes
ENVIRONMENTAL TECHNOLOGY BEST PRACTICE PROGRAMME
OIL ISSUE SHEET
GG227 published by the Environmental Technology Best Practice Programme. Helpline: 0800 585794
Date Name Oil issued Locationof oil use
Quantityused (litres)
Comments
ENVIRONMENTAL TECHNOLOGY BEST PRACTICE PROGRAMME
OIL STORE CHECKLIST
GG227 published by the Environmental Technology Best Practice Programme. Helpline: 0800 585794
Date: Checked by:
Tick list Action
1 Store has good access with no obstructions
2 Identification labels on all oil storage containers are visible
3 Each oil has a location within the store
4 Similar oils are grouped to assist staff in the event of one oil running out
5 Stock rotation is taking place
6 Signs are displayed to assist staff with oils used
7 Drums in use have tap or pump fitted for dispensing oil
8 Containers are available for dispensing oil
9 Drip trays are placed under taps
10 Oils are being logged
11 Devices are available for transporting oils
12 Containers are readily available for waste oil
13 Containers are readily available for waste oil products (eg used granules)
14 Bunding is in place and intact around racking or in doorways
15 A form of communication of oil problems or comments is available and checked
16 The store is free from spills or leaks on the floor
ENVIRONMENTAL TECHNOLOGY BEST PRACTICE PROGRAMME
VISCOSITY COMPARISON CHART
GG227 published by the Environmental Technology Best Practice Programme. Helpline: 0800 585794
22
75W
80W
85W
90
140
250
32
46
68
100
150
220
320
460
680
ISO viscositygrades
SAE gearviscositynumbers
0W/5W
10W
2020W15W
30
40
50
SAE engineviscositynumbers
Low
vis
cosi
tyH
igh
vis
cosi
ty
