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Standard Operating Procedure (SOP)
Read all of the steps in this SOP before beginning work.
Follow customer labor requirements (i.e. respect Union work)
SOP: Storage & Handling Study DATE NEW
7/18/2014 REVISED PAGE 1 of 10
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TYPICAL CUSTOMERS WORK TYPE WORK ACTIVITY (Description)
Gen. Manu., Prmary Metals, Cement, Lubricant Storage & Handling Perform a Lubricant Storage & Handling (S&H) study in order to ensure optimal
Mining, Energy, Pulp/ Paper, etc. (S&H) Study lubrication
DEVELOPMENT TEAM POSITION / TITLE REVIEWED BY/DATE POSITION / TITLE
Tom Schiff Global FES Manager Thomas Schiff Aug 28, 2014 Global FES Manager
Gilles Delafague FES Advisor
PLEASE UTLIZE ATTCHED GENERAL JSA AS GUIDANCE AND, IF YOU HAVE DONE A SITE SPECIFIC JSA.
PLEASE ASSESS YOUR OWN CONDITIONS OR SPECIFIC SAFETY REQUIRMENTS OR 3rd PARTY SITES, AND BE SAFE:
http://intratta.na.xom.com/emdn/sbps/docs/safety/jsa/JSA_Storage_and_Handlng_Study.xls
EQUIPMENT INDEPENDENT OF JSA DESIRED DOCUMENTATION
CLIPBOARD OR IPAD / TABLET PC DATE OF – (ESN) Engineering Service Notice as a leave behind
IR GUN CUSTOMER UOA REPORTS (SIGNUM/DATA HARVESTER)
FLASHLIGHT(with safety hand string) FINAL – (ESR) Engineering Service Report OR PROPOSAL
SAMPLE THIEF, BOTTLES & LABELS INSPECTION SPREADSHEET / IPAD SITE STUDY OUTPUT
RAGS LINT FREE REPRESENTATIVE OIL CLEANLINESS SUPPLY CHAIN REPORT
CAMERA (with safety hand string) PLANT ANALYSIS IPAD APP OUTPUT
IPAD WITH SITE STUDY APP CUSTOMER S&H PROCEDURES
CUSTOMER S&H TRAINING PLAN/MATERIAL
CUSTOMER CLEANLINESS GOALS BY APPLICATION
CUSTOMER SAFETY RECORD (LUBE S&H RELATED INCIDENTS)
OTHER (SPECIFY)
TIME ESTIMATED TO COMPLETE THIS TASK NUMBER OF PEOPLE TO PERFORM THIS TASK
PLANNING – ½ DAY; SITE EXECUTION – 1 DAY; POST ANALYSIS TYPICALLY ONE LUBE ENGINEER WITH CUSTOMER ESCORT/ FOR LARGE
– ½ DAY; REPORT GENERATION – ½ DAY FACILITIES MAY USE TEAM OF LUBE ENGINEERS, DISTRIBUTOR LUBE
ENGINEERS/TECHNICIANS
FREQUENCY TO PERFORM THIS TASK SKLLS REQUIREED TO PERFORM THIS TASK
DEPENDS ON CUSTOMER NEEDS. ALSO DEPEND ON THE MECHANICAL APPTITUDE.
QUANTITY OF EQUIPMENT SELECTED BY THE CUSTOMER. PRODUCT KNOWLEDGE.
TYPICALLY A STUDY IS CONDUCTED AS A PROJECT FILTRATION/LUBE CLEABLINESS KNOWLEDGE.
(ANNUAL+) AND CAN BE COMPLEMENTED BY ROUTINE LUBE S&H EQUIPMENT KNOWLEDGE.
INSPECTIONS ON MORE FREQUENT BASIS (BEST EXPERIENCE WITH BREATHERS.
INCORPORATED INTO CUSTOMER OWN INSPECTION CONTAMINATION CONTROL EXPERIENCE.
PROGRAM BUT EM CAN BUILD INTO OTHER INSPECTIONS OR TYPICAL PROBLEMS WITH CONTAMINATION.
HAVE DISTRIBUTOR/CONTRACTOR TECHNICIAN EXECUTE) CONDITION EQUIPMENT DETAILED OBSERVATION
WAREHOUSE AND STORAGE INSPECTION EXPERIENCE.
SAMPLE TAKING EXPERIENCE.
OIL ANALYSIS AND INTERPRETATION EXPERIENCE.
JOB COMPETANCIES REQUIRED TO PERFORM THIS TASK TRAINING REQUIRED TO PERFORM THIS TASK
UOA INTERPRETATION lms e-Learning– LUBE S&H
SAMPLING TECHNIQUES 2nd Edition Lubrication Fundementals Book (Chapters 18 & 19)
BASIC LUBRICATION OF GEARS, BEARINGS, HYDRAULICS EM S&H Internal/External Offer Sheets
FILTRATION & DIALYSIS. Contamination Control Training (file attached)
PSPS (PROFESSIONAL SELLING PROCESS SKILLS) / SPIN Product knowledge and Recommendations
TCO / BENEFIT REPORT WRITTING UOA Interpretation ( Cleanliness).
LUBE STORAGE, HANLDING AND DISPENSING Filtration & Dialysis. (file attached)
OJT – observe competitent person doing S&H study
OJT – be observed by competitent person doing S&H study
Site specific safety training
OTHERS RESORCES OR RELATED INTEREST SITES
TECHNICAL HELP DESK (THD) (tsc.amerias@exxonmobil.com) LTS (LUBRICANT TECHNICAL SUPPORT)
Lube GBU Technical Resource Library
www.mobilindustrial.com
www.looble.com
PURPOSE – To describe the process for developing a Lubricant Storage & Handling Study in
a new or an an existing customer. The main objective through the Oil cleanliness study is to
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monitor the oil condition along the supply chain (from warehouse/tanks to different
equipment) identifying sources of contamination in order to propose improvements for
keeping clean the oil and to increase equipment life.
LOCATION JOB STEPS
Prior your call, collect customer Ask customer for personal protection equipment you will need
information. previous to visit different locations. Review JSA, etc.
Identify customer sector and prep for suffering points for this industry
(Example, Cement: a lot of contamination).
Determine why the Lubricant Storage & Handling Study is needed.
What is the goal of the customer?. Identify cost or potential cost
impacts due to poor lubricant storage and handling (leverage data
harvester UOA results, removed equipment components that show
failure modes of contamination, get store room part usage, etc.)
Get preliminary information: General equipment layout, Current Lube
Routes, Current Lubricant used, Lubrication practices ( How they
apply the lubricant, how they handle the oil, where do they store
lubricants, what tool do they use to apply the lubricant), warehouses
used for storage lubricants and what kind of filtration they use.
Get process diagrams to understand customer equipment and
nomenclature.
Consult support information and owner/OEM manuals for cleanliness
specifications.
Collect all used oil analysis information they have about the specific
equipment. Ask for cleanliness information. Ask for the laboratory
they use.
Get organization diagrams in order to know what people is
responsible for lubricant application, oil filtering, oil storage, etc.
Ask customer for frequency of oil drain interval change and top off oil
rates for major system consumers/
Ask customer for visiting the equipment, the oil warehouse and tool
warehouse (Some customers use one warehouse for sealed drums
and other for drums that already open).
Be ready with SPIN questions regarding the equipment: Filtration, oil
drain interval, samples, personnel, tools, etc.
Equipment inspection/Field Be accompanied by a customer representative.
Analysis Be aware of potential hazards close to the equipment.
Ultize the IPad Plant study tool to record information
Identified the objective of the equipment in the manufacturing
process.
Review with the customer the path of the lubricant from storage to
equipment fill – including purification steps along the path. Focus on
critical equipment and especially focus on equipment that you
identified has potential for TCO impacts due to poor storage and
handling practices.
Review how the customer receives product. Do they take a sample
when they receive bulk for retain, do they compare the sample for
clear and brightness against a reference. When critical cleanliness
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requirement do they check the particle count (themselves or by
supplier)
Anayze if they store there oil to utilize first in/first out management
control
Anayze their storage drums/pails to prevent safety incidents while in
storage or handling
Anayze if they stage the main oil storage and satellite storage areas
to optimize travel time for lubrication handlers as well as minimize
environmental contamination impacts
Determine if the customer understands how to determine the package
product shelf life and do they check their slow moving inventory shelf
life
Check if the customer has good and written lubricant storage and
handling procedures/expectations
Evaluate if the customer has a formal lubricant storage and handling
program for the appropriate personnel
Check if the customer has a periodic/routine (e.g. monthly walk
arounds by appropriate management) lubrication storage and
handling assessment (someone surveys the lube storage sights to
observe for deviations from expectations)
Take notes of the brand and models of the equipment and the
components. See if there are filters attached to the equipment. Ask
for the information about those filters (Brand, Model, Beta, change
frequency). Ask how they know when they have to change the oil.
See if there is any label attached to the equipment and
storage/dispensing equipment that show basic information like oil
used, date of oil changed, refill, etc. How they use visual
management to avoid cross-contamination.
Review customer’s purification equipment used in the lubricant supply
or reclaimation chain. Take notes of brand, model, filters quantity,
beta and change frequency. If it is possible ask the customer if you
can see how they purify the oil (Look for potential issues). Take
samples before and after the purification processes.
Select key lubrication supply chains and take oil samples for
cleanliness/contamination determination from distributor to customer
receiving, to main oil storage, to satellite oil storage and to equipment
as well as the transfer devices.
Review customer on site equipment rebuild shop’s (e.g. machine
shops, pump rebuild shops, roll shops, mobile equipment shops, etc.)
lubricant storage and handling procedures and actual practices
Review customer off site equipment rebuild shop’s (e.g. other
vendors that repair/build customer rotating equipment) lubricant
storage and handling procedures and actual practices
Review customer equipment construction/project lubricant storage
and handling procedures as well as procedures to align with rest of
facility fewest correct lubricants. Also review lubrication hand over
procedures that ensure the new equipment is properly lubricate prior
to hand over to the facility
Evaluate high lube consumption applications/equipment as they can
drive more oil handling and ingression to determine opportunities to
reduce consumption (good to reduce lube usage as well as reduce
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potential for contamination ingression from new oil being added)
Inspect customer’s all loss central lubrications systems (oil, grease,
mist) to determine how do they transfer lubricant into these devices,
do the devices have labels, do they have appropriate filters, etc.
Equipment inspection/Field Create a list of current lubricants, delivery container sizes and usage
Analysis by department using storeroom, lube storage areas and lube
cabinets.
Observe the warehouse used for storage the oil ( Ceiling, floor, walls).
Ask the customer if there is only for oil, how they prevent
contamination in the room. Does the area have proper temperature
control.
Assess any outside lubricant storage for proper sheltering, oil drums
stored in right position, drum cover use, etc.
Observe the lubricant storage areas for basic housekeeping
opporutnities (floors clean, lids/caps always used, labels in place,
etc.)
Observe types of containers (Bulk, drum or pail) and their
appropriateness for type of use/application
Observe the equipment used to deliver the oil (pneumatic pump,
manual pump, etc.). See if there is one pump for one kind of oil.
Observe how the tip of the gun is. Identify potential issues.
Observe if they use breathers on the drums or the bulk tanks.
Assess if the customer uses decicant (some gases use gravity
separation units where higher humidity exists) breathers on drums or
bulk tanks in areas with moisture.
Assess bulk tanks to determine if proper tank atmospheric
padding/ventilation is in place. Typically use dry/clean instrument air
or dry/clean nitrogen.
Determine if customer has appropriate drain ports on storage tanks
and cracks them periodically to inspect for water/particulate
contamination. In addition, best practice is that the bulk tank is sloped
downward to the drain (approximately 1 down to 10 across slope
demension) and away from the dispenser pick up.
Assess the customer bulk tanks for proper inventory management
including low level alarming, inspection routines, procedures to
expedite lubricant orders from supplier, written supplier supply
expectations, and periodic quality sampling (especially when bulk oil
feeds into equipment sensitive to contamination).
Assess customer oil transfer equipment to determine if they have
appropriate filtration. In addition, assess critical applications for
filtration on the equipment reservoirs and devices like specific
connectors to prevent cross contamination with other lubes/liquids
(color coded hose/pipe connectors with different demensions than
other systems so someone can not hook up the wrong
connector/hose).
Ask if they purify new oil. Ask for used oil analysis information . If is is
possible take a sample before and after the dialysis. Ask for the
information of the equipment use to purify new oil (Brand, Model,
quantity of filters, beta, change frequency).
For customers with high grease consumption, assess if they have the
optimium dispensing equipment. For sites that require mobility they
should have portable kegs with pumps (if pneumatic ensure proper
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pressure regulation, air hose size, grease hose length/diameter – big
impact on flow rate, and clean/dry air). Also determine for specific
applications or central storage areas that containers like grease bag
systems or fixed bulk systems are used instead of drums.
Observe types of containers for preventing ingression of
contaminants (are they sealed, are they labeled). Are they use
funnel? How clean is the funnel? Are the funnels dedicated, labeled,
stored in clean place, are they cleaned after each usage.
Review if containers are dedicated by product
Observe the oil container labeling ( Drums, pails, small containers).
How they use visual management to avoid mistakes.
Make a general note on housekeeping of containers and materials
management.
Determine if the customer has proper oil spill clean up material,
expectations and training.
Assess customer for proper oil disposal facilities (didcated, marked
containers), procedures, training, etc.
Determine if the customer lubricant storage facility complies with
appropriate regulations (country, state/region/providence, local, and
company)
Observe the tools they use to apply the lubricant. Are they labeled?.
Are they proper storage?.
Take photographs with customer’s permission.
At the end of the visit write an Engineering Service Notice to the
customer, highlighting the main items covered, agreements next steps,
and timeframe
Home Office – analyzing all Send samples to the lab. Ask for particule counter analysis.
data (Information Analysis) Confirm the lubricant used in the equipment to ensure they customer
is using the fewest correct lubricants. Utlize OEM Manuals, Technical
Help Desk, Looble, EMEBS, EB Engineer, etc.
Consult with purification/filtration/lube transfer equipment specialist
(other vendors). Confirm purification and transfer equipment are
optimized.
Ask your colleagues about similar situations and how they were
solved.
Review in Inside Sales – Technical – Model Reports and the VDR site
for similar applications, products and how others have built a benefit
report.
Factor investment costs for storage/handling/purification upgrades
Review the photos and mark the issues. Find photos with best
practices in order to compare.
Prepare the ESR Using the 3D Report Writer format, prepare the ESR. Store in Value
Document Repository (VDR)
Apply the applicable TCO Categories: Revenue, Assets, Process,
Expenses and Others.
Use photos to explain your findings. Use best practices.
Set a follow up meeting with Confirm with the customer the findings and explain why you thing are
customer to review draft. potential issues. Use support data like used oil analysis, OEM
recommendations and other customer best practices.
Explain your recommendations and the necessary changes to meet
the goal.
Explain the next steps to achieve this value and express as
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opportunities for improvement.
Manage implementation and Get customers cooperation to implement your recommendation –
expand relationships colloaborate with customer to arrive at recommendations
Offer your technical post-sale expertise expand relationships
Feedback about this SOP -
send Chief Engineer
Storage inspection examples.
Take notes about quantity of oils used in the plant.
Identify if the storage is for close or open drums or pails.
Identify if the warehouse is close or is in an open space.
Identify if there
See the tip of is one pump
the gun for per product.
any trail of
contamination
Take notes
about how
clean is the
Indentify warehouse
Breathers
Indentify the type How the
of packaging customer
used for fillings avoid cross
contamination
Fuente:
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Before
After
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World Class
Before After
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Before – Everything Exposed
New Design - Enclosed
Mine Bulk Best Class (labeling, breathers, filters-receive, recirculate, feed, level monitor/alarm)
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State of the art mine fuel and lube truck with enclosed dispensing with meters, filtration
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APPENDIX 1 - RELATED DOCUMENTS
Model Engineering Service Reports/Proposals
Product Consolidation Example
General Manufacturing S&H Example
Mining S&H Example
Grease Gold Bag Example
Pulp & Paper S&H Example
Power Plant S&H Example
TCO Categories
Revenue Examples
Equipment downtime due to failure caused by contamination stemming from poor lube S&H
Equipment down time due to poor lubricant inventory management (run out of oil)
Expenditure Examples
Lubricant usage due to replacing from S&H contamination
Less than optimial equipment component life due to contamination from poor S&H
Increased lube costs due to damaged lube containers/spills
Increased costs due to fines for safety/environmental fines
Potential increase investment costs to purchase new/upgraded S&H equipment
Asset Examples
Increased inventory carry costs due non optimal inventory management
Increased inventory carry costs due to not having the fewest correct lubricants
Increased inventory costs due to less than optimal machinery inventory due to frequent repair from poor S&H
Increased labor costs to transfer and apply lubes due to less than ideal storage locations
Increased asset carry costs for new S&H equipment
Process (labor) Examples
Increased labor costs due to additional lube disposal from poor S&H
Increased labor costs due to repair equipment from poor S&H
Increased labor costs to transfer and apply lubes due to less than ideal storage locations
Increased costs to install new S&H equipment
Safety Examples
Increase machinery risks exposure due to more frequent lube addition to equipment from poor S&H
Increase machinery risks exposure due to more equipment repair from poor S&H
Increase machinery risks exposure due to more lube leaks from poor S&H
Increased machinery risk exposure from less than ideal lube storage locations and extra travel
Enviromental Examples
Increased waste lube volume due to additional lube disposal (shorter oil life) from poor S&H
Increased environmental impact exposure due to lube leakage from poor S&H
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S&H Equipment Examples
http://descase.com/products/fluid-handling-filtration/
http://descase.com/products/lubrication-transformation-services/design/lube-room-
design/
http://www.rock-tech.net/ - for underground mine lube storage solutions
Filtration Information
http://ishareteam2.na.xom.com/sites/LSSG031/TechResources/Tech%20Resources%20Do
cs/Filtration.ppt
http://www.pall.com/main/industrial-manufacturing/pocket-book-contamination-and-
filtration-42674.page
http://ishareteam2.na.xom.com/sites/LSSG031/TechResources/Tech%20Resources%20Docs/Beta%20
Ratio%20Technical%20Bulletin.ppt
Contamination Control
http://ishareteam2.na.xom.com/sites/LSSG031/TechResources/Tech%20Resources%20D
ocs/Contamination%20Control%20Basics.pdf
Other Storage and Handling Reference Material
http://ishareteam2.na.xom.com/sites/LSSG031/TechResources/Tech%20Resources%20Docs/Lub
ricant%20Storage%20Basic%20Guide.pdf
http://ishareteam2.na.xom.com/sites/LSSG031/TechResources/Tech%20Resources%20Docs/tt-
handling-and-storing-lubricants.pdf
http://ishareteam2.na.xom.com/sites/LSSG031/TechResources/Tech%20Resources%20Docs/TIS-
17_Dispensing_Lubricants.doc
http://ishareteam2.na.xom.com/sites/LSSG031/TechResources/Tech%20Resources%20Docs/tt-
safety-in-lubrication.pdf
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