Machinery Lubrication July-August 2010

CONTENTS July - August 2010

Features

machinerylubrication.com Features in Detail

4

As I See It Strategies to Extend Oil Drain Intervals and Reduce Lubricant Consumption When you look at the true cost of an oil change and the associated risks, there is an abundance of financial and business motivation to maximize, or at least optimize, the oil change interval.

8

Viewpoint Take a Plant Safety Approach to Your Lubrication Efforts Human error incidents can be minimized through a combination of awareness and consistent reinforcement.

10 The Exponent Understanding the Social Psychology of Reliability Management Drew Troyer examines some common mistakes made in managing plant personnel.

26 Hydraulics at Work

14 Cover S tory Pizza Plant Goes All In

Hose vs. Tube: What’s the Best Call

Jane’s Dough Foods, a division of Donatos, shuff led the deck and turned to biobased lubricants for its production facility in Ohio. ML’s Paul V. Arnold provides the details in this in-depth case study. (Pictured above: Greg Wilkett and Tom Krouse)

for Hydraulic Equipment? Hydraulic hoses and tubes are not interchangeable. They are different “tools” for different jobs.

28 From the Field 52

64

How Do You Know if You’re Using the Right Hydraulic Oil? Stephen Sumerlin provides tips to help you select the right oil for the equipment and application.

52 Oil Analysis A New Technique for Filter Debris Analysis A new method has been developed to recover filtered debris particles efficiently, productively and economically.

56

56 Lubricant Storage Pennsylvania Power Plant Gives Oil Storage Room a Makeover Elrama Generating Station has revamped its facilities and practices for lubrication storage and handling.

64 Contamination Control

EditorialFeatures 2 4 8 10 26 28

Editor’s column As I See It Viewpoint The Exp onent Hydraulics at Work From th e Fie ld

Machinery Lubrication

Departments 33 52 56 62 64 66

Reliable Plant 2010 Oil Ana lysis Lubricant St orage Certification News Contam Contro l Back Page Basics

24 30 32 50 60

Product News Product Supermarket Product Spotlight Crossword Puzzler Web Preview

www.machinerylubrication.com

Five of the Most Common Filter Cart Mistakes While most plants use filter carts, many don’t use them in the most effective way.

66 Back Page Basics Telltale Signs and Tips to Tame Machinery Vibration Jeremy Wright explores causes, ef fects and characteristics of vibration, and offers some prevention ideas. July - August 2010 1

EDITOR

ML Wins, VW Gets Athletic, and a VP Worth Checking Out PAUL V. ARNOLD N ORIA C ORPORATION

I

get to chat with you through this column just six times a year, so there’s usually a ton of information that I wish to share/discuss/pontificate about and a limited amount of opportunity, time and space to do so. Therefore, I’m devoting this issue’s column to clearing my memory bank and scattershooting on several topics.

Honored by an Honor We at Noria are in the knowledge-dissemination business, not the trophy-gathering business, but it’s always nice to be recognized by your peers for outstanding or enterprising work. As such, I and the Machinery Lubrication magazine team were

day. Shouldn’t they expect the same from the people who work with those machines? Volkswagen now does. The car manufacturer made headlines this spring by announcing that workers hired for its new assembly plant in Chattanooga, Tenn., were being put through a fitness program, on top of the normal job training, with the goal of creating “industrial athletes” who could achieve peak performance – without unscheduled slowdown or breakdown – throughout the course of the work day. According to company wellnessdisability specialist Marsha Wood, exercises in the two-hour daily workout sessions are linked to movements that plant workers will do every day and include stretching, cardiovascular strength, endurance and physical strength (grip, push and pull). Volk swagen Chattanooga spokesman Scott Wilson says the company’s classroom, hands-on and fitness training is all “focused on getting each and every one of us, no matter what our job is at the plant, prepared to show up and perform at the highest level of professional excellence.” It goes back to a column I wrote recently. Whether you’re talking about the industrial machine or the human machine, you truly do get out of it only what you put into it.

humbled recently to have won an award for editorial excellence in the 32nd annual American Society for Business Publication Editors competition. More than 2,000 entries, from editorial products published in 2009, were considered for awards in this year’s ASBPE contest. After five months of judging, only a small fraction of entries were cited for honors. The judges selected my cover story on lubrication and reliability excellence at Texas Instruments (“Texas Instruments: Pure and Reliable”, July/August 2009 issue) as a winner in the case history category. This is the second time in the last three Catch a Rising Star years that Machinery Lubricationwas recogNissan received a lot of press in late May nized in the ASBPE competition. Over the last when it began construction on a manufacfive years, Noria media products have won 21 turing facility in Smyrna, Tenn., that will awards for editorial and design excellence. produce the lithium-ion batteries that power the Nissan LEAF zero-emission Crafting ‘Industrial vehicle. The all-electric LEAF will be produced at Nissan’s vehicle assembly Athletes’ facility in Smyrna beginning in 2012. Industrial companies expect their Taking center stage and commenting at machinery to run at peak performance – the groundbreaking ceremony were Nissan without unscheduled slowdown or breakdown – throughout the course of the work president/CEO Carlos Ghosn, Tennessee 2 July - August 2010


Governor Phil Bredesen and Mark Swenson, Nissan North America’s vice president of manufacturing engineering and vehicle production engineering. Swenson, a true rising star in the auto sector, will provide the opening keynote address on August 31 at Noria’s RELIABLE PLANT 2010 conference and exhibition in Nashville. Swenson’s keynote speech, titled “From Adversity to Competitive Advantage: Nissan Turns Over a New LEAF”, will surely be among the high points of the three-day event (visit http://conference.reliableplant.com formore info and to register). I’ve already received requests from media outlets to cover the Nissan VP’s address. On a side note, Nissan LEAF and battery production will create up to 1,300 jobs when the plants are operating at full capacity. The battery plant, 1.3 million square feet when it’s completed, will be capable of producing 200,000 advancedtechnology batteries annually. It will be located adjacent to the vehicle assembly plant, which will be retooled to accommodate LEAF production and will be capable of producing 150,000 electric cars annually.

And, Furthermore ... Is it just me or do you think that the whole BP catastrophe could have been solved right away by putting a bunch of Machinery Lubrication readers in a room and letting them hash out some ideas? I’m totally serious. ... ICML’s Suzy Jamieson does so much for the lubrication profession. Be sure to say thanks when you see her at the RELIABLE PLANT conference. ... The MachineryLubrication.com Web site is on pace to draw more than 1 million visitors this year. - Paul V. Arnold, editor-in-chief Machinery Lubrication

AS I SEE IT

Strategies to Extend Drain Intervals and Reduce Lubricant Consumption

JIM FITCH N ORIA C ORPORATION

T

he reasons that lubricants age and need to be replaced periodically aging altogether. Lubricating oils need to be changed for the are well known. It is true that many of the factors that influence following reasons: 1) There is a current or impending loss of the lubricant’ s performlubricant consumption and oil change intervals are not within the ance (friction control, wear control, deposit control, corrosion realm of control of most users. However, there are far more controlcontrol, etc.). lable factors that many user organizations fail to capitalize on in reducing both costs and risks associated with relubrication. 2) The lubricant has become acarrier of one or more harmful and According to one report, the true cost of an oil change can non-removable contaminants (sludge, glycol, bacteria, acids, etc.). exceed 40 times the cost of the oil itself. In fact, there are many 3) There is fear that the lubricant might need to be changed (due hidden costs and unknown risks that are encountered during reluto one or both of the first two reasons) without a convenient brication that must be considered. Let’s look at some of the risks in means to confirm. doing a simple oil change: The following are several common and a few not-so-common • Introducing a wrong, mixed or incompatible oil • Introducing a contaminated oil

• Introducing a defective oil (blend or formulation re lated)

methods lubricant consumption andapplication extending drain intervals. for Notreducing all of these methods have practical in every case where lubricants are used. However, in those cases where extended drain intervals have the greatest potential benefit, a strategy for success relating to the methods can usually be constructed.

• Disturbing sediment and sludge during the oil change ( this is known as the fish bowl effect and can lead to subsequent oilway blockage and starvation)

Select Lubricants with Enhanced Performance and Durable Service Life

• Introducing a lubricant that degraded in storage (severe additive stratification is a common example)

There are a great many differences in the durability of lubricants when exposed to machine operating conditions. Therefore, one simplistic strategy is to select lubricants with robust formulations • Dry restarts, dirty oil restarts (before filter can restore cleanliness) that resist degradation in the target application. The use of highpurity mineral oils, oxidatively stable synthetics, enhanced • Human agency failures during or direc tly after an oil change antioxidant systems, better demulsifiers, robust over-base additives (over-charging, under-charging, failure to open/close valves, and long-life dispersants can substantially extend service life of the dead-heading pumps, etc.) lubricant. Additionally, select lubricants for the applications for When you look collectively at the true cost of an oil change and the which they were formulated. For instance, a high-performance associated risks, there is an abundance of financial and business moti- motor oil might exhibit superior performance in a diesel engine, but vation to maximize, or at least optimize, the oil change interval. When it might fail rapidly when used in a hydraulic system. well implemented, this can translate to sharply reduced oil consumption, lower maintenance costs and greater machine reliability. Reduce the Density of Critical Let’s begin by examining the need for an oil change. Oil doesn’t Exposures that Stress Additives last forever; it ages in ways similar to the human body. By exposing a lubricant to the elements within a machine (heat, air, water, glycol, and Harm Base Oils particulates, shear, etc.), irreparable damage is often done. Additives Most additives deplete at a rate proportional to the density of can extend a lubricant’s life, but they can’t prevent degradation and exposure to a range of contaminants and operating conditions. • Dislodging sludge and deposits, causing leakage (disturbed oil clotting)

4 July - August 2010



Water, dirt, metal particles, soot, heat, acids and air are all contaminants that put stress on additives and lead to their depletion. Additive depletion is the usual precursor to base oil failure, impaired machine performance and eventual machine failure. The following are examples of how to reduce exposure density: •

The greater the oil volume, the more total amount of additive protection there is and the more diluted contaminants become. Contaminant dilution reduces the severity of the stress (activation energy in the case of heat) on both additives and base oil. However, increasing oil volume is not a practical option in many applications.

• Keeping oils cooler, cleaner, dryer and wellprotected can substantially extend service life. This is done by restricting contaminant ingression and rapid removal (filtration, coolers, separators, etc.). It is important to not only reduce the density of these contaminants but also the longevity of exposure.

•

Free radicals, hydroperoxides and other oil oxidation byproducts accelerate the additive depletion rate (antioxidants) once new oil is added. In many cases, it is important to flush these prooxidants from a machine before new oil is added. Oil analysis can alert users to the need to perform a f lush during an oil change.

Restore Depleted Additives Depleted additives can be restored in a couple of different ways for the purpose of extending the oil change interval and to avoid the wasteful disposal of otherwise healthy oil. These are the two options available to users’ organizations: •

is the practice of giving certain depleting additives a booster shot. Additive reconstruction involves introducing an additive concentrate to circulating in-service oil. Only certain additives can be reconstructed with suitable success, and the practice is usually only applied to machines with large oil volumes (e.g., turbine oil, compressor lubricants and hydraulic fluids).

PUBLISHER Mike Ramsey - [email protected] GROUP PUBLISHER Brett O’Kelley - [email protected] EDITOR-IN-CHIEF Paul V. Arnold - [email protected] SENIOR EDITORS Jim Fi tch - jfitc [email protected] Drew Troyer - [email protected] Mark Barnes - [email protected] TECHNICAL WRITERS Jeremy Wr ight - jwright@nori a.com Stephen Sumerlin - [email protected] CREATIVE DIRECTOR Ryan Kiker - [email protected] GRAPHIC ARTIST Kam Stinnett - [email protected] ADVERTISING SALES Brett O’Kelley - [email protected] Phone: 800-597-5460, ext. 112 PRODUCTION MANAGER Rhonda Johnson - [email protected] CORRESPONDENCE You may address articles, case studies, special requests and other correspondence to: Paul V. Arnold - Editor-in-chief

MACHINERY LUBRICATION Noria Corporation P.O. Box 87 Fort Atkinson, WI 53538 Phone: 920-568-9768 Fax: 920-568-9769 E-mail address: [email protected]

SUBSCRIBER SERVICES: The publisher reserves the right to accept or reject any subscription. Send subscription orders, change of address and all subscription related correspondence to: Noria Corporation, P.O. Box 47702, Plymouth, MN 55447. 800-869-6882 o r Fax: 866-658-6156. MACHINERY LUBRICATION USPS #021-695 is published bimonthly by Noria Corporation, 1328 E. 43rd Court, Tulsa, OK 74105. Periodical postage paid at Tulsa, OK and additional mailing offices. Copyright © 2010 Noria Corporation. Noria, Machinery Lubrication and associated logos are trademarks of Noria Corporation. All rights reserved. Reproduction in whole or in part in any form or medium without express written permission of Noria Corporation is prohibited. Machinery Lubrication is an independently produced publication of Noria Corporation. Noria Corporation reserves the right, with respect to submissions, to revise, republish and authorize its readers to use the tips and articles submitted for personal and commercial use. The opinions of those interviewed and those who write articles for this magazine are not necessarily shared by Noria Corporation. POSTMASTER: addressPlymouth, changes MN and55447. form Canada 3579 toPost Machinery Lubrication, P.O.Send Box 47702, International Publications Mail Product (Canadian Distribution) Publications Mail Agreement #40612608. Send returns (Canada) to BleuChip International, P.O. Box 25542, London, Ontario, N6C 6B2.

Award Winner, 2008 and 2010

VOLUME 10 - NU MBER 4

AS I SEE IT

Further, it should only be done after laboratory testing has confirmed that a lubricant has: 1) not experienced irreparable harm, 2) there are no threatening contaminants that can’t be easily removed (glycol, for instance), and 3) the use of an additive supplement has been determined not to impair performance of other lubricant properties. • When it is inconvenient or risky to do an oil cha nge, one option is to perform a . This involves draining a portion (say one-third) of the oil volume, immediately followed by the introduction of new oil. The drained oil removes some of the contaminants, and the new oil dilutes the remaining contaminants and brings in fresh additive.

Optimize the Timing of Lubricant Changes A vast amount of lubricant is wasted each year due to premature and unnecessary oil changes. In fact, the life expectancy of a lubricant cannot be accurately predicted due to the numerous factors that both induce aging and resist aging. No lubrication expert or computer program can forecast the need for an oil change. Therefore, users are faced with either changing the oil well in advance of any expected end-of-life oil condition (a wasteful and risky p ractice) or to periodically analyze the oil to monitor the advancing end of life (a far better practice).


Analyzing the oil using routine oil analysis is a far more practical and reliable alternative.

Lower Leakage Of course, leakag e doesn’t actually trigger the need for an oil change, but it certainly does result in unnecessary oil consumption through repeated addition of make-up oil. Fortunately, healthy, uncontaminated oil can have an amazing positive impact on reducing oil leakage. Likewise, leakage is often associated with excessive contaminant ingression, which, of course, shortens oil life. All told, there are many opportunities to reduce oil change frequency and the associated costs and risks. All of these involve some form of intervention, transforming past practices to oil-life-extending new practices. Precision lubrication is about selecting the correct intervention action(s) to systematically achieve the intended objective at the lowest possible cost and risk to the organization. In this case, lower oil consumption by extending oil drain intervals.

About the Author Jim Fitch has a wealth of “in the trenches” experience in lubrication, oil analysis, tribology and machinery failure investigations. Over the past two decades, he has presented hundreds of lectures on these subjects. Jim has published more than 200 technical articles, papers and publications. He serves as a U.S. delegate to the ISO tribology and oil analysis working group. Since 2002, he has been director and board member of the International Council for Machinery Lubrication. He is the CEO and a co-founder of Noria Corporation. Contact Jim at [email protected].



VIEWPOINT

MARK BARNES N ORIA C ORPORATION

Take a Plant Safety Approach to Your Lubrication Efforts ike most of the Noria technical team, I spend a considerable Lpharmaceuticals amount of time visiting many different types of plants. From to mining, food production to steel making, tire making to roof shingles, I’ve seen most of what the United States manufacturing base has to offer. But while the challenges and equipment used are many and varied, my day in the plant always starts the same way: a walk through the front gate after signing in with security. And, that’s where you’ll see the most striking similarity between these very diverse plants. The signage at the front gate usually states something like: “We have worked X man days with a lost-time accident. Work safe.” If you stop to think about, do we really need to be reminded about safety every day? Isn’t it enough to be told once a year in a short safety class that, yes, safety is indeed important and something that should be considered above everything else? The answer, of course, is a resounding NO! Having a daily reminder in the form of signage at the front gate, awareness posters throughout the plant and a safety notice at the machine are an important tool in avoiding complacency – the most common cause of workplace accidents. In other areas of plant life, complacency also is one of the leading causes of failure to succeed. This includes lubrication. Like other maintenance tasks, lubrication often is performed poorly due to one or more of a combination of factors, the most common of which are lack of training and lack of procedure (see my Viewpoint column in the July/August 2009 issue of Machinery Lubrication magazine, www.machinerylubrication.com). But even where good procedures and well-trained people are in place, mistakes do still happen, usually due to complacency. So, how can we avoid complacency in lubrication? Just like safety, accidental human error resulting in poor lubrication can be minimized through a combination of awareness and consistent reenforcement of the mission and vision. What better way to do this than through signage, metrics and awareness notices.

Achieving Awareness on Three Levels Taking our lesson from safety, lubrication awareness needs to take three basic forms. The first is to provide awareness of the importance of lubrication at a macroscopic level. This is 8 July - August 2010

equivalent to the “lost time” notification at the front gate. For lubrication, there are several macroscopic metrics we can use, but the most effective is overall lubrication effectiveness, or OLE (read Drew Troyer’s column on this important subject at www.machinerylubrication.com/Read/363/lubrication-metric). Taken as the produc t of lubrication pre ventive mai nte nance compliance, lubricant quality compliance and contamination control compliance, OLE serves as a metric to identify the effectiveness of current lubrication performance in mitigating the causative factors of lubrication-related failure: • failure to do lubrication tasks on time, • failure to keep contaminants out of the machine, and • failure to keep lubricant in good health. Just like the lost-time notif ication is intended to inspire us to exceed previous safety records, publishing OLE in the form of a monthly graphical analysis serves to inspire those who can influence the outcome of lubrication to constantly strive for excellence. At the shop-floor level, safety often is proclaimed through a series of awareness posters sometimes featuring photos of family members of co-workers to help stress the point that safety affects everyone and is everyone’s responsibility. For lubrication, a similar approach can be taken. For example, a simple awareness poster showing the effects of over-greasing on a bearing or a laminated poster showing the different colors assigned to each lubricant in the plant helps to reinforce the importance of precision lubrication and dispel the myth that oil is oil, grease is grease, and the more the better. At the machine level, pinch points or locations where safety hazards exist are usually identified with signage. While useful for all employees, safety hazard labels are most important for new employees and those least experienced with a specific machine. For lubrication, the same holds true. At each point of application, a simple color-coded label identifying the correct lubricant, or a more elaborate schema including the correct quantity of grease to apply, easily can be developed. The same applies to lubrication inspections. Simple annotated photographs showing various points on the plant and what the desired state should be during inspection serve to help reinforce best practice and encourage precision. The approach is often referred to as the “visual plant”.



Standardized Work Plans In addition to labels, metrics and awareness posters, safety also is made a priority through the use of standardized work plans which provide (or should provide) specific details about a task and the associated hazards. For lubrication, the same holds true. Lubrication instructions need to provide specific details and guidelines that are simple and easy to understand, but contain specific details for how to perform the task according to prescribed best practice.

Training and Reinforcement Finally, no safety program would be complete without formal and informal safety training. Even though an employee may have been through safety training during his or her initial hiring, safety is reinforced through regular routine, formal training as well as informal reinforcement at the start of a crew meeting or other group gathering. For lubrication, the same approach also applies. Both formal and less formal awareness sessions should be held with those that can influence the outcome of lubrication to help insure that the need for precision and the consequences of imprecise practices


are brought to the forefront. Often, picking a specific topic (e.g. the importance of proper oil sampling or the effects of contaminants on element bearings) is a good way to stay focused on an area where perhaps preferred practices are starting to lapse. Just like safety and the various ways we help to insure that we minimize the number of lost-time accidents, think about how we also can apply a similar approach to help insure you strive toward lubrication excellence. As always, this is my opinion; I’m interested in yours. About the Author As a skilled educator and consultant in the areas of oil analysis and machinery lubrication, Mark Barnes has helped numerous clients develop effective machinery lubrication programs and troubleshoot complex lubrication problems through precision lubrication and oil analysis. As chief technical officer of Noria Corporation, Mark and his team work on projects in the areas of: plant audits and gap analysis, machinery lubrication and oil analysis program design, lube PM rationalization and redesign, lubricant storage and handling, contamination control system design and lubrication, and mechanical failure investigations. Contact Mark at [email protected].


July - August 2010 9

THE EXPONENT

Understanding the Social Psychology of Reliability Management

DREW TROYER

s a reliability engineer and MBA, I concluded early in my career A that managing reliability in a manufacturing plant is approximately 80 percent engineering and 20 percent business management. Boy, was I wrong. With experience over time, my views have changed – dramatically. I think it’s about 20 percent engineering, 30 percent business management and 50 percent social psychology. Sure, a plant is an electromechanical thing (engineering) that’s built to create shareholder value (business management). But it’s run by groups of people – the social psychological piece of the pie. In fact, I may be grossly underestimating the people side of the equation. As a consultant, I hear it again and again – “we can’t get the people part figured out.” Let’s explore some common mistakes we make managing our people.

What Gets Rewarded Gets Done Early in my career, I taught a course on contamination control for hydraulic systems to an angry group of mechanics. I didn’t understand why they were angry. It’s pretty simple: If you control contaminants in a hydraulic system, pumps last longer, seals last longer and valves don’t jam or fail near as often. It wasn’t until a break that a master mechanic enlightened me that the guys weren’t directing their anger at me, nor did they disagree with the technical message I was delivering. The problem was that I was talking about

Conscious Competence

Drivers:

• Crisis • Profitability • Aspiration

e c n a t is s e R l a n t io a z i n a g r O /t r o ff E

Unconscious Competence

Old Business as Usual

New Business as Usual

Second Nature Time Tim e

Figure 1. The Journey to the ‘New Business as Usual’ 10 July - A ugust 2010

2) Production managers receive a bonus for hitting production goals, even if it creates inventory for which there’s no demand. 3) Equipment design and procurement teams receive a bonus and recognition for getting functional, fast and cheap, even when it increases the life-cycle cost of ownership. 4) Purchasing teams are rewarded for cutting c osts, even if it results in large transitional costs (e.g. changing lube suppliers) or reduced material quality (e.g. increased dimensional variability in bottles).

 Measurement • Peer Pressure • Sustained Management Support • Success

Unconscious Incompetence

Ignorance is Bliss

We’ve heard that what gets measured gets done. In truth, it’s what gets rewarded that gets done. Here are some other common reward mistakes: 1) Operators get an unscheduled break when the manufacturing process fails.

Drivers:

Culture Shock

Loss o off Conscious Incompetence Innoce Innocence nce

taking away their boats, cabins, vacations, etc. It hit me like a load of bricks; for many mechanics, overtime represents a good chunk of their total pay. For overtime to occur, something’s got to break. We’ve been extrinsically rewarding failure with overtime for decades. If we don’t replace the overtime pay opportunity with a reliability-based opportunity that’s the equivalent or better, we’re not looking after the WIFMs (what’s in it for me) of our people. In fact, we’re reinforcing the behaviors that lead to failure. Moreover, if a mechanic comes in on overtime and fixes a machine in the middle of the night, we intrinsically reward him by lavishing praise on him for getting us back up and running. When was the last time you plant managers lavished praise on a team member for changing a filter, performing an inspection, completing a laser alignment, etc.?

5) Sales teams are rewarded for selling product even if it produces a loss due to manufacturability problems (e.g. packaging solutions that require plenty of manual intervention). There are many other examples. The key is to create reward systems that drive the right kinds of behaviors. These systems must include the extrinsic drivers (money, benefits, etc.) and intrinsic drivers (recognition and “atta-boys”, feeling like a part of a team, etc.). I also believe they should be based on a balanced scorecard of individual, team and organization goals. Above all, they must drive behaviors that promote reliability and value creation for the firm.



THE EXPONENT

Who’s Wa tching the Bottom Li ne? Large organizations are grouped into functional subsets by necessity. Unfortunately, these groups interpret the mission based upon their context of the world and drive forward based upon this interpretation, creating functional action plans, key performance indicators, reward systems, etc. Let’s use physics to illustrate the point. Think of a functional group in the organization as a vector, a force that has direction and magnitude. If a different functional group interprets the mission in such a way that sends them on a vector that has the same magnitude but is 180 degrees opposite to the fir st group, the physical resultant is nullified. This happens all the time. In many cases, it’s worse than just negating the efforts of another function. In some cases, the vectors collide to destroy value. For example, the sales organization makes commitments to deliver a product that has no chance of being profitable because the manufacturing lot size is too small, or the process of creating or packaging the product can’t be automated, etc. Design engineers and equipment specialists build and install plant equipment that’s cheap up front but has high life-cycle costs. There are many other examples along the value stream of the organization. Now there’s an important concept – value stream. Organizations are created to create value. Our most fundamental performance metric, return on net assets (RONA)/return on capital employed (ROCE), is a value-based metric. Stock analysts call it a measure of “management effectiveness”. It, more than any other KPI, determines whether or not people want to buy or sell your stock. It is also the basis for economic value added (EVA) calculations, which drive executive bonuses, stock options, etc. If maximizing value is so important, why then do most functional groups in the organization focus their efforts on revenue maximization or cost minimization. Who’s watching the bottom line? Sure, revenue and costs are a part of the value equation, but increasing revenue or decreasing costs can – and often does – destroy value. I think it’s because value is so difficult to measure, particularly at the functional level, where the functional group only contributes a part of the value equation. However, if we don’t get our functional teams working for (not against) each other, we stand little chance of creating lasting value. The winners figure out how to minimize the silo effect.

A New ‘Business as Usual’ Using physics metaphorically again, organizations experience “psychological inertia.” A body at rest remains at rest. To create movement, we must increase propelling force or decrease impedance. In other words, people – and particularly groups of people – resist change. As a consulting reliability engineer, I observe practices. If I see a bad practice and ask why it’s done that way, the most common response is, “It’s how we’ve always done it.” Likewise, when I observe a good practice and ask the same question, I get the same response: “It’s how we’ve always done it.” It’s business as usual. 12 July - A ugust 2010

The key to successfully changing an organization is to replace the old, failed “business as usual” with a new “business as usual” that works to achieve the goal. The problem, typically, is our approach. In the book “Learning to Fly” by Chris Collison and Geoff Parcell, the authors clearly illustrate why change usually fails. Organizations undergo a predictable change process. They have a current practice, the current business as usual, a state which Collison and Parcell call “unconsc ious incompetence” (se e Figure 1). We’re lousy, but unaware; ignorance is bliss. A manager reads an article, speaks to a colleague, attends a seminar or in some other way discovers that there’s a better way – “conscious incompetence.” Now we have a gap that needs to be closed. So a “program” is put in place to close the gap. This new business process, which has the organization in a state of conscious competence, takes much energy for the organization and is very uncomfortable. Remember, psychological inertia. Frequently, the change agent who put the “program” in place to start with bails out and moves on to the next big thing. Without relentless leadership support, the organization, which is resisting the change, will predictably drift back to its old practice, back to its comfort zone. To succeed, we must achieve a state of “unconscious competence”, where doing it right is second nature. This requires a combination of mechanical support mechanisms like procedures and training, enforcement of the new practices, and plenty of encouragement and coddling. Don’t underestimate the importance of this concept. Most new initiatives fail because we fail to recognize the impact of psychological inertia. Making matters worse, if we fail to execute a business process change initiative, the next time we try it, the organization collectively responds that “we tried that and it didn’t work here”, making it harder to implement the second time around (think TPM, lean manufacturing, etc.).

It Is All About the People In this column, I’ve touched on three important social psychological aspects of reliability management. There are many more. E-mail me if you’d like to discuss these factors specifically as they relate to your organization. Also, ping me if you want to see more on the social psychology of reliability management. It’s a fascinating subject. In the immortal words of Kurt Vonnegut, “If only it weren’t for the people, the (expletive removed) people … always getting tangled up with the machinery. If it weren’t for them, Earth would be an engineer’s paradise.” It is all about the people. About the Author

Drew D. Troyer is a champion of effective reliability management and passionate about helping companies find hidden profits inside their plants. As a highly sought consultant to Fortune 500 manufacturing firms, awardwinning columnist and teacher, he understands both management expectations and plant-floor realities. Drew is a Certified Reliability Engineer (CRE), a Certified Maintenance and Reliability Professional (CMRP), and chairs the standards committee of the Society for Maintenance and Reliability Professionals (SMRP). Contact him [email protected] .



COVER STORY

14 July - A ugust 2010



Pizza Plant Goes All In Jane’s Dough Foods, a Division of Donatos, Shuffles the Deck and Turns to Bio-Based Lubricants for Ohio Production Facility BY PAUL V. ARNOLD

T grow up with the country.’ Instead, he’d point to that deck of cards on the table and say, ‘Shuffle up and deal.’”

“

here’s opportunity in poker. ... If Horace Greeley were alive today, his advice wouldn’t be ‘Go West, young man, and – Lou Krieger, professional poker player and best-selling author on poker strategy

Did you hear the one about the pizza guy who cleaned up after placing an “all in” bet in a factory version of draw poker? The guy is sitting with a strong hand, by all accounts – trip Queens with an Ace-Nine kicker. Stand pat, and the odds say he’s got the pot. But with ice water in his veins, he tosses in the Ace-Nine and rakes in two fresh cards from the dealer. Twin deuces. Full house. He goes all in. He gets the call, and the chip pile grows. Flip ’em over ... ka-ching. “The smart approach may be ‘if it’s not broke, don’t fix it’, but that’s not what we’re all about. We’re about ‘it’s not broke, but let’s make it better,’” says Greg Wilkett, the “pizza guy” in this analogy, whose business card reads vice president of manufacturing at Jane’s Dough Foods, a pizza and dough producer in Columbus, Ohio, and the baking division of the Donatos family of pizza restaurants and retail/grocery brands. “The data indicated that it would be better. It’s not blind faith. It’s a calculated move.” Tom Krouse, Donatos’ president of expansion brands, chimes in: “You were more nervous than you were letting on.” If so, that’s one heck of a bluff. Wilkett had the cards falling his way when he ditched the petroleum-based lubricants at Jane’s Dough Foods’ 50,000-square-foot plant in the fall of 200 9 in favor of synthetic lubes. Over a fourmonth period following the conversion, the advantages were apparent – a reduction in downtime and the elimination of catastrophic failures. But he didn’t stand pat. In early 2010, he dumped the synthetics and wound up strengthening his hand with bio-based lubricants. As a result, the house is full. Record uptime is allowing the plant to fill an increasing number of orders and raise capacity utilization into uncharted territory. More than two million pizzas and nearly 15.5 million pounds of dough (both all-time highs) will be made this year. Good move? You bet.

Dealing With Downtime The Columbus plant traditionally had been solid in its maintenance practices and performance. While normally staffed by a




COVER STORY

Freshly cut shells move down the production line at the Jane’s Dough Foods plant in Columbus.

Vice president of manufacturing Gregg Wilkett is a proponent of really good pizza and bio-based lubricants. The Columbus plant is on pace to produce 2.3 million topped pizzas this year.

A SliceDonatos, of Life in Columbus headquartered in Columbus, Ohio, consists of Donatos Pizza, a 180-restaurant chain and marketer of retail/grocery pizza products, and Jane’s Dough Foods, a manufacturer of pizza and dough products. The company had annual sales exceeding $10 million in 2009 and forecasts nearly $20 million in sales for 2010. Jane’s Dough Foods in Columbus. The facility, which opened in 1996 and expanded in 2006, is rated as “Superior” by the American Institute of Baking. Approximately 50,000 square feet. The site employs 68 workers, including six in maintenance (one manager, five hourly technicians). The plant produced 1.5 million topped pizzas in 2009 and is slated to produce 2.3 million in 2010. All total, it produced 10.7 million pounds of dough in 2009 and is forecasted to make 15.4 million pounds in ’10. Current capacity is 5 million pizzas and 26 million pounds of dough. CEO Jim Grote started Donatos in 1963 while a student at Ohio State University. He bought a Columbus pizzeria for $1,300. ... Jane’s Dough Foods is named after Donatos president and COO Jane Abell, the daughter of Jim Grote. 16 July - A ugust 2010

small number of maintenance department employees, it had knowledgeable veterans in manager Kevin Rine (hired in 1996) and multi-craft technicians Steve Van Horn (1988), Kim Siv (1990) and Homer Ashcraft (2001); talented newcomers Doug Morrison and Derek Zwirner were added in 2008. The crew utilized progressive tactics for preventive and predictive maintenance. Lubrication-based PMs had long been driven by data (run time) and schedule (sanitation cycles). PdM followed an inside/outside approach, with plant maintenance handling the sampling piece of oil analysis, and contractors tackling the laboratory end of that, as well as vibration analysis and infrared

freezer registers minus-175. That environment, though, had a tendency to trump maintenance’s best efforts. “Our maintenance record has always been what I would consider ‘good’,” says Wilkett. “We really did have a pretty good preventive and predictive program. But we were having major breakdowns – two or three catastrophic ones where we broke shafts because bearings seized and gears broke. If you go down because of a part you can’t readily buy and replace, you may be down for four days.” If pizzas aren’t being produced, orders aren’t filled. Increased uptime became essential as a boom in sales required epic productivity. The maintenance and manufacturing

thermography. As a result, unplanned downtime constituted 11 percent of the work day, an adequate total considering the extreme temperatures to which key machinery components were exposed – the dough proofing system operates at more than 100 degrees Fahrenheit and the tunnel

team traced the root cause of the failures to the petroleum-based oils and greases lubricating those critical components. “We had to have lubricants that could hold up in those temperatures,” says Wilkett. The plant knew when to hold ’em and knew when to fold ’em.



COVER STORY

Maintenance technician Steve Van Horn greases machinery during a PM route.

Bearings get a workout in the pizza plant. The tunnel freezer operates at minus-175 degrees Fahrenheit. Leaders at Jane’s Dough Foods feel that the benefits of bio-based lubes are clear.

Synthetics Suit Plant Needs As stated earlier, the next hand that Wilkett and his Jane’s Dough colleagues played was synthetic lubricants, beginning in September 2009. “We acknowledge that better lubrication not only ties into our preventive maintenance and predictive maintenance programs, but it also ties in to better operating procedures and policies – standard operating procedures – which allow us to gain consistency,” says Wilkett. “To run a facility effectively every day, you have to look at everything ... including your lubricants.” The plant drained its equipment and sumps, purged its inventory, and replaced it all with synthetic oils and greases. The benefits were immediate and dramatic. Gearboxes and bearings on the oven and freezer lines weren’t failing. Run time moved to previously unreachable levels. The amp draw for the proofer oven’s variable frequency drives dropped nearly 20 percent (from an average of 34 amps down to around 28). “We used thermal cameras and imaging to see what kind of heat buildup we were getting,” says Wilkett. “We knew that the bearings

were getting better lubricated. We had a real good baseline with the synthetics over a 4.5-month period.” That’s when Jane’s Dough Foods raised the ante. In February 2010, the synthetics were removed and replaced by bio-based lubricants.

A Royal Flush and Fill Some may think that Wilkett was gambling with house money (or not playing with a full deck) when he decided to switch the “known” for the disagrees that sentiment, characterizing the“unknown”. decision as aHesafe bet andwith bio-lubricants as a known, mature industrial lubrication option. “Bio-lubricants are one of the more advanced areas of environmental technologies for manufacturing facilities,” he says. “These are high-quality lubricants that perform just like a synthetic.” Bio-based oils were indeed around before the development of petroleum-based oils in the 19th century. They have become the subject of renewed interest with the advent of bio-fuels, the unexpected supply of foreign petroleum and the push for green products.

‘Consistently Excellent’ Pizzas Start at the Columbus Plant While Donatos has been making pizzas since 1963, it didn’t have a central manufacturing plant until 1992. Enter the site and business now known as Jane’s Dough Foods. Company executives, particularly founder/CEO Jim Grote, felt development of such a facility was long overdue. “Jim is a stickler. He is consumed with the consisJim Grote tency of the product,” says Tom Santor, Donatos’ executive director of marketing and public relations. “In the early years, he used to work like 100 hours a week. He didn’t want to leave because he thought the pizza might be made differently. As we expanded, he vowed to put together a pizza making system. To round this system out, we


manufacture our dough at a single site. It’s the same flour, the same water, the same temperature, the same yeast. Everything is exactly the same.” The company believes that high levels of consistency and quality make a difference in a very crowded, competitive marketplace. “Consistency is not the sexiest word in the world, but our customers recognize it,” says Tom Krouse, president of expansion brands. “We have everything in place – the team, the facility and the capabilities – to manufacture a product that is consistently excellent. There is a gap in the mass-produced pizza market for quality. The industry is kind of designed around speed first and quality second. Fortunately, the culture of this company is about quality. Quality comes first, and then we add speed to it.”



COVER STORY

Here are Some of the Cards Up the Columbus Pizza Plant’s Sleeve According to Renewable Lubricants Inc. (RLI), the supplier of bio-based products to Jane’s Dough Foods, the following oils and greases are among those used at the Columbus, Ohio, plant. • RLI Bi o-Food Grad e Gear Oil s (ISO 32-460), for gear drives and rightangle gear drives

• BPL Food -Grade Bi o-Penetrat ing Lubricant (NSF H1, H2), for closetolerant areas in order to lubricate and prevent corrosion

• RLI Bio-Food Grade General-Purpose Lubricant (SAE 20; NSK H1, H2, H3), for various applications

To lear n more about thes e and othe r products, visit the Renewable Lubricants Web site at www.renewablelube.com.

• RLI Bio-Food Grade Extreme-Pressure Grease (NLGI #0, #1, #2), high temperature, for food processing and packaging machinery

According to a 2008 report from the United Soybean Board, bio-lubricants can be generally defined as friction- and wearreducing fluids and semi-solids based on biodegradable and renewable materials. Bio-lubricants do not need to be composed entirely of vegetable oil basestocks. They can be products derived from renewable oils, such as the fatty acids from fats and oils, reacted with synthetic alcohols or polyols to produce esters that can be considered bio-lubricants. “We more than knew what we were getting into,” Wilkett says. For production and corporate image purposes, the company had been investigating the application of bio-lubricants for some

time before the eventual switch. And, Wilkett and corporate management had a strong “green” background – Wilkett as a degreed environmental engineer who worked in that capacity at Pillsbury in the late 1990s; and chief executive officer Jim Grote as an owner of a Ohio-based butanol production company (former chief operating officer Tom Grote now runs that business). To top it off, Tom Grote introduced Jane’s Dough leaders to colleagues at Renewable Lubricants, a local manufacturer and supplier of bio-based lubes, leading to an exchange of dialogue and information. When it came down to it, switching lubricants was the right call at the right time for the right size and type of company. “We are in a unique situation, and it was as if the stars aligned when this came along,” says Wilkett. “We are small enough in our capacity to make this happen. If we had been running at 94 percent capacity, I’m not sure we would have done a carte blanche change. But when you are running at 30 percent capacity, you can still treat this like an innovation center. Let’s figure all this stuff out before we get to 90 percent. “The companies that I came from were expanding every year. They were adding on to the building because they were constantly running out of capacity. They had co-packers packing. I’m not sure that smart people would pull the trigger on a project like this if they were at 98 percent capacity.” Donatos is also privately held and, as a result (according to plant leaders), can be faster and more flexible than publicly traded,

red-tape-laden firms. This was tantamount in the “all in” decision six months ago. “Do you know how long that conversion would have taken at a blue-chip, Fortune 500 company?” says Wilkett. “A conversion from petroleum to synthetic or from synthetic to bio-based would have taken years. That would have been test-bedded and ‘beta sited’ to death. We didn’t do any of that. We did it in 11 days. We flushed all of the machines and converted the entire facility. We went with Renewable Lubricants’ bio-based products for the bearings, gearboxes, even the spray lubricants that we use every day. We went all in.”

How long can in-service lubricants go? The maintenance crew doesn’t know. “We are in the run time between failure extension mode,” he says. “What that means to us is, we are letting things fail so that we know how long we can run them. I am either happy to report or, for this program, unhappy to report that we don’t know when it’s going to fail because we can’t make one fail. We don’t know what the baseline is because we haven’t had a failure. We have a large gearbox; it runs with an 80-horsepower motor. It has more than 2,000 hours on it, and we haven’t changed the lubricant. Typically, the PM cycle on that was 1,000 hours, so we are double the typical

Raising the Metrics

PM cycle. It’s still not making noise. We use stethoscopes, infrared cameras, etc. – there’s nothing to report. I’ll call you when we have a failure, but I don’t know when that will be.” This uncertainty has led to the urge to perform maintenance when none is truly needed. Wilkett says, “The technicians had to get over the fear. They would remark, ‘Are you sure you don’t want to change that oil? Do you know that gearbox costs $21,000?’ Then you get into the mirage mode – ‘Did you hear that noise? Does that feel hot to you?’ – when everything is fine. You try to talk yourself out of caving in.”

Production equipment at the Jane’s Dough plant has not skipped a beat since the flop to bio-based oils and greases. As with the synthetics, there have been no catastrophic failures, no bearing or gearbox failures, no issues whatsoever. Run time, oil life and component life are obliterating the old standards. Components that typically went 500 hours or 1,000 hours between oil changes are hitting 2,000 and 3,000 hours, and they still haven’t been changed. “We do oil analysis, and we do see some degradation,” says Wilkett. “After 2,000 hours in the proofer, we are starting to see degradation. We are getting more particulate in the oil. But it is not at the level where we need to change the oil.”

Stacking Up Chips, and Pizzas Bio-based lubricants are roughly twice the cost to purchase as petroleum-based products (they are comparable in price to

COVER STORY

synthetics), but a host of factors make them a better overall deal for Jane’s Dough Foods. “The cost is minor,” says Wilkett. “Failure of high-dollar components, the downtime associated with it, the frustration for your associates – that is the real cost of having a poor lubrication program. If you can get expanded run time between stoppages and you can eliminate your catastrophic or unplanned failures, those are advantages.” Downtime has dropped to a mere 4 percent. “RightCase the first quality is atfor 99.8 percent. fill istime” at 100 percent 2010. And, because production is humming, and existing and new customers are happy, capacity will double this year. There are other benef its, too. First, there’s the time and cost associated with the proper disposal or reclamation of petroleum products and items (sorbents, shop rags, etc.) that have come in contact with them. On a related note, Wilkett says that because the bio-lubes are deemed nonhazardous, the regulatory requirements are less complex and less costly from an administrative perspective. The conversion away Bio-based lubricants have helped drop the plant’s downtime to a mere 4 percent. from petroleum-based lubricants is one reason why the plant hopes to be landfillThe plant has a close relationship with manufacfree by the end of 2010. turing and packaging programs at Western Second, because the bio-lubes have a much Michigan University and other colleges. “We feel wider temperature range than the petroleum that we can attract these Western Michigan products, the facility has been able to consolidate University students to work with us following its supply down to just three gearbox lubricants graduation,” says Wilkett. “We can attract the (for low, medium and high temperatures), two best talent because we have this philosophy and spray lubricants (for chains, conveyors, etc.) and we have these programs.” two greases (for low and high temperatures). Thinking for a moment, he lays all of his cards “For the gearboxes, it’s just straight weight; it’s on the table. “I think it’s a pretty cool story when not based on viscosity,” he says. “Technicians you can do something for the environment and normally like to have seven viscosities of grease the community and have social responsibility and and 14 viscosities of lubricant, and they want to at the same time create better reliability in your have seven different spray cans with different facility. How do you beat that?” colored lubricants. But it’s not needed anymore. It would be like hauling around a tool box with 30 wrenches when you only need three of them.” A Winning Hand Third, the public sees Jane’s Dough Foods and This article closes with another quote from Donatos more and more as a “green” business. poker maven Lou Krieger: Research shows that an increasing percentage of “I believe in poker the way I believe in the U.S. consumers prefer to buy from environmenAmerican Dream. Poker is good for you. It enriches tally conscious companies. “Consumers are the soul, sharpens the intellect, heals the spirit and, looking to make the right choices in everything, when played well, nourishes the wallet.” including what consumer goods to buy from I think if Lou knew the plant floor the same responsible companies,” says Krouse. way he knows the casino floor, he would say, Fourth, the next generation of industrial “Well played, Donatos and Jane’s Dough Foods. leaders place value in the company’s “green” side. Well played.” 22 July - A ugust 2010



PRODUCT NEWS Mist and Fume Control

Wireless Shaf t Align ment

The OILMISER Vapor Guard (OVG) is designed for rotating, lubricated machinery such as gearboxes and bearing housings. The OVG has a central diffuser post inside a sealed containment chamber. Migrating vapors are dispersed inside the containment chamber, where they condense back into liquid oil. The condensate runs down the diffuser post and inside walls of the containment chamber and collects

Alignment Supplies released its newest Easy-Laser product, the E710. The E710 continues on the development path of the Easy-Laser E-Series products, which all offer next-generation features like wireless Bluetooth operation; isp, cr color graphics; and Endurio Power Management for enhanced operating time. This product’s integrated battery automatically charges itself from four ordinary Ccell batteries. The E710 also can be purchased with a barcode scanner accessory.

at the bottom. The recovered and uncontaminated lube oil is then channeled back into the machinery. JLM Systems Limited www.oilmiser.com 888-736-8645

Grease Lubricator The KPL-24 Grease Lubricator from Yamada America is a 24-volt DC-powered tool that allows for the efficient greasing of heavy-duty equipment without tapping into hydraulic or pneumatic lines. The KPL-24 is easy to set up and fits directly onto a five-gallon grease pail (a 16-gallon version also is available). It works in conjunction with a hose reel and hand grease gun and can be used as a standalone or centralized lubrication system. Weighing just 24 pounds, it is easy to transport and resists tipping.

Alignment Supplies Inc. www.alignmentsupplies.com 800-997-4467

Square Infrared Window IRISS Inc. expanded its product line of Custom Application Products (CAP) to include the world’s first Square Infrared Window for infrared (IR) thermography applications. The company incorporates a polymer lens material in this product, enabling the manufacture of custom windows in virtually any shape or size. IRISS can take a panel, machine guard or cowling and use it as a template to make not only an infrared viewing pane, but also an optical viewing pane. IRISS Inc. www.iriss.com 941-907-9128

Battery-Powered Grease Gun

Yamada America Inc. www.yamadalubricator.com 847-631-9200

Software for V ibration Data Emerson’s AMS Machinery Manager v5.4 bolsters predictive diagnostics from all types of mechanical assets by adding wireless access to spectral and waveform vibration diagnostics. This solution integrates machinery health diagnostics information between the protection system, asset management software and control system, enabling maintenance and operations access to real-time machinery information

LE now offers a convenient Battery-Powered Clear Grease Gun. Available with the same high-quality clear tubes and anodized aluminum collars, this product is useful for lubricating hard-to-reach areas or equipment that requires frequent or large-scale lubrication. The new gun has a maximum pressure of 8,500 psi, delivers up to 4.9 ounces of grease per minute and provides 19.2 volts of power. It comes with two 1,500mAh rechargeable battery packs and an extra-long 30-inch whip hose.

that allows them to identify and resolve issues before interruptions occur. Emerson Process Management www.emersonprocess.com 865-675-2400


Lubrication Engineers Inc. www.cleargreaseguns.com 800-537-7683



Fluorescent Oil Dye

Portable FTIR Analyzer

OIL-GLO 33 fluorescent oil dye detects leaks in systems with all types of oil-based fluids, including hydraulic and lubrication fluids, compressor oil, engine oil, and gearbox oil. Simply add a small amount of the dye to any oil-based system and allow it to circulate. Wherever there is a leak, the dye escapes with the oil and remains at the leak site. Scan the system with a Spectroline high-intensity UV or blue-light inspection lamp and observe the dye’s bright green glow.

Analyze diesel fuel with the portable Grabner IROX Diesel FTIR Analyzer. The heart of the instrument is an extremely compact mid-FTIR spectrometer, which features a fully automatic optical realignment during the warm-up to ensure high stability even after long use or transport of the tester. The IROX Diesel measures the complete absorption spectrum, which provides complete analysis of the substances present in the diesel fuel, eliminates variations of the baseline and minimizes interferences. AMETEK Petrolab Company www.petrolab.com 918-459-7170

Spectroline www.spectroline.com 516-333-4840

Sure-grip Hand Protection Ansell introduced HyFlex 11-830, an ergonomically designed glove that incorporatesZonzKnit Advanced Comfort Technology for comfort and fit. Ansell’s new foam nitrile metallic gray coating provides abrasion protection and a sure grip for workers handling objects in light oil or dry environments. The metallic coating extends product wear life and provides a distinctive modern look for quick and easy identification. The HyFlex 11-830 product is launderable, with minimal shrinkage and excellent recovery.

Triton Dehydration Station Schroeder Industries offers the patent-pending Triton Dehydration Station for water and particulate removal. The product is designed to eliminate 100 percent of the free and 90 percent of the dissolved water from small reservoirs, barrels and gearboxes. The unit is extremely portable using either the central lifting port or the optional cart to access tight areas. It features simple controls and high dewatering rates and particulate removal in one system. The product has the same diameter as a 55-gallon drum. Schroeder Industries www.schroederindustries.com 724-318-1100

Food and Beverage Solutions

Ansell Limited www.ansellzonz.com 800-800-0444

Outdoor Drum Storage The new Ultra-HardTop P4 Plus from UltraTech safely stores hazardous drums outdoors. Designed to accommodate four 55-gallon drums, the unit features a unique “two-way” entry system. To access drum tops, the ergonomically friendly, roll-top cover can easily be lifted from waist height. To load or unload drums, swing-out doors provide safety and convenience. The lockable, two-way entry system is located on two opposite sides of the unit, allowing quick access to all four drums.

For food and beverage processing where product quality and safety are UltraTech International Inc. critical, Henkel offers Loctite products designed to meet rigorous FDA, www.spillcontainment.com NSF and CFIA requirements. Used in facilities from industrial bakeries to 800-353-1611 dairy and meat plants, Loctite threadlockers, thread sealants, liquid gaskets, retaining compounds, lubricants, cleaners and floor/concrete repair compounds extend equipment life, increase line efficiency, improve operator safety, protect product quality, enhance plant hygiene and reduce costs. Henkel Corporation www.henkelna.com/mro 800-562-8483 Machinery Lubrication



HYDRAULICS AT WORK

Hose vs. Tube: What’s the Best Call for Hydraulic Equipment?

BRENDAN CASEY

W

hat do lifting chains, bladder-type accumulators and hydraulic hoses all have in common? Well, they typically have only one mode of failure – and that’s catastrophic. One minute they’re working as they should, and the next thing you know, they’ve gone to hell. Oh, sure, hoses can leak from around their ferrules and show obvious signs of abrasion, both of which are early warning signs that a change-out would be pr udent. But even under these conditions, estimating their remaining service life is virtually impossible.

The Trouble with Hose Beyond the fact that their service life is finite and difficult to estimate, other disadvantages of hydraulic hoses when compared to tubes include: • They expand and stretch under pressure. This flexing requires extra volume and adds to machine cycle time. • They typically have a limited ope rating temperature range. • Their requirement for regular replacement makes them a source of contaminant ingression. • They are expensive. Despite the above disadvantages, hoses are a necessary feature of most hydraulic systems. This is because the alternative conductor – tubes – cannot be used where: • There is limited s pace (particularly in mobile hy draulics). • There is relative mov ement between machine components and superstructure. • Noise and vibration need to be suppressed. However, hose is often substituted for tube when it’s not necessary. This is because a hose assembly can usually be fabricated much faster than a tube assembly. And, the additional labor cost required to fabricate and install a tube can make hose appear to be the cheaper solution. But this belies the fact that the same hose may need to be replaced many times over the life of the machine. This false economy is similar to buying the machine itself on initial capital outlay alone without considering its total life-of-ownership cost. 26 July - A ugust 2010

Tube is Cool Hydraulic tubing has some compelling advantages of its own. One of these is its superior heat transfer, especially if it’s painted. One aspect of heat transfer is thermal radiation. The total radiation from an object is the sum of its reflection, emissivity and transmission of heat through the object. When hydraulic tubing is painted, it reduces its reflectance and increases its emissivity, enabling better heat rejection, as this case study published in Hydraulics and Pneumaticsmagazine1 illustrates: An industrial hydraulic installation was srcinally designed to operate at 1,200 psi and at a maximum operating temperature of 120 degrees Fahrenheit (49 degrees Celsius). Zinc dichromatecoated steel tube distributes fluid from the 600-liter reservoir to the various stations around the plant. Over the years, the system had been added to (without any increase in installed cooling capacity)— to the point where it was now overheating in the summer months. Because the system operated satisfactorily for 10 months out of the year, management did not want to spend the money necessary to upgrade the cooling system. So, one of the maintenance guys on staff who was familiar with the thermal radiation theory described earlier suggested painting the hydraulic system’s tubing. Before proceeding, the maintenance team did a test. Team members applied electrical tape to two of the hydraulic tubes, and using an infrared camera, they measured the difference in temperature between the taped and untaped areas. They found the taped areas on the tubes were 7 degrees F (4 degrees C) cooler thanthe untaped areas. This gave the maintenance team the conf idence to proceed with the idea. Because the rest of the hydraulic system was painted flat white, the tubing was painted the same color. And, the result? A week and 12 cans of spray paint later, the system was running 10 degrees F (5.5 degrees C) cooler. This might not sound like much, but the end result meant that the hydraulic system could now operate through the two hottest months of the year without overheating. It also meant that the need to increase installed cooling capacity was at least deferred, if not eliminated.

Managing Hose Replacement Despite the superior reliability of tubing, for reasons already explained, hoses are a necessary feature of most hydraulic machines. And unlike tubing, hoses are a maintenance item, one



which usually gives no warning of impending failure. So in a condition-based maintenance environment, how can you proactively manage the replacement of hydraulic hoses? Well, there are two considerations which should be foremost in your mind: the downtime cost of in-service hose failures, and NOT treating all hoses equally. Consider this example: A couple of years ago, I worked with a mining client whose ad-hoc replacement of hoses which failed in ser vice on hydraulic shovels had resulted in machine availability falling to as low as 65 percent. In this company’s case, when a multi-million-dollar shovel stops, so does a multi-million-dollar fleet of haul trucks. Downtime is a major cost.This So,involved it implemented hydraulic hoseon replacement program. changingaout every hose the machine every 18 months. Whenever a shovel was down for planned maintenance, a portion of the hoses were changed out, beginning with the oldest first. The plan worked. Machine availability was soon back above 90 percent. Of course, large-diameter, multi-spiral hydraulic hoses aren’t cheap. However, hose expense paled to insignificance when compared to the cost of the downtime it prevented. By any economic measure, the hose replacement program was a great success. But, it did have a fundamental flaw. It was treating all hoses the same. And, it was highly unlikely that each hose on the machine was equally responsible for an equal proportion of the inservice failures and downtime.


I advised this company to study the historical data. I alsostated that it should expect to find that a relatively small percentage of hoses were responsible for the majority of the in-service failures and downtime. In fact, the available data revealed that less than 20 percent of the hoses on the machine were responsible for nearly 90 percent of the failures. Armed with this information, the hose replacement program was optimized to reduce unnecessary hose change-outs.

The Final Selection Hydraulic hoses and tubes are not interchangeable. They are different “tools” for different jobs. The benefits of hose – which make it a necessary feature of most hydraulic machines – come at a cost. It has a finite service life and usually gives no warning of failure. This makes it a difficult maintenance item to manage. For these reasons, hose should only be used where tubing cannot. Reference: 1. Hays, D., “Little Things Mean a lot In Manufacturing”, Hydraulics & Pneumatics magazine, May 2009, pp 38-41.

About the Author Brendan Casey has more than 20 years experience in the maintenance, repair and overhaul of mobile and industrial hydraulic equipment. For more information on reducing the operating cost and increasing the uptime of your hydraulic equipment, visit his Web site, www.HydraulicSupermarket.com.



FROM THE FIELD

STEPHEN SUMERLIN N ORIA C ORPORATION

How Do You Know if You’re Using the Right Hydraulic Oil?

F

or most lubricated machines, there are many options when it comes to lubricant selection. Just because a machine will run with a particular product doesn’t mean that product is optimum for the application. Most lubricant misspecifications don’t lead to sudden and catastrophic failure; rather, a misspecification shortens the average life of the lubricated components and, thus, goes unnoticed. With hydraulics, there are two primary considerations – the viscosity grade and the hydraulic oil type (AW or R&O). These specifications are typically determined by the type of hydraulic pump employed in the system, the operating temperature and the system’s operating pressure. Selecting the best product for your system requires that you collect and utilize all available information.

Hydraulic Fluid Hydraulic has many roles in the smooth a wellbalanced andfluid designed system. These roles range operation from a heatoftransfer medium, a power transfer medium and a lubrication medium. The chemical makeup of a hydraulic fluid can take many forms when selecting it for specific applications. It can range from full synthetic (to handle drastic temperature and pressure swings) to water-based fluids (used in applications where there is a risk of fire).

Gear

70/158 60/140 70/158 70/158 60/140 40/104 70/158 70/158 60/140 40/104 70/158 60/140 40/104

Vane

Piston

34.5/500 34.5/500 34.5/500 69/1,000 69/1,000 69/1,000 34.5/500 172.5/2,500 172.5/2,500 172.5/2,500 293/4,250 293/4,250 293/4,250

32-68 15-32 15-22 22-46 15-32 10-15 15-22 22-46 32-46 15-22 46-68 22-46 15-22

Figure 1. Viscosity Selection for Hydraulic Fluids 28 July - August 2010

A synthetic fluid is a manmade chain of molecules that are precisely arranged to provide excellent fluid stability, lubricity and other performance-enhancing characteristics. These fluids are great choices where high or low temperatures are present and/or high pressures are required. There are some disadvantages to these fluids, including high cost, toxicity and potential incompatibility with certain seal materials. A petroleum fluid is a more common fluid and is made from refining crude to a desired level to achieve better lubricant performance with the inclusion of additives, which range from anti-wear (AW), rust and oxidation inhibitors (RO) and viscosity index (VI) improvers. These fluids offer a lower-cost alternative to synthetics and can be very comparable in performance when certain additive packages are included. Water-based fluids are the least common of the fluid types. These fluids are typically needed where there is a high probability of fire. They are more expensive than petroleum but less expensive than synthetics. While they offer good protection for fire, they do lack on wear protection abilities.

Pumps and Viscosity Requirements There are three major design types of pumps used in hydraulic systems: vane, piston and gear (internal and external), and each of these pump designs are deployed for certain performance tasks and operations. Each pump type must be treated on a case-by-case basis for lubricant selection. The design of a vane pump is exactly what its name depicts. Inside the pump, there are rotors with slots mounted to a shaft that is spinning eccentrically to a cam ring. As the rotors and vanes spin within the ring, the vanes become worn due to the internal contact between the two contacting surfaces. For this reason, these pumps are typically more expensive to maintain, but they are very good at maintaining steady flow. Vane pumps typically require a viscosity range of 14 to 160 centistokes (cSt) at operating temperatures. Piston pumps are your typical middle-of-the-road hydraulic pump, and are more durable in design and operation than a vane pump; they can produce much higher operating pressures, up to 6,000 psi. The typical viscosity range for piston pumps is 15 to 160 cSt at operating temperatures.



Application-Based Selection Application-based selection techniques are the reality checks to make sure all of the time spent selecting the proper viscosity, additives, etc., was not wasted by simply ignoring the application’s requirements and operating conditions. Just following OEM specifications will not be enough to ensure that the correct hydraulic oil is selected; these are typically for best-case scenarios. Ignoring these reality checks will most often still lead to failures down the road. They may not be as rapid as selecting the wrong viscosity, but they will eventually happen; therefore, application and operating factors should be taken seriously. About the Author Stephen Sumerlin is a technical consultant with Noria Corporation, working on Lubrication Process Design Phase II projects for clients. He is a mechanical engineer and a certified Level I Machine Lubrication Technician (MLT) through the International Council for Machinery Lubrication. Contact Stephen at [email protected].

Figure 2. Example of a Hydraulic System From Page 50

Gear pumps are typically the most inefficient of the three pump types, but are more agreeable with larger amounts of contamination. Gear pumps operate by pressurizing the fluid between the trapped air volume of the meshing teeth of a gear set and the inside wall of the gear housing, then expelling that fluid. There are two main types of gear pumps, internal and external. • Internal gear pumps offer a wide rang e of viscosity ch oices, the highest of which can be up to 2,200 cSt. This type offers good efficiency and quiet operation, and can produce pressures from 3,000 to 3,500 psi. • External gear pumps are less efficient tha n there counterpart, but have some advantages. They offer ease of maintenance, steady flow, and are less expensive to buy and repair. As with the internal gear pump, this variety can produce pressures ranging from 3,000 to 3,500 psi, but the viscosity range is limited to 300 cSt.




PRODUCT SUPERMARKET

30

PAID ADVERTISING SECTION

A new full-color 104-page catalog is available on Oil-Rite’s lubrication equipment, featuring PurgeX® Centralized Lubrication Systems. Complete turnkey systems are available for immediate delivery, liquid or grease delivery, air or electric motor-operated. The catalog also feature s an entire line of level gauges, lubricators, valves, vent plugs and f ilters. www.oilrite.com 920-682-6173

Summit Syngear FG Series Gear Oils are a full synthetic, formulated for gear systems used in the food service, beverage and packaging industries. They are NSF regist ered H1, ISO 21469 certif ied, Kosher approved and CFIA accepted. Summit Industrial Products www.klsummit.com 800-749-5823 [email protected]

CONTROL WATER CONTAMINATION. Remove 100% free water and 95% dissolved water with C.C. JENSEN Desorbers. Proven, effective and reliable. Suitable for oil systems with small or large volumes. Guaranteed performance. Contact us today for information or purchase. C.C. Jensen Inc. www.ccjensen.com 800-221-1430 [email protected]

MEMOLUB ® Lubrication Systems – Precise, Reliable. Lube up to 12 points with the reusable MEMOLUB ®. Available in 3 sizes and 4 power options, MEMOLUB® uses low-cost replaceable lube cartridges with customer-specified grease or oil. PLI, LLC www.memolub.com 800-635-8170 [email protected]

Quickly monitor the remaining useful life of lubricants. The RULER provides an easy on-site method for monitoring antioxidants and identifying problems like lube oil varnish. Maximize lubricant life with the RULER. Fluitec www.fluitec.com 888-557-9575 [email protected]

Simple and cost-effective, LE’s Clear Grease Gun will make an immediate impact on your reliability efforts. No more mistakes or cross-contamination. Be confident in knowing you are using the right grease, time after time. Lubrication Engineers Inc. www.cleargreaseguns.com 800-537-7683 [email protected]

In addition to particle counting and automatic type of wear classification into non-metallic, cutting, fatigue, sliding, fibers, water droplets offering images and trending, the new SpectroLNF Q200 also reports dynamic viscosity. Spectro Inc. www.SpectroInc.com 978-431-1120 [email protected]

An EP grease for extended, heavy-duty service, LE’s Almagard Vari-Purpose Lubricant stays put – even in severe conditions. It lengthens intervals, will not harden with age, and extends bearing life by up to threefold. Lubrication Engineers Inc. www.le-inc.com 800-537-7683 [email protected]

July - A ugust 2010


Thi s DVD inc lud es ins tru ctiv e vide os and animations to give viewers a better understanding of electric motor bearings and how to lubricate them properly. Noria Corporation www.noria.com/secure 800-597-5460 Machinery Lubrication

Easy Vac Inc. provides the right tool for an

Des-Case Extreme Duty breathers have been

Inolex Chemical Company synthesizes premium

important job! Vampire fluid sampling pumps ... small, hand-operated vacuum pumps accept any size sampling tube (with an OD of 3/16 inch to 5/16 inch) without changing fittings. “Super Clean” sampling containers, tubing and accessories are also available. Easy Vac Inc. www.easyvac.com 865-691-7510

designed to take contamination control to a whole new level, standing up to a wide variety of applications in challenging environments. They attack the cause of contamination, keeping dirt and water where it belongs – out of your equipment. Des-Case Corporation www.descase.com 615-672-8800 [email protected]

ester base oils for high-performance lubricant applications such as chain formulations for oven temperatures up to 550°C. HX-1 food grade oils for baking chains are available. Inolex Chemical Company www.inolex.com 1-800-521-9891 [email protected]

REMOVE VARNISH, PARTICLES AND WATER.is Three pro blems, one solu tion . C.C. JENSEN focused on supplying highly efficient and reliable offline filters and filter carts. Guaranteed performance. Contact us today for more information or to purchase. C.C. Jensen Inc. www.ccjensen.com 800-221-1430 [email protected]

Keep your hands free and your lubricant spot-on with perma® automatic lubricators. Preloaded with premium LE lubricants, they provide continuous, precise application. The result: reliability, efficiency, safety and savings. Lubrication Engineers Inc. www.le-inc.com 800-537-7683 [email protected]

In this information-packed course, you’ll discover how to build a world-class lubrication program and put an end to your lubrication frustrations. Noria Corporation www.noria.com 800-597-5460

Because viscosity measurement should be simple, CANNON is excited to introduce the SimpleVIS™ portable viscometer. Everything is included to get you started, minus your sample and solvent. Contact us for more information. Cannon Instrument Company www.cannoninstrument.com 800-676-6232 [email protected]

Best Practices for Lubricant Storage and Handling video-based training provides procedures you can implement right away for managing lubricants, from delivery to dispensing to f illing the machine. Preview at Noria.com. Noria Corporation www.noria.com 800-597-5460



Harvard’s filter systems are designed and built with quality materials and craftsmanship to provide years of trouble-free service. Filter elements for viscosity ranges from fuels to gear oils (ISO 1000). Customers report clean fluids to ISO 13/12/8 in operation. Contaminant capacity per element is about four pounds. The product has demonstrated the ability to remove one gallon of water from oil. Harvard Corporation www.harvardcorp.com 800-523-1327 July - August 2010 31

PRODUCT SPOTLIGHT SYSTEM 24 Lubricators

Foam Lubricant Applicator

SYSTEM 24 single-point automatic lubricators from SKF provide timely and accurate “hands-off” solutions to deliver the proper preset amount of lubricant when needed for bearings in industrial machinery. The product line includes cost-effective gas-driven feed versions and newly introduced electromechanicaldriven systems engineered for reusability. All perform reliably on a 24-hour basis without manual intervention and can resolve issues typically associated with hard-to-access or potentially hazardous lube points. All SYSTEM 24 lubricators feature flexible and adjustable dispense settings ranging up to 12 months and transparent lubricant containers for visual inspection of dispense rate. They are filled with SKF high-quality lubricant.

Correctly relubricating open gears and rack & pinion systems is now easier with the advanced open cellular polyurethane foam applicator from PLI. The low-density foam pinion holds in 9 0 percent of the lubricant volume, thereby avoiding hardening that can happen with conventional felt pinions. This saturation provides a proper lubricant film to ensure uniform coverage of equipment wear points. The applicator is available as standard straight and helical pinions and has operating speeds up to 20 feet per second. This product, when used with the MEMOLUB lubricator, provides a complete automatic lubrication system. MEMOLUB lubricators are available in three sizes and use low-cost pre-filled replaceable cartridges.

SKF USA Inc. www.skfusa.com 800-440-4753

PLI LLC www.memolub.com 800-635-8170

Single-point Jack Luber

perma Automatic Lubricators

ATS Electro-Lube’s newest single-point lubricator is the 125cc (4 ounce) Jack Luber. It joins the company’s family of single-use Origina l Electro-Lubers and the refillable, motor-driven Ultimate and Titan Series offerings. The Jack Luber operates on a programmable timer to release exact quantities of lubrication when needed. It can be mounted directly on a bearing or mounted as far as 20 feet away from the lube point. It is weatherproof and can operate in temperatures from minus-40 to plus-60 degrees Celsius (-40 to 140 Fahrenheit). The product is reusable by unscrewing the empty grease cartridge and replacing it with a new one, prefilled with the grease of your choice. It can operate on a replaceable battery

LE carries a full line of perma automatic single-point lubricators, including electrochemical and electromechanical units, which deliver lubricant at the right time, in the right place, in the right amount. Thes e pro ducts rep lace the need for rou tin e manual lubrication, thus lowering labor costs. They are commonly used on roller and sliding bearings, chains, motors, open gears, and conveyors. LE perma lubricators come filled with industryproven greases, including: Monolec Multiplex Lubricant (4622), Monolec Industrial Lubricant (4701), Almasol High Temperature Lubricant (1251), Almasol Syntemp Lubricant (9901), Almaplex Industri al Lubr icant (1275),

pack or be configured to run on AC or DC power.

Almaplex Ultra-Syn Lubricant (1299), Almagard Vari-Purpose Lubricant (3751 & 3752) and Quinplex H1 Food Machinery Lubricant (4024).

ATS Electro-Lube International Inc. www.atselectrolube.com 800-663-8141


Lubrication Engineers Inc. www.le-inc.com 800-537-7683



INCLUDES 3-DAY Noria Training Coupon See Page 3 for Details. Visit conference.reliableplant.com or call 800-597-5460

ONE BADGE. THREE CONFERENCES.

Opening Keynote Session Mark Swenson VP for vehicle production and manufacturing engineering, Nissan North America

Voices of Experience

PLUS Lubrication, Reliability and Lean Case Studies From:

Presented by practicing professionals for professionals, including: Kevin Desrosiers engineer, Anheuser-Busch InBev

Samuel Bethea director of N.A. maintenance and reliability, Campbell Soup

Claudia Faye reliability engineer, Alcoa

Eric Bigelow lean industrial engineer and continuous improvement expert, Yamaha Motor

• • • • •

Ene rgi zer B att ery Ala bam a Po wer El i Li ll y Good ye ar Frit o- La y

• • • • •

Ca rg ille-I l nland Temp Ra yt he on Xe r ox Mi lle rCoors

Welcome to Reliable Plant 2010 3 Co-Located Conferences The three co-located events at Reliable Plant 2010 supply the tactics and solutions for substantial advances in plant performance and profitability. The leading conference devoted exclusively to using effective lubrication practices to get the most from a plant’s physical equipment assets. These unique presentations, delivered by subject matter experts and successful lubrication practitioners, demonstrate how to achieve the efficiencies and financial benefits of a proper, proactive lubrication program. Spotlights the winning strategies and best practices that drive reliability results to the bottom line. Industry experts deliver compelling, practical learning sessions, with particular focus on case studies where the use of effective reliability strategies has led to measurable economic and productivity benefits. Identifies and examines the specific tools needed toquickly improve a plant’s total productivity, profitability, and safety and environmental performance. Case studies reveal how best-in-class companies use lean tools to improve the reliability and performance of their mechanical assets and overall operations.

Table of Contents Opening Keynote ....................................................................................3 What’s Included ......................................................................................3 Conference Schedule ..............................................................................3 Certification ............................................................................................4 Pre-Conference Workshops ....................................................................5

How You’ll Benefit From Attending and Implementing What You Learn • Secure answ ers and ideas to addr ess specif ic issues and needs at your plant • Acquire new sk ills you can immedi ately apply on the job • Go home with the b est tools and p rocesses to implement and sustain a successful plant reliability program

Company Advantages • More time o perating – less downtime • More output per hour – yield • Higher fir st-pass quality – few er rejects • Help develop a new gene ration of lead ers • Teams leav e with a common vis ion and understanding • Low maintenance cos ts – organizations with the highest reliability have the lowest maintenance costs

“OUTSTANDING! We’ve already seen a HUGE RETURN on our INVESTMENT

in attending this conference – and we’ve only just begun to implement the STRATEGIES we learned.” - Glenn Moore, Alcoa Mill Products

Lubrication Excellence Sessions..............................................................6 Reliability World Sessions ....................................................................10 Lean Manufacturing Sessions ..............................................................13 Exhibitor List..........................................................................................15 Take Home the Tools Game ..................................................................15 Hotel and Travel ....................................................................................16 Conference Fees....................................................................................16 Registration Form..................................................................................17

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For complete conference and expo information and updates, visit conference.reliableplant.com

Real Strategies. Measurable Results.

Opening Keynote Session From Adversity to Competitive Advantage: Sponsored by: Nissan Turns Over a New LEAF

Conference Schedule MONDAY, AUGUST 30 7:00 am – 6:00 p m Registration a t th e N ashville Convention Center 8:00 am – 4:30 pm Pre-C onference Workshops 5:30 pm – 8:30 pm Certification Testing (ICML)

Mark Swenson, vice president for manufacturing engineering and vehicle production engineering, Nissan North America Tuesday, August 31, 8:00 am Mark Swenson, vice president of engineering at Nissan North America, knows something about responding to a crisis. Mark had just been promoted to the Nissan leadership team in the late 1990s when the company salvaged its future by forming an alliance with France’s Renault. Mark will sharehis observations on how that crisis molded the company that Nissan became and how the experience in handling adversity has given the company a competitive advantage during the current economic downturn. Nissan has a steadily growing market share and is poised to become the market leader in mass-produced zero-emissions, all-electric vehicles with the production of the Nissan LEAF beginning later this year. In his keynote address, Mark will describe how Nissan’s forward-looking vision to promote sustainability, efficiency and quality has become part of the culture.

TUESDAY, AUGUST 31 7:00 am – 6:00 pm Registration at the Nashville Convention Center 7:30 am – 8:00 am Continental Breakfast 8:00 am – 9:20 am Opening Keynote Session 9:30 am – 10:50 am Exhibit Hall Grand Opening 11:00 am – 11:50 am Conference Sessions 12:00 pm – 1:20 pm Lunch in Exhibit Hall 1:30 pm – 5:20 pm Conference Sessions 5:30 pm – 6:30 pm Meet and Greet Reception in Exhibit Hall 9:30 am – 6:30 pm Exhibition Hours

WEDNESDAY, S EPTEMBER 1 7:00 am – 6:00 pm Registration at the Nashville Convention Center 7:30 am – 8:00 am Continental Breakfast 8:00 am – 9:50 am Conference Sessions 10:00 am – 10:50 am Refreshments in E xhibit H all 11:00 am – 11:50 am Conference Sessions 12:00 pm – 1:20 pm Lunch in Exhibit Hall 1:30 pm – 5:20 pm Conference Sessions 3:30 pm – 4:40 pm Refreshments in Exhibit Hall 5:30 pm – 6:30 pm Networking Reception in Exhibit Hall 6:00 pm – 9:00 pm Certification Testing (ICML) 9:30 am – 6:30 pm Exhibition Hours

Get a $1,195 Noria Training Coupon FREE Full conference registration includes an $1,195 training coupon you can use toward Noria’s training courses for up to one year. Use it yourself or give it to a co-worker to use for training. It ’s like attending the conference and getting Noria training for free! Terms and conditions below. Imagine the possibilities … • Attend Rel iable Plant 2010 in Nash ville. Then red eem your coupon for three days of Noria classroom or online lubrication best practices training. • Bring a gro up of 10 to Reliab le Plant 2010 in Nas hville for only $350 each. Get 10 coupons for Noria training worth $1,195 each.

THURSDAY, S EPTEMBER 2

• worker Attend Relia ble Plant in Nashv ille. Giveor your pon totraining. a cofor three days2010 of Noria lubrication oil cou analysis • Bring a group of 3 to Reliable Plant 2010 in Nashville for only $550 each. Get 3 coupons for Noria training worth $1,195 each. Terms and Conditions. Only one coupon will be issued per person. The coupon is transferrable within your organization and must be presented when registering for the training. The coupon is valid for Noria public training courses in the United States taking place between September 4, 2010, and September 3, 2011, or online training courses purchased prior to September 4, 2011. Coupons are given to full conference (Tuesday – Thursday) attendees who pay their conference registration fee and attend the conference. Speakers and exhibitors are not eligible unless paying full conference registration fees. Coupons may not be used for onsite training.

7:30 am – 11:00 am Registration at the Nashville 7:30 am 8:00 am 8:50 am 9:20 am

– 8:00 am – 8:50 am – 9:20 am – 11:10 am 11:15 am 8:50 am – 12:00 pm

Convention Center Continental Breakfast Conference Sessions Refreshments in Exhibit Hall Conference Sessions Giveaways in Exhibit Hall Exhibition Hours 3

Need a Reason to Attend Reliable Plant 2010?

TEAM D

I

S C O UN B ri ng y o TS ur team and cov session er all of s at Rel t he i a ble Plan See pag t 2 0 10. e 16 for details.

Here’s a preview of what you’ll be able to do after attending the educational sessions:

• Make lubrication PMs more effe ctive • Choose the be st personnel for lubri cation jobs • Employ pre cision greasing for rolli ng element bearings • Modify reservoirs and gear boxes for contamination control and serviceability • Use a ration al and syste matic app roach to selecting a new lubricant supplier • Design an effectiv e contamina tion contr ol program • Use best pr actices to consisten tly pull data-rich, representative oil samples • Spec a new filter cart to meet your exact needs • Reduce energy consump tion and operati ng expenses with a lubrication program • Control sludge and v arnish in lub ricants

• Provide effici ent maintenan ce systems whil e satisfying customer demands • Improve a conditi on monitor ing program through continuous improvement and measurement • Systematically engine er costs out of your maintenance budget • Use TPM to mov e from reac tive to pro active maintenance • Use more effec tive prob lem-solv ing methods in maintenance • Engage and invest in yo ur people to improv e your reliability program • Develop a FRACAS sys tem to drive equ ipment asset reliability • Determine whether an elect ric motor is truly

• Set oil targ et cleanliness levels

green • Build reliability and maintai nability into new or modified assets

• Conduct an audit to ident ify gaps in you r lubrication program

• Integrate energy managem ent into your reliability and maintenance strategies

• Convert to lubricant storag e best practi ces

• Apply lean manufactu ring conc epts within a non-manufacturing environment

• Maximize the talent of a team s o it works at the highest potential • Reduce your cha ngeovers from hour s to minutes with SMED • Accelerate operational improvement results by applying lean principles to maintenance and reliability

• Make effective use of kaiz en teams and kaizen projects • Dramatically reduce your cy cle times , as well as scrap and rework costs • Increase your inve ntory turn s and on-time delivery • Attain the le an goals of “bet ter, faster and cheaper”

Certification Set Yourself Apart as a Leader Among Peers

The International Council for Machinery Lubrication (ICML) will offer certification exam opportunities during Reliable Plant 2010. Advance registration is required. All exams will be conducted at the Nashville Convention Center on Monday, August 30, from 5:30 to 8:30 p.m. and on Wednesday, September 1, from 6:00 to 9:00 p.m. To learn more about the certification types, registration fees and exam preparation, visit the ICML Web site at www.LubeCouncil.org or call 918-259-2950

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Who Should Attend Whether you’re entry-level or a seasoned member of your plant’s management team, you’ll benefit from the comprehensive schedule of sessions, case studies and peer interactions. Attendees include:

Asset Care Planners CBM Coordinators & Specialists Chief Engineers Design Engineers Engineering Managers Engineers Facility Managers General Managers Hydraulic Specialists Industrial Maintenance Supervisors Industrial Mechanics Infrared/Vibration Technicians Lab Managers Lean Leaders Lean Managers Lube Analysts Lubrication Specialists Lubrication Technologists & Technicians Machinery Engineers Maintenance Engineers Maintenance Managers Maintenance Planners Maintenance Supervisors & Foremen Managers of Maintenance & Reliability Mechanical Engineers Operations Managers PdM Analysts & Specialists Planners & Schedulers Plant Engineers Plant Managers Preventive Maintenance Coordinators Preventive Maintenance Specialists Production Managers Project Leaders Quality Managers Reliability Coordinators Reliability Engineers Reliability Team Leaders Reliability Technicians Safety Managers & Directors Senior Reliability Engineers TPM Coordinators & Facilitators … and more



Case Studies at Reliable Plant 2010 Learn from These Practical, Real Life Examples

Pre-Conference Workshops Monday, August 30 How to Optimize Preventive Maintenance Plans Eliminate useless tasks and get more ROI from PM activities Drew D. Troyer, Sigma Reliability Solutions 8:00 – 4:30, August 30 Are you getting the return on investment you’d like from preventive maintenance activities? Do wasteful PM activities continue to drain your resources ? In this workshop, learn the logic and process for creating effective, optimized PM plans. You’ll first learn how to critically evalua te current PM plans to assess their value proposition. Then, you’ll learn effective decision-making approaches and when to choose each approach. Next, you’ll learn the process of building an enterprise-level PM plan for various equipment classes, and determine how to apply those plans at the site-specific and equipment-specific levels. The objectives for this workshop are to teach you how to: • Assess the value proposition of current preventive maintenance plans

How to Rate and Select Oil Filtration Make informed filtration decisions and eliminate costly trial and error Jim Fitch, Noria Corporation 8:00 – 4:30, August 30

Every day, contamination is robbing industrial lubricants and machinery of precious life. Most plants realize significant losses from lubricant contamination. But smart companies are taking action. By systematically reducing in-service lubricant contaminant levels, they are boosting machine and lubricant life. Small improvements in oil cleanliness are handsomely rewarded with dramatic declines in bearing replacements, pump failures, turbine and gearbox repairs, and more. The opportunity is significant, but selecting the right filtration for the job can be confusing. Filter performance ratings don’t align with oil cleanliness codes and there are hundreds of filter sizes and types to choose from, making it easy to specify too much or too little filtration. After this workshop, you’ll have a clear understanding of oil filter ratings and how to achieve oil cleanliness goals quickly and efficiently. You’ll make informed filtration decisions and eliminate costly trial and error.

• Eliminate tasks that fail to add value or actually create problems

“Contamination is the No. 1 cause of bearing damage that leads to premature removal.”

• Reduce the ambig uity of mainten ance task s

– TRW Bear ings Divis ion

• Avoid “PM stacking”, where condition monitoring tasks are incorporated in the plan but you fail to eliminate the time-directed tasks they’re

You will learn:

intended to replace • Standardize PM plans for enterprise-level deployment

• 3 types of filters to replace or upgrade immediately

• How to achieve target cleanliness levels at the lowest possible cost • How to understand oil filter performance and test specifications • Filter strategies that remove more contamination for less money • When and wher e offline filtr ation mak es sense

Pre-Conference Workshops

• Effective strategies for filtering high-viscosity oils

One-day with Full Conference Registration ...................................$375 ............... $450 One-day without Full Conference Registration.................................. ............

• 7 simple methods for getting longer filter life and educing r filtration costs • New and practical ways to reach oil target cleanliness levels 5

Learning Sessions

Essentials for Best-Practice Lubrication PMs and Inspections Jim Fitch, Noria Corporation

A Comprehensive Look at How a Temple-Inland Plant Changed its Lubrication Program

Designing Your Contamination Control Strategy Jarrod Potteiger, product and educational services manager,

Daily one-minute inspections can often be more effective Randy Hall, predictive maintenance technician, Temple-Inland Des-Case Corporation This session will help you design an effective contaminathan even the most sophisticated oil analysis program per-In this case study session, Randy Hall will share his informed monthly. The key is high frequency (daily) and the sights on the progress of the Temple-Inland Gypsum tion control program and the topics covered include: defining optimum fluid cleanliness levels, identifying the most costrevealing quality and thoroughness of the inspection. SimiWallboard plant’s lubrication program. Included in this preseffective measures to achieve those targets, and finally how lar to fishing, you can’t catch a fish unless your hook is entation in the are the improvements made to the lubrication to He effectively measure contaminant levels. You’ll learn the water (inspection frequency), and you’ve got to know how storage shed, servicing equipment and bulk oil filtration. most common lubricant contaminants, how they affect mato fish (quality of the inspection). Leading organizationswill have highlight the modifications that were made to reservoirs chinery and how to stop them. Plus, you’ll leave with some learned these skills. In this session, you’ll learn the techand gearboxes to help prevent contamination and make simple-yet-effective methods for analyzing the cost and benniques of these essential inspection practices. servicing easier. He will share some ideas that didn’t work efits of contamination control to ensure that available very well and what was done to correct them. He also will resources are deployed in the most effective way possible. provide a list of items used and where they were purchased.

What It Takes to Build an Award-Winning Lubrication Program Rick Staley, predictive maintenance analyst, Energizer Battery Company

Oil Sampling Fundamentals: A Step-by-Step Guide to Doing it Right

Causes, Effects and Mitigation of Varnish Jim Fitch, Noria Corporation

Varnish, sludge and surface deposits are a persistent In this session, Rick Staley will discuss the lean journey Jeremy Wright, Noria Corporation problem among lubricant users. Often, the problem has Energizer’s lubrication program went through – from dirtyProper oil oil sampling is critical to an effective oil analysis been entering the plant to its current status as an international program. Without a representative sample, further oil analy- extremely chronic, leading to expensive repairs and award-winner (2009 Augustus H. Gill Award recipient).sisHeendeavors are futile. There are two primary goals lost in production. While we know much more today about will stress pitfalls, challenges and how to gain support obtaining from a representative oil sample. The first goal is the to causes and some solutions, no silver bullet is currently to eradicate the problem entirely. This session fomanagement to get buy-in. He will coveroil analysis trending, maximize data density. The sample should be taken in a available way how early detection paid huge benefits and proper sampling that ensures there is as much information per milliliter cuses of oil on the current state of these problems and the future needs for a permanent solution. techniques. The presentation will consist of the fundamenas possible. This information relates to such criteria as tals, which is setting the foundation a strong cleanliness Also and dryness of the oil, depletion of additives, covered will be standardstothat must beprogram. maintained andtothe presence of wear particles being generated by the prevent setbacks (it’s much easier to hold astandard than to machine. The second goal is to minimize data disturbance. “The Future Significance of FTIR for slip and have to rebuild), performing auditsfor these set stanThe sample should be extracted so that the concentrationCondition Monitoring Analysis” dards, and choosing the correct personnel for positions.of information is uniform, consistent and representative. It is also important not to contaminate the sample during the David Pinchuk, co-founder and president, Thermal-Lube Inc. sampling process. In this session, you’ll learn the sampling This presentation will review the new ASTM accepted procedures, sampling hardware and sampling locations for practice and methods for FTIR analysis of in-service lubriWhat Makes a Good Lubrication PM? getting the best possible, consistent oil samples. cants. It will also detail the direction FTIR research is Mark Barnes, Noria Corporation heading using indirect engineered chemical markers to generate quantitative (in lieu of qualitative), repeatable and Lubrication preventive maintenance (PM) tasks traditionreproducible data such as acid content, base number, ally have been vague at best. It is still not uncommon toBest Practices for Analyzing Used moisture and fuel dilution. come across a lubrication PM fora critical machine that simLubricating Grease ply states: “Lubricate the machine.” This special double session will explore what really makes a good lube PM David and Turner, lubricants technical advisor, Shell Global what format it should be presented in. You’ll learn whySolutions and Lubrication’s Role in Equipment how to use a variety of formal PMs, which include full referThe analysis of in-service lubricating grease is often a Energy Consumption ence procedures for the newlube technician, task sheetschallenging for task, since the amount of grease in many apthe experienced tech and visual documents for operators. plications is quite small, the grease is often totally replaced John Sander, vice president of technology, each time new grease is added, and access to the lubriLubrication Engineers Inc. cated contact zone may be difficult. Many commercialToday more than ever before, plant managers are driven in-service lubricant analysis laboratories lack the specialto reduce operating costs. Yet due to government regulaSelecting a New Lubricant ized test equipment required for grease analysis, so that tions, they are now being asked to do things that are in type of analysis is performed by a limited number of labodirect contradiction to reducing costs, such as increased Supplier – Beyond Price safety measures and reducing plant emissions. Surprisratories, primarily those of the grease manufacturers. Mark Barnes, Noria Corporation ingly, one of the major ways to achieve these goals is Various techniques are employed to determine both the There’s more to selecting a new lubricants supplier than through their lubrication program. It may seem far-fetched macro and micro condition of used lubricating grease. the price of lubricants. Price does play a role, but today, that something as seemingly minimal as lubricants can proThose techniques, their strengths and weaknesses, and most suppliers offer a range of products and services to vide hidden returns. This session will describe exactly how how the results are combined to provide a complete picture support your lubrication excellence initiatives. This session a plant’s energy consumption and emissions can be deof the state of grease lubricated equipment are discussed will help you navigate the window dressing and help you creased while reducing and operating expenses through a in this session. A few case studies are included to illusformulate a rational and systematic approach to selecting trate the value of analysis of used lubricating grease. plant’s lubrication program. a new lubricant supplier.

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Your full-conference badge gets you into sessions from all three co-located conferences.

Oil Analysis Gets to the Root of a Power Plant’s Gearbox Problem


Strategic Greasing for Rolling Element Bearings

Managing Risk with Food-Grade Lubricants and the HACCP Program

James D. “Pete” Peterson, senior CBM specialist, Stephen Sumerlin, Noria Corporation Stephen Sumerlin, Noria Corporation Alabama Power Company When compared to other lubrication tasks, greasing is Determining where food-grade lubricants should and This case study session explores the action plan of Alaone of the more simple tasks in execution, but it can prove should not be used is sometimes a tricky and tedious task bama Power Company when a problem was discovered onto be a difficult task to execute without flaw. This session simply due to misguided regulations and improper in-house will explore the strategies for proper greasing techniques a pulverizer gearbox. This was the very first “find” that the techniques. The Hazard Analysis and Critical Control Points the program was developed to aid in determining critspeaker was involved in after being brought on to the for element bearings, and will expand your perception of(HACCP) and precision that is required to get the most ical points and their safety hazards related to contamination plant’s condition-based maintenance team. It provides dedication a from each stoke of the grease gun. and key health and safety risks. The primary area of use for good demonstration of the importance of having “in-house” the HACCP program is the food and beverage industry, but oil testing capabilities. industries such as pharmaceuticals and cosmetics are adopting the program now as well. This session will discuss Lubrication Program at Goodyear: the HACCP program and show how food contamination can Goals, Gains and Challenges of Achieving Hydraulic and Lubrication be limited with the use of food-grade lubricants.

System Reliability in a Tough Environment Multi-Plant Deployment

Mike Shekhtman, manager of maintenance and reliability, Aaron Hoeg, operations manager, Hy-Pro Filtration Goodyear Tire & Rubber Company Preventing Ingress Contamination Saw mills operate multiple pieces of large equipment Practicing Lubrication Excellence in a large-scale manuwith sensitive hydraulic and lubrication systems. When through Bearing Cavity Pressurization facturing facility with intricate equipment of great variety this equipment faces unplanned downtime due to imporpresents significant challenges. Doing so in a multi-locaHenry Dombroski, president, Air-Tight LLC tant components becoming fouled from contaminated tion organization with every plant having both their In this session, you’ll learn about prevention of ingress lubricants, profits decrease while production costs inindividual advantages and their own issues of manufacturcontamination by means of: 1) hermetically sealing the bearcrease. Applying a total systems cleanliness approach is ing objectives, technical expertise, historic cultures, ing cavity; 2) pressurizing the bearing cavity with low air or necessary to maximize uptime, extend component life, exresources allocation and local collective bargaining agreenitrogen pressure; 3) controlling the pressure in the bearing tend fluid life, reduce maintenance resource demands and ment precedents is a much more demanding task. In thiscavity 24/7; 4) giving a visual indication of the amount of reduce fluid disposal costs. session, the speaker will show what Goodyear is trying to pressure; and, 5) indicating bearing cavity integrity 24/7. If

This approach was implemented recently at a saw millachieve, how it attempts to address weaknesses and leveryou have current bearing contamination issues, and have by upgrading existing filter elements, breathers and adding age strengths, and where the company is in the tried everything, attend and learn about these alternative additional dedicated off-line filtration where suitable. implementation process. methods for preventing ingress contamination.

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was great! I will be applying many of the products and processes in my plant immediately.” 7

Learning Sessions

Best Practices for the Use of Off-line Filtration Units

How to Use a Lubrication Program Audit Expert Advice on Creating a to Increase Equipment Reliability World-Class Lube Room

Christopher Eger, product manag er for oil services, Schroeder Industries

Tom Hiatt, reliability engineer, Covance Inc., and Wayne Ferguson, associate consulting engineer– reliability, Eli Lilly and Company To have the best off-line filtration requires that you un-

Rick Staley, predictive maintenance analyst, Energizer Battery Company

Rick Staley was instrumental in transforming the lubri-

derstand three basic areas: What are particulate, waterThis session provides an overview of the development cation storage room at Energizer’s factory in Maryville, and gas contamination? What does contamination cost and performance of a lubrication program audit. These auMo., into a world-class example of organization, cleanliyou? Where are you in regards to contamination and where dits lead to the creation of an action plan that addresses ness and functionality. In this session, he will share the do you need to be? After understanding the basics of conthe gaps in your lubrication program, and if implemented, lessons learned from the transformation at Energizer and tamination, what products are available in the market will to lead to an improvement in equipment reliability. Lubriwill outline what’s required for creating a world-class luprovide you with a solution? Off-line filtration systems cation inaudits measure your current program practicesbrication storage room at your facility. Topics and tips will clude filtration carts and skids, contamination monitors, range from storage and filtration to br eathers and spill conagainst industry “best practices.” dehydration systems and diagnostic equipment. tainment systems to identification and safety measures.

MillerCoors’ Approach to Lubrication Excellence and Asset Reliability Leonard Bouwman, manager for asset management, MillerCoors

Attend this session and gain the knowledge to make over your lube room.

Specifying Filter Carts Correctly for Maximum ROI

Setting Up a Cost-Effective Preventive

Jeremy Wright, Noria Corporation

Filter carts are an ideal way to periodically decontami-Maintenance Program nate lubricated systems. Every filter cart should be Increasing pressure to drive out operational cost Tor Idhammar, president, IDCON compatible with the lubricant and the intended application. throughout the manufacturing organization in a highly comWhen considering the addition of a filter cart to your con-This presentation discusses how operations and mainpetitive beer market necessitated a radical shift from should closely integrate equipment and process tamination control program, there are many things tenance to reactive maintenance to one of being proactive. This sesinspections and preventive measures in a cost-effective consider. This presentation will cover all of the variables sion will share some of the steps covered to show a 26 manner. Several simple steps, tools and thought processes that need to be accounted for to help determine exactly percent improvement in machine efficiencies. It features that you can apply in your plant immediately will be disthe integration of maintenance into operations as part what of details you need to pr ovide your supplier. The leading cussed. You will see examples of inspection standards for suppliers will be able to design the filter cart to meet your fully integrated team structures, where operations owns production, maintenance, quality, service and safety. Atexact needs, giving you the most for your investment. common components using colorful andineasyto-understand Excel data sheets thatdocuments you can use your tend this session and learn how an increase in performance organization to analyze cost-effective PMs. Financial tools can defer the need for capital expenditures by getting curfor analyzing which maintenance method is most cost efrent installed capacity to perform optimally. The 100 Failure Modes of Lubrication fective will also be presented.

from RCM Analysis

One Hydraulic Filter for Your Entire Factory – Is it Possible?

Terry Harris, president, Reliable Process Solutions

Understanding failures modes of your equipment,The Benefits of Synthetic Greases processes and individual components is an important funcKim Smallwood, product line manager – greases, CITGO Garret Hendrix, owner, Hendrix Engineering tion. Every manufacturing or processing plant has rotating Synthetics offer persuasive options that can go a long Purchasing, tracking and stocking dozens of different hyequipment that is performing plant functions. When this ways in helping to solve maintenance and performance isdraulic filter elements burdens many companies and hasequipment a stops working, your processes cease to perform sues. It is to this effort that a fundamental review of these negative impact on hydraulic reliability when replacement their designed expectations. The negative impacts are operadvantages is being presented along with evaluation of elements aren’t available. This session will introduce you to downtime, reduced capacity, lower quality and EH&S ations case studies relating the use of synthetic greases. hydraulic filter standardization based on SAE Standard incidents. Reliability-Centered Maintenance can be used to J6022, with the ultimate goal of using only one filter element define these failure modes. Lubricants and lubrication protype for the entire factory. A case study of a standardization grams have more than 100 failure modes that can be defined project implemented for a Tier 1 automotive supplier having and controlled. Understanding each failure mode can helpMethods for Comprehensive more than 160 hydraulic power units, and approximately 80 plant decide how to prevent and eliminate each of them. your Contamination Control in different filter types and sizes will be presented.

Industrial Fluid Applications

How to Set Oil Target Cleanliness Levels

How Cargill Transformed its Lubrication Practices at its Sioux CityFacility

Christian Bauer, staff scientist, Pall Corporation

In this session, you’ll hydraulic learn the common of contamination in industrial and lube types systems, the devastating effects of these types of contaminants and effective methods for controlling and reducing them. The Controlling particle-induced machinery failures must This session will explain the evolution of a machinery lubenefits of implementing a comprehensive approach to begin with defining a customized standard of oil cleanlibrication program, focusing on the oil portion. The speaker cleanliness control, coupling high-efficiency filtration sysness for each machine that it affects. This session reviews tems for the removal of particulate contamination with the range of methods used to define the correct targetwill detail the past, present and future of lubrication at the plant. He will cover everything from pulling oil samples,vacuum setdehydration purifiers for the removal of free and cleanliness level and the most critical influencing facting up gearboxes, handling and storing oil, filtering and dissolved water, and diagnostic instrumentation for meastors. You’ll learn the most reliable and effective tools used setting up permanent filtration on bigger assets as well urement as of levels of particulate and water contamination in the lubrication field relating to setting cleanliness goals assets that are almost impossible to safely access. will be discussed. and establishing contaminant tolerance. Jim Fitch, Noria Corporation

8

Troy Rooney, lubrication technician, Cargill



Dynamic Equilibrium Revisited – The Behavior of LargeParticles in Lubricating Oil Thomas G. Barraclough and Daniel P. Walsh, Spectro Inc.

How to Develop a World-Class Lube Program Through aTeam Concept Tom Hiatt, reliability engineer, Covance Inc., and Wayne Ferguson, associate consulting engineer – reliability, Eli Lilly


Establishing an Effective ConditionBased Oil Analysis Program for Wind Turbines Dave Wooton, principal, Wooton-Consulting, and Greg

Developing a world-class lubrication program takes Livingstone, a executive VP of marketing and technology, Fluitec The term “dynamic equilibrium” describes the process by which particles of a given size range reach their own unique concerted effort to implement and sustain. From the lubri-This presentation will outline how to establish an effeccation technician to the lubricant supplier, teamwork is the equilibrium level. It is these levels which can be used to tive CBOA program for wind turbines. Interested attendees keyob-to success. In this session, you will get an in-depth trend and set alarms. This result is often not intuitively of this session are those that are involved with establishview of the path we took to build an award-winning provious when setting up an oil sampling strategy. This session ing oil analysis programs, operators of wind turbines and gram. You will learn the benefits of a lubrication program revisits some previously documented mathematical modservice providers (including labs, filter manufacturers, gearand how to get started on your own path toward success. els on this subject that show from first principles how box manufacturers, service companies, etc.) to the wind particles of a given size reach a ceiling value. energy market. They will learn the basics of establishing a condition-based oil analysis program and how that is apHow to Interpret an Oil Analysis Report plied to wind energy applications.

Reduce Water Content, and Save Oil and Cash withVacuum Dehydration

Stacy Heston, field servicesmanager, POLARIS Laboratories

Reading an oil analysis report can be an overwhelming An Explanation on the ISO-Based and sometimes seemingly impossible task without an Changes to ICML Certification Programs understanding of the basic fundamentals for interpreting laboratory results and recommendations. This session will Suzy Jamieson, executivedirector, In this case study session, learn how in a rece nt steel mill explain the cause and effect relationships between certain International Council for Machinery Lubrication rolling mill application, vacuum dehydration reduced the test results and how the changes or trends in these resultsISO 18436-4 is the first international standard on qualiwater content of an 8,000-gallon reservoir from 29,000 ppm affect the maintenance recommendations made. It will fication also and assessment of field lubricant analysis (2.8%) to 17,735 ppm (1.7735%) in one day. Over two weeks, stress the impact of accurate and complete equipment and the water content fell to 383 ppm (.0383%). Applying vacpersonnel. This session will explain in easy-tolubricant information on the severity assigned to the report. uum dehydration also allowed the mill to end the decanting understand terms the career path outlined in this ISO Knowing the components of an oil analysis report and how routine, saving 25,200 gallons of oil (valued at approximately for lubrication and analysis professionals. The they relate to the condition of the component and the standard luJon P. Michel, engineering and maintenance manager, ArcelorMittal, and Richard Trent, technical field services manager, Hy-Pro Filtration

$201,600) annually and decreasing lubricant disposal costs. bricant will take the mystery out of reading an oil analysis presentation will cover the purposes, categories, requirements and syllabus as per this standard, as well as the report and allow users to make the most of the maintealignment ICML’s certification program has undergone to nance actions recommended. Ensuring Pump Reliability with Oil Mist reflect its equivalence to ISO 18436-4 categories and the Lubrication role it has played in the development of this and other upNew Methods for Analyzing In-Service coming standards of interest for the lubrication and Don Ehlert, manager of EPC sales and business development, analysis professional. Lubrication Systems Company

Greases

New technology always brings a learning curve, and oil Rich Wurzbach, president, MRG Labs mist has had its share of misapplications and misunderstandings. Systems installed in the 1960s over-lubricated,This session will discuss the challenges and options to obtain representative and consistent grease samples from plugged up and were not reliable. During the late 1970s motors, gears and other critical equipment. It also will intro- TEAM DISCOUNTS and into the 1980s, the systems were studied and examduce a new method for reliably and repeatably determining Bring your team and cover all of the ined to better understand the shortcomings and what was changes in consistency for samples of grease as small as 1 needed to make them more reliable. With renewed interest sessions at Reliable Plant 2010 and save gram, and efficiently preparing those samples for subsequent and determination, the modern-day oil mist systems are up to $645 per person by oil analysis lab equipment to determine wear, extremely reliable. Come learn about oil mist and how analysis it oxidation, contamination and consistency conditions. can work for you.

HYDAC / Schroeder Industries Networking Reception Nashville Convention Center Wednesday, September 1 Sponsored by: 5:30 - 6:30pm

9

Learning Sessions

Building The Total Maintenance System

Improve Operator Confidence and Reduce Errors withDecision Trees

Samuel Bethea, director of NorthAmerican maintenance and reliability, Campbell Soup Company Julien Le Bleu Jr., SageGuides.com

All I Really Need to Know About Maintenance I Learned in a Nuclear Submarine

This session will examine how the application of process Decision trees – logical, visual tools that list relevant Ned ques-Mitenius, senior consultant, Periscope Consulting management, Six Sigma and other facetscan enhance maintions and likely outcomes – can be highlybeneficial in leading Share everything. Play fair. Don’t hit people. Hold hands tenance processes and the implementation of an optimized trained operators to fact-based conclusions. To be useful,and thestick together. We learned these practices in kindermaintenance strategy. Driven by the need for improvedquestions supasked must be straightforward, such asthose that garten and can apply the wisdom of them to life today. The ply chain efficiencies such as lower inventories and by operators are likely to run into on a regular basis (“Is the oil for this session learned maintenance and operational speaker producing to the demand schedule of customers, maintetoo hot?” “Is the level too low?”“Is there too much vibration?) practices 30 years ago aboard U.S. Navy nuclear subnance teams have had to become nimble and flexible in The theirbeauty of a decision tree methodology is that, if agreed marines, achieving greater than 99%system reliability. These approach to establishing maintenance efficiency. You’ll learn to by management and followed faithfully by operating perpractices are directly transferable to manufacturing industry ways to navigate the needs to satisfy customer demands sonnel, it makes doing the correctthing clear-cut and easy. today. Design. Train. Clean machines. Follow procedures. while providing efficient maintenance systems. MethodsManagement of will see better decisions and reduced Standardize. Lube. Listen. Inspect. Record/Analyze. Stock. integrating maintenance best practice tools into the day-tomaintenance costs by incorporating decision trees into the Motivate. Be accountable. Drill. How can these prac tices be day manufacturing process to facilitate optimized operating culture. For example, by training operators toapplied use today to your factory to improve your reliability? maintenance will also be discussed. a logic tree for pump decisions, a petrochemical facility reduced maintenance overtime by 30% by reducing the number of pumps that were not repaired on an emergency or expedited basis. Successful Reliability Program

How to Maximize Your Condition Monitoring Program and Really Impact the Bottom Line

Alain Pellegrino, reliability technician and senior technical consultant, Laurentide Controls

Implementation Begins with Strategic Planning and Key Partnerships Effective Problem Solving in the Clay Calk, Lubrication Engineers Inc. Maintenance and Reliability Organization Most maintenance professionals understand the impor-

John Crossan, former manufacturing and maintenance leader tance of implementing or upgrading a reliability program, In recent years a lot of plants have invested in condition and they already have the knowledge and training about (recently retired), Clorox Corporation, and Randall Quick, monitoring technologies. Many realized early successes what to do and how to do it. Unfortunately, because of the engineering manager, Manufacturing SolutionsInternational and reduced downtime, improved availability and lowered Most companies still use the traditional approach of daily hav- demands and responsibilities of their jobs, the need to maintenance costs. But many investments haven’t realized

their full potential. We have new tools but still use theming the elite groups and then pass their solutions increase production outputs and the constant required to keep critical systems running, they“firefighting” often fail to to those whosolve mustproblems, now actually do the work. Using this old way. Using a real case study of a large zinc smelter,onthis allocate enough time to the strategic planning that is cruapproach, you can get to adequate performance. You might session describes the strategies deployed ot improve a coneven get to good, dependingon your definition of “good”.cial Butto program success. dition monitoring program through continuous improvement inand measurement. You’ll see how these improvementsyou im- will never get to excellent. Excellence takes routine Strategic planning and key vendor partnerships can simvolvement at all levels, using problem situations as ways to pact the plant’s bottom line, and how small, continuous plify the strategic planning process and provide the and develop people, rather than just as issues to improvements can change the way you do business intoinvolve a answers to these questions, paving the way for a seamsolve. new “business as usual” that is more efficient and cost ef- John Crossan and Randy Quick have worked on operless, turnkey program customized to fit the company’s ational and maintenance improvement at the shop-floor level fective, directly impacting the bottom line. reliability objectives. To be successful, the program should in plants for many years. In this session, they will describe address the needs of the maintenance staff, source all maways to build this routine involvement and development. terials required for installation, ensure onsite assistance through all phases of implementation, provide education Failure Reporting, Analysis and and training to staff, and set up the metrics and tracking Corrective Action System (FRACAS) Bearing Life: If 90% of Bearings that justifies the program’s overall cost.

Strategies for Manufacturing

Drew Troyer, Sigma Reliability Solutions

Outlast the Asset They’re Put In, Why Don’t Mine?

Data is the difference between deciding andguessing. In a Equipment Failure Modes:Your Dave Staples, business development manager, benchmark study by the AberdeenGroup, 59% of top-quartile Components Can Last Forever! SKF Reliability Systems performers utilize real-time and historical asset performance In order to make predictions regarding bearing life, most data to drive decisions and actions, compared to 21% for the Terry Harris, president, Reliable Process Solutions do the L10 math. However, theory doesn’t always reprelaggards. Top performers report 88% OEE and 2% unschedIn this session, you’ll learn the various failure modes that sent reality. The bearing didn’t reach end-of-life because of uled downtime, compared to 75% OEE and18% unscheduled lead different components down the path to early wear-out. metal fatigue; it failed sooner. It failed, perhaps, due to facdowntime for the laggards. FRACAS is about leveragingdata By using methods from RCM analysis and FMEA, you’ll extors not considered in the L10 calculation, like wear, to improve decisions and is the process for gathering inforthe failure modes of some basic equipment and contamination, misalignment, corrosion, or as a result plore of mation about failures and other losses, analyzing them, and components in most industrial plant operations. cage, lubrication or seal failure. The L10 calculation is equipment an creating and implementing corrective actions as required. For every example, a proactive or precision technique will older theory based on traditional ISO and ABMA standards. be presented and discussed. Can a motor last for 10 to 15 Unlike FMEA, which is predominantly utilized in the deThis does not take into consideration operating conditions years without failures? Can a bearing last 30 years without sign phase of the asset’s life cycle to hypothesize potential that are considered by newer calculations like the “New failing? Can belts and chains last five to six years without failure modes and effects, FRACAS is more “real world” Life Theory” or the “Adjusted Life Theory”. Bearing life can failing? These and many other components of plant operatand empirical. In this session, you’ll learn how to develop be calculated with different degrees of sophistication and ing equipment will be studied. For every dollar you save in a FRACAS system and then use the collected information (as a result) accuracy, depending on the knowledge of the maintenance due to improved equipment reliability, there is to drive equipment asset and manufacturing process relireal operating conditions and environmental variables. This ability and p rofitability. session will take a look at these newer calculations. another $5 to $10 added to the bottom line.

10



Strategies for Energy Management and Energy Reduction Johnny Bofilios, director of global asset sustainability, INFOR


Moving from Reactive to Proactive: How to Get TPM Working for You

The Secret Asset: What’s Missing in Your Reliability Program?

Ellis New, senior management consultant, Productivity Inc.

Larry Hoing, reliability and engineering systems manager,

Wells Dairy It is well known that there is a direct connection between Moving from reactive maintenance to proactive mainteAsset performance is the name of the game in everyone’s the reliability of assets and their consumption of energy. nance In requires a whole new look at theway the maintenance

fact, energy use is a leading indicator of predictive performprocess is managed. To reach this goal, you must declare book. war The thought process is, if we can increase our asset which increases our return on net assets ance of an asset. But what are the strategies to start on unplanned equipment downtime due to failure andbuildperformance, a (RONA), then this will help us lower the total cost of goods managing and reducing your plant’s energy? Did you know maintenance organization unburdened by firefighting. Movsold and increase our profit margins. Simple, right? So, why that you can factor energy use with asset management ingtofrom technical fixing to equipment management means is it that a large number of companies never fully achieve maintain and extend the life of equipment and, therefore, having reliable and available equipment providing the flexibilthe net positive results of the investment to improve their lower your costs? In this session, find out the best pr actices ity necessary to substantially reduce costs and generate assets, or if they do have some improvement, they cannot to integrate energy into your reliability and maintenance additional income by increasing overall capacity. sustain it for any period of time? Have you considered your strategies so you can start identifying, optimizing and au-In this session, we will look at what it takes to transipeople assets in the same way that you do your physical tomating proactive maintenance, comparing both the asset tion from reactive to proactive by using the principlesassets? of Most every company mission or vision statement performance and its energy usage across your enterprise. Total Productive Maintenance in an accelerated and costincludes the following sentence. “Our people are our greatThis presentation will be based on case studies of a higheffective manner. We’ll look at the pillars of TPM and how est assets.” Is this really true? Do we really invest in and profile paper manufacturer, a well-known East Coast and when you implement them to get the biggest return continuously in improve our people assets? How many imuniversity and a Tier 1 automotive manufacturer, who the haveshortest perio d of time. Plus, we will tal k about the provement or updating activities did we do for them in the already reduced energy consumption by a minimum ofproper 6% use of predictive technologies and learn what is neclast fiscal year? Oh yeah, that’s right, the training budget and reduced their carbon emissions at the same time. essary to build strong, effective teams to support an overall was the first thing to go in the budget-cutting process. The equipment reliability improvement effort. fact of the matter is we cannot perform at a higher level of asset reliability and not invest in a skilled, well-informed, During this session we will explore: Predictive Maintenance/Condition well-educated and engaged workforce. The key for success • The role of TPM in a lean implementation in any reliability or lubrication program is the people. Monitoring Through Airborne • The benefits of a team-based approach to equipment care Lubrication is the cornerstone for any reliability program. UltrasoundTechnology • Root cause tools like visual management, checklist The cornerstones for a successful lubrication program are and CMMS to guide your transition Mark Goodman, vice president of engineering, the people. How do you invest in your people to make them UE Systems Inc. successful? How do you grow or revive a lubrication pro• The use of predictive maintenance technologies as Instruments based on airborne/structure-borne ultra- part of the overall effort gram? What are the keys to success? Attend this session; we will explore some of the possibilities of how to engage sound technology offer many opportunities for plant-wide• The importance of building people’s capabilities to some of your greatest assets – your people. predictive maintenance activities, ranging from determin- sustain the effort ing a lack of lubrication to locating compressed air leaks. Usually portable, these instruments are used to trend and• The significance of having operators involved maintenance activities analyze bearing condition, detect leaks, identify electrical What Makes a Good PM, and How to problems such as corona, arcing and tracking, and identify• Transition metrics, standard work and proactive mainMake Sure It Is Executed Properly potential problems in operating mechanical equipment. Thistenance policies presentation will provide a brief overview of the technology, Jeff Shiver, managing principal, People and Processes its applications and suggested inspection techniques. In a recent survey of more than 1,300 plant professionHow to Really Use Metrics and KPIs to als in 40 countries, 62% said they either did not have a preventive maintenance program or are in the process of Improve Your Maintenance Program building one. Do you have a real program? A better quesHow to Systematically Engineer Costs Kevin Desrosiers, engineer, Anheuser-Busch InBev tion might be “How would my engineering and operations Out of Your Maintenance Budget Maintenance practices and execution can't improve with‘partners’ respond to a similar survey?” Can you truly measout continuously measuring where you are and taking steps ure and communicate the success your PM program Drew Mackley, product line manager, to improve. But what are the right metrics or key performEmerson Process Management generates to ensure a favorable survey response from all" partners? What would happen if you were asked that those In an increasingly competitive market, organizationsance are indicators? Unfortunately, there is no "one size fits answer. A maintenance organization in the early stagesquestion will in a court of law? Does your CMMS data support challenged to run their plants more profitably and with measure differently than one with a well-established pro“perceptions” or “reality”? Do you know if your data is the greater efficiency. Yet mechanical equipment deteriorates, gram. If you are maintaining airplanes where a failure could result of “pencil-whipping”? Are the PM task activities the causing a decrease in performance, a reduction in throughbe catastrophic, you will look at maintenance differently “right” work and value-added? How can you tell? put and a rise in operatingcosts – or an unplanned shutdown grinds production to a halt, resulting in a large loss inthan rev- you would for a series of pumps where there is re-This presentation will address the components of a good enue. Deterioration in machinery health and performance dundancy is and failures do not have a major impact. PM and methods to ensure the PM activities are executed usually associated with misalignment or imbalance, corroIn this session will discuss various maintenance KPIs properly. In addition to the PM components necessary, learn sion and wear, fouling, sediment buildup or poorly lubricated how they can be used (or not used) when evaluating your tools and techniques for establishing an effective PM process, parts. Detecting these underlying problems early allowsmaintenance you program. You'll learn how to benchmark your adding a continuous improvement loop for optimization, to correct issues before they affect your process, optimizing maintenance program for both content and costs and dismeasuring the value of the PM program and inspecting to enthe performance of your plant. In this session, we will focus cuss what to do if people find ways to "cheat" the metrics. sure the right execution. Understand why pencil-whipping on best practices for planning for and implementing thePlus, pre- you'll learn how to use the KPI data to improve rather occurs and how to break the habit. Gain insights on commudictive maintenance technologies and services necessary than as a hammer. Regardless of where you are in your nicating and managing the perceptions with your operations for cutting expense out of your maintenance budget. Realmaintenance evolution, you'll get several new ideas on and howengineering partners to eliminate disconnects so that world examples and case histories will be included. to improve their maintenance program. everyone is on board with the value your organization adds. 11

Learning Sessions

How to Determine Whether a Motor is Truly Green Noah Bethel, VP of product development, PdMA Corporation

Reliability: The Ultimate Green Initiative Robert Apelgren, Reliability-Centered Maintenance analyst, ITT Corporation

Overcoming the Challenges to Implementing an ISO-Certified Asset Management Process

The ever-present emphasis on technological efficiencyThere is a new focus in society for “going green” in alRamesh Gulati, asset management and reliability planning most everything we do. Manufacturing is no exceptionmanager, and is just one of several forces behind the pressure on comAerospace Testing Alliance at Arnold Engineering Development Center panies to “go green” despite a trying economy. The ultimate has been negatively impacted by diverting funds to green This generates no revenue and can carry in-This paper will discuss quality systems requirements for criterion that determines whether a motor is truly greeninitiatives. is creased cost, which affects a company’s competitive energy efficiency. Technology, long the key to efficiency, physical asset management and what challenges are faced viability. Many times, these diverted funds come from other can help resolve this issue through detailed computerized to establish an effective system that is compliant with inthat have a heavy impact on reliability. Reliability is analysis of the motor, the power environment in whichareas it ternational standards ISO 9000 and PAS 55. ISO 9000 is a operates, and even its reliability. the ultimate green initiative. Though rarely referred to family as of standards for quality management systems, in“green”, it is most beneficial to the company, consumer cluding and the management of physical assets. PAS 55 – the environment. Reliability is achieved through the culmiOptimal management of physical assets is a Publicly Availnation of training and various tools from reliability analysis, able Specification published by the British Standards So What’s the Need for root cause, maintenance planning and scheduling, and preInstitution. The latter gives guidance and a 28-point rePredictive Maintenance? dictive technologies. Proper employment of these tools quirements checklist of good practices in physical asset leads to many “green” benefits, which include energy management. effiAsset management at the Arnold Engineering Terry Haycraft, national reliabilitymanager, Frito-Lay ciency, waste reduction and increased productivity. InDevelopment this Center (AEDC), located at Arnold Air Force Each 0.1 percent of equipment downtime reduction gets session you’ll learn how to employ Reliability-Centered Base, has been an ISO-certified organization since 2004. tougher to get each year. As seasoned mechanics retire Maintenance effectively, how to set goals, and how to defrom Frito-Lay’s workforce, the company’s cannot afford termine when to start investing in other green initiatives. the “learning curve” for new mechanics. In many cases, ac-

cording to this session’s speaker, there is no directfeedback The Critical Elements of Procedureon corrective or preventive maintenance jobs in the CMMS. Based Manufacturing Frito-Lay needed tools to start the transition fromHow to Maximize the Life Cycle time/usage PMs to condition-based predictive maintenance Drew Troyer, Sigma Reliability Solutions Costs of Production Equipment and help it avoid the premature failure due to unnecessary Standard operating and maintenance procedures can proover-lubrication of equipment. This session will provideClaudia a Faye, reliability engineer, Alcoa foundly influence the reliability of your equipment assets and brief overview of the company’s Alpha / Beta sites utilizing If 85 to 97 percent of base life cycle costs are commitmanufacturing processes. A recent study found that 70% of the Ultraprobe 10000 and Utraprobe 201 Grease Caddy that ted by the time that equipment is handed over to top-quartile performers employ documented operating and achieved enough positive results to quantify the implemenoperations and maintenance, then life cycle costs (equal maintenance procedures, compared to 20% of the lower-quartation of the predictive technology on a national level. to approximately 20 times the total installed cost) can tile be performers. Top-quartile performers enjoy an 88% OEE, to 75% for the lower-quartile performers. Their most influenced during the capital process. However, 3compared to downtime is only 2 percent, compared to18% for the lower15 percent of life cycle costs can be influenced outside the Effective Inspection ofSteam Traps quartile performers. In another study, it was discovered that design, purchase, construction and installation of new and Valves Through Ultrasound equipment. How can businesses really affect their cost75% of of what goes wrong in the factory is, in fact, human error. The same study revealed that lack of procedures tops the list production? Attend this session and find out! Paul Klimuc, national service manager, SDT North America of reasons why. In this session, we’ll discuss: why procedureThis presentation will cover how ultrasound allows for based maintenance is so critical to your success, how to the effective inspection of steam traps and valves. It will convert tacit knowledge into documented knowledge, and Plant System Reliability with On-line also explain the basic principles of how ultrasound detects how to deploy your preferred practices enterprise-wide. Condition Assessment leakage and other basic faults.

Design for Maintainability and Reliability: How to Get Everyone on the Same Page

Wayne J. Chatterton, Ph.D, technical applications sales manager, UtilX Corporation

Get Your Head in the Clouds -

On-line condition assessment analyzes the entire powerMachine Condition Monitoring system when current activity is at operating voltage. Noand PdM over the Web switching operations or outage time occurs while this caD. Corak, Eric J. Olson and Daniel P. Walsh, Spectro pacitance testing is performed. The entire system Robert is Inc./QinetiQ North America Ramesh Gulati, asset management and reliability planning analyzed, including cable, switchgear and any attached manager, Aerospace Testing Alliance at Arnold Engineering transformers or terminations. The responsive capacitanceCMMS and LIMS software in typical deployments leave Development Center large gaps in a comprehensive condition-based PdM program. sensor can detect partial discharge (PD) activity, as well Most reliability programs focus on creating an effective inability to connect oil analysis data, vibration, theras numerous pre-discharge events, such as the growth Their of maintenance existing assets. Those who have water trees and defects in the cable or components. A labmography and ultrasound measurements to asset history, been involvedprogram with afor Reliability-Centered Maintenance oratory-control led PD occurrence will demonstrate howoperational condition, maintenance activity and root cause analysis project on existing assets know that some designs leave predictive tools limited in their analytical capapre-discharge activity is visible numerous minutes prior analysis to create additional challenges that may have been avoided if bilities. The new capabilities of cloud connectivity (Internet) PD activity. Systems are graded from Level 1, where the operators and maintainers had an opportunity to provide are changing the paradigm and assetowners can make maincomponent is in excellent condition, to Level 5, where the input based on resident knowledge and experience. This tenance decisions based on holistic machine condition, by component is at the end of its useful life. The condition assession will discuss how Arnold AFB/ATA capital project giving them end-to-end data access. This session will focus sessment technology is a useful tool to assist in prioritizing managers and designers work in conjunction with operaon the benefits of an asset-centric system vs. the traditional maintenance tasks and facilitating a planned maintenance tors and maintainers to build reliability and maintainability program, as it provides critical performance data on the LIMS system and detail some significant advantages that into new or modified assets. Attend this session and learn condition of installed cables and components. Web-based systems can have over traditional systems. how to truly optimize your life cycle costs.

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sustained; 2) Standardized work to insure that the gains sprint. are Syngenta will share the experiences and learnings gained from using traditional lean tools in a non-traditional delivered everywhere; 3) Continuous improvement to idenlean tify the next improvement to become the standard; and 4)manufacturing environment. The company’s continued and victories prove that a lean journey is an onLeveraging insures everyone understands the standardstumbling and Aqua Porter, vice president, strategic projects and business new potential improvements are identified. Attend thisgoing ses- marathon and not a 50-yard dash. The Syngenta case results for Corporate Lean Six Sigma Operations, study is a story of application of lean manufacturing princision and learn the keys to workforce productivity, methods Xerox Corporation to attain management simplification and agility, and the ples man-in a continuous process agrichemical world. At its core, Lean Six Sigma is a change management ininer in which to achieve standard performance through a lean tiative. To successfully deploy Lean Six Sigma and sustain system across your company’s divisions and plants. results in the long term, organizations must create an enHow Does a Utility Implement Lean? vironment with reinforcing loops to encourage smart decision making and facilitate momentum. In her keynote Best Practices from the Country’s address, Aqua Porter will discuss three areas critical to Applying artLean Practices to Largest Nuclear Plant fully integrating Lean Six Sigma into a corporate culture: Maintenance and Reliability

The 3 Critical Steps to Integrate Lean Six Sigma into a Corporate Culture

Kirk Gould, process improvement consultant in the Center of The executive team creates a vision for using Lean Six Darrin Wikoff, education facilitator, Life Cycle Engineering Process Excellence, Arizona Public Service Company Sigma in an organization. Leading from the front involves Lean manufacturing, Lean Six Sigma or simply just lean Arizona Public Service is a power utility based in the getting hands dirty and empowering employees with reare all common terms used in today’s manufacturing orsouthwestern United States. With more than one million sources to be successful. How do executive leaders ganizations to describe a method of operational become Lean Six Sigma champions? customers, Arizona Public Service must build and maintain But what about maintenance and reliability the electrical infrastructure and keep the air conditioners Organizations need to embrace the upside-down andimprovement. inimprovement? Do lean principles and practices apply to the on for a large part of the Southwest. APS is a part-owner side-out communication flow created by social media. system? In 2007, IndustryWeek reported that of the Palo Verde Nuclear Generating Station, the largest Information doesn’t always flow from the top anymore.maintenance Em74% of companies engaged in lean efforts were not satisfied power plant of any kind in the United States. APS operates ployees use social networks to create a community and e plant for the other six corporate owners. This presenthe share best practices with each other and peers in the with in- progress being made and the subsequent results. W now understand that a significant risk to lean implementatation will be a case study on the journey Arizona Public dustry. How can organizations use this collaboration already tions is the lack of a stable foundation for improvement. Service This taking place to further Lean Six Sigma use ineveryday work? has taken to apply business process management instability is a result of inadequate maintenance and reliaand lean manufacturing concepts within this non-manuPeople are the mos t critical change agen ts, and cultibility systems. In this session, participants will discover facturing environment. vating strong project teams is the key to innovation and how lean principles can be applied to maintenance and reimplementation. For Lean Six Sigma to take hold in the culliability to accelerate operational improvement results. ture of the ranks, employees must be engaged and

consulted. What is the best way to maximize the talent of a team so it works at the highest potential?

Employee Involvement and Empowerment in Lean: A Yamaha Case Study

Master the SMED System inYour Plant Mike Wroblewski, senior operations consultant, Gemba Consulting

In this session, lean lessons spanning more than two decades on mastering the SMED system will be shared which can enable companies to achieve year-over-year success in a lean transformation. The SMED system, or Mark Steward, senior manager for lean productivity, largesingle-minute exchange of dies, is one of the most powerscale food manufacturing company This session will explore the subject of employee inful methods in the lean approach, yet it is still not widely volvement and empowerment within a lean environment In many ways, we are often blinded by those things that used or successfully applied in many manufacturing comare right in front of us. Our perception in day-to-day lifeusing is a diagram that the speaker calls “Lean Agri-Culture”. panies. You will learn about the challenges and practices of key to discovering pockets of gold as we make our way The in presentation will illustrate in a dynamic style the posincorporating and sustaining the SMED system. See why a life of continuous improvement. In this session, the sibilities and the successes that a company can experience speaker aims to help you gain a set of “fresh eyes” to use when the basic rule of kaizen is followed: People come 5-S first,is an important foundation to the SMED system. Included in this presentation are several case studies with in your daily life around the plant. The lessons exploredand in everything else comes second. The speaker will proconcrete examples of using the SMED system. Find out this session were gained from years leading lean program vide examples of the concepts in action at Yamaha’s improvements at large manufacturing companies in the 1,000-employee recreational vehicles plant in Newnan,how Ga. to achieve maximum productivity and flexibility using this amazing system to reduce your changeovers from power management and food products industries. hours to minutes.

Learning to See: Finding Gold on the Plant Floor

Sustaining the Gains through Standardization and Leveraging Jeff Slater, Operating Excellence leader, Sonoco

Eric Bigelow, lean industrial engineer and continuous improvement expert, Yamaha Motor Corporation

Using Traditional Lean Tools in a NonTraditional Manufacturing Environment Kelly Moore, lean manufacturing leader, Syngenta Crop Protection

Machine and Line Reliability Can Help You Become Better, Faster, Cheaper

Thom Longcore, seniorproductivity manager,Woodbridge A consultant study of Operating Excellence productivity St. Gabriel, La., is home to Syngenta’s largest agrichemFoam Corporation projects at Sonoco showed that over a three-year span,ical ap-manufacturing and formulation site in North America, proximately 50% of the benefits were no longer being and is comprised of eight continuous and batch chemicalThis session will explore how high levels of reliability achieved. Back-sliding and project erosion has made production it areas. In late 2006, a declining agrichemicalmust mar- be achieved to attain the lean program goals of “better, faster, cheaper”. Furthermore, it will explain not only harder for Sonoco to attain its net productivity goals. Aket good and generic competition drove Syngenta to a strategic how reliability has helped lean, but how lean has helped “rule of thumb” is that without a system to sustain the gains, decision that the St. Gabriel plant would become a lean and how these two concepts work together to an additional 15 to 20% per year of productivity projects will manufacturing site. In early 2007, the facility took itsreliability, first be required to overcome erosion. A system locks in the gains tentative steps on its lean journey. Six months later, inmake mid- your manufacturing facility a more secure work enthrough: 1) Standard metrics to insure that gains are 2007, an unexpected market uplift turned the journey intovironment a and a better money-making machine.

13

Learning Sessions

matter of just a few years, the company won the Arizona every resource needed to transform raw materials into your Governor’s Award for Quality; the U.S. Navy designatedend theproducts and every waste generated be understood and quantified. This calls for a deep dive into each production Agile Improvement Process as an “Industry Best Practice”; process and into your supply chain for the materials you use. Hughes was recognized by IndustryWeek with “America’s Robert B. Hafey, RBH Consulting LLC Best Plant” award; and in 2004 (now Raytheon) won theLean thinking focuses deeply on processes and engages Without trust, lean is a bust! A common requirement to atcoveted Shingo Prize. The Missile Systems Lean Teameveryone had in continuous improvement, and “green” thinking tain either world-class lean or world-class safety is the

Lean Safety – A SafePath to Achieve Lean Results

ongoing engagement of the workforce. Lean thinkers developed all and implemented a proven, repeatable deploydoes the same. Hence, Attend the opportunity is clear applythe lean in a “green” initiative. this session andtolearn: ment process, the employees were trained on lean and agree that it is this culture-changing employee engagement “green” implication to every “lean” type of waste, the “green” on the elimination of waste, and the results realactivity that leads to long-term lean success. Too often, focused lean data you need to capture in your value streams, and how ized were amazing. Cycle times were dramatically reduced, has been employed as a cost-savings methodology by mankaizens can be focused on environmental impact to provide inventory turns were increasing, scrap and rework costs agement and, as a result, gaining employee interest and transparency, planning and concrete bottom-line returns. were decreasing, and on-time delivery, cost and quality buy-in can be at best difficult. This keynote session suggests were at new levels. So, what happened ...? a different path to lean success – a safe path that focuses the power of lean improvement on the universal topic of Fast forward to 2010. Today, pockets of lean excellence olume workplace safety. By utilizing lean thinking, along with some can be found throughout many of the srcinal factories inLean in High-Mix/Low-V of the common tools in a lean thinker’s toolbox, and focusTucson. Employees on occasion can be heard discussingProduction ing on safety instead of cycle time, you can easily start leantoterms such as error-proofing, takt, kanbans, and 7-S Sam MacPherson, president, MacPherson BusinessAdvisors build an understanding and the acceptance of lean whilewith ou y a new and aggressive commitment for safety. Walk(MBA), and dojocho, Lean Leadership Academy improve safety in your facility. Lean has to be taught,ing andthrough the factories, though, one can clearly tell that Do you struggle with applying popular lean tools based when you use safety as your textbook or road map, yousomething will is missing. on manual assembly cell or assembly lines to your largegain everyone’s attention. Everyone will rally around safety Follow the Raytheon Lean Team as we embark on “Back scale product? Do you have trouble visualizing how to apply for it is and should be everyone’s first priority. to Basics”, a case study of what we missed along the lean standardized work to a “job shop”? Have you struggled Examples and case studies of lean tool usage that sijourney the first time, and what we know now that we with fitting lean concepts such as takt time, pull production multaneously drove safety and lean improvement will be must do to get back on track. and “high-mix/low-volume mixed model production” to covered in this session. your operation because you have large-scale product, longduration machining cycle times and assembly times? Are you a producer of large-scale parts or OEM production Linking Lean with Environmental Raytheon Gets Back to Basics equipment? Does your operation include batch operations Sustainability or does the thought of moving large-scale product or pro(and Back on Track) with Lean duction equipment into a U-shaped cell not appear to be Phil Coy, partner and chief technology officer, EWT Julie Goswick, senior manager and Operations Excellence option or cost effective? In this session, attendees will “Green”, or environmental responsibility, has crossedanthe leader, Raytheon Missile Systems learn “The Toyota Production System For ‘Large-Scale’ Protipping point to become a mandatory element of corporate Tucson-based Raytheon Missile Systems (formerly duction.” The speaker will present the secrets to strategy. In challenging economic times, an open-ended Hughes Aircraft) had everything going for it in the worldmandate of standardizing production for the custom or job shop envito “go green” cannot be sustained without considlean. From 1996 to 2004, the defense industry buzzed about ronment in order to apply the concepts pull production, takt eration for bottom-line profit. While global warming, Raytheon’s successes leaning out 14 factories using greenhouse their time, gases and oil spills in the Gulf of Mexico get at- standardized work, lean material handling and mixhomegrown version of the Toyota Production System. tention, In a creating a truly sustainable business requiresmodel that production.

Hy-Pro Filtration Meet and Greet Reception Nashville Convention Center Tuesday, August 31 Sponsored by: 5:30 - 6:30pm

“An

extremely valuable conference. If you’re looking to get the most bang for the buck, this is the one event of the year I would recommend to anyone involved in reliabilty” - Doug McBride, Temple-Inland

14



Exhibitor List

(as of July 19, 2010)

The exhibits at Reliable Plant 2010work in tandem with sessions andworkshops to enhance your experience. You’ll have the opportunity to compare products, solutions and services from leading vendors. Take what you learn in the classroom to find and evaluate solutions you need on the exhibit floor. Academy of Infrared Training (AIRT) Air Sentry Air-Tight, LLC ALS Laboratory Group Anton Paar USA Argo-Hytos, Inc. A.T.S. Electro-Lube Brady Corporation Cannon Instrument Company CheckFluid, Inc. Chevron Product Company

CITGO Petroleum Corporation Des-Case Corporation Dexsil Corporation Donaldson Company, Inc. Dupont Performance Lubricants EasyVac, Inc.

Emerson Process Management Esco Products, Inc. Fluid Technologies, Inc.

Fluidall, LLC Hach Company Harvard Corporation Hendrix Engineering, Inc.

Herguth Laboratories, Inc. HYDAC Technology Corporation/ Schroeder Industries

Interested in exhibiting at Reliable Plant 2010? Contact Brett O’Kelley at 800-597-5460 extension 112 or e-mail [email protected]. Sponsorship opportunities also available.

Hy-Pro Filtration

POLARIS Laboratories

International Council for Machinery Lubrication IDESCO Corporation IFH Group Indiana Bottle Company

Productivity, Inc. Quality Filtration R&G Laboratories, Inc.

Infor

Royal Purple Ltd. SDT Ultrasound Solutions SenGenuity (Division of Vectron Int’l.)

Inpro/Seal Company Insight Services Internormen Technology JAX INC. JLM Systems Limited Kaman Industrial Technologies

Kimbro Oil Company Koehler Instrument Company, Inc.

Life Cycle Engineering Lincoln Industrial Liquidynamics

Lubrication Engineers, Inc. Ludeca, Inc.

Midland Manufacturing MP Filtri USA Noria Corporation Novinium Oil Filtration Systems One Eye Industries, Inc. Pamas USA Parker Hannifin PdMA Corporation Penn Hills Scientific PerkinElmer, Inc.

Rhino Tuff Tanks

Shell Lubricants SKF USA, Inc. Snap-on Industrial / J.H. Williams Tool Group Specialty Manufacturing, Inc.

Spectro, Inc. Tannas Company Thermal Lube UE Systems, Inc. University of Tennessee Utilx Corporation WD-40 Company

Y2K Fluid Power *Sponsors shown in orange

Petro-Canada

Take Home the Tools Game How to Win: Check out the latest products and services from the sponsoring exhibiting companies, get your entry form stamped and then register to win. Visit our Web site at conference.reliableplant.com for complete contest rules. Come compare the tools for building a reliable plant and you might go home with one of three Snap-on/J.H. Williams/Bahco tool sets for the garage or workshop. Three sensational prize packages – one each day. Snap-on tools have inspired the trustand confidence of professional craftsmen since 1920. Designed to deliver superior performance, durability and comfort, Snap-on tools not only last for years, they last for generations. Giveaways sponsored by: CITGO Petroleum Corporation, Des-Case Corporation, Emerson Process Management, Fluidall, Herguth, HYDAC / Schroeder Industries, Hy-Pro Filtration, Infor, Life Cycle Engineering, Lubrication Engineers, Midland Manufacturing Company, MP Filtri USA, POLARIS Laboratories, Rhino Tuff Tanks, Shell Lubricants, SKF USA, Spectro, Y2K

15

Hotel and Venue Reliable Plant 2010 is held at the Nashville Convention Center in Nashville, Tennessee. Reliable Plant 2010 attendees receive discounted room rates at the Renaissance Nashville Hotel, which is connected to the Nashville Convention Center. You can take advantage of these rates by booking your room(s) directly with the Renaissance using the group name “Reliable Plant Conference” at the time of reservation. Availability is limited and you are encouraged to make reservationsearly.

Conference Fees (USD) Full Conference Registration ..........................................$995 Group Discounts 3 to 9 Attendees: Send three or more full conference registrations for only $550 each, plus a 20 % discount on all pre-conf erence workshop fees. 10 or More Attendees:Send 10 or more full conference registrations for only $350 each, plus a 20% discount on all pre-conference workshop fees.

Renaissance Nashville Hotel 611 Commerce Street Nashville, TN 37203-3725 Telephone: 800-266-9432 / 506-474-2009 Room Rates – Book Early and Save Before August 14 - Single Occupancy: $135.00 Rates Expire: August 14, 2010 * All room rates exclusive of state and local taxes or applicable service, or hotel specific fees in effect at the time of the meeting. Hotel tax rates are subject to change without notice. Reserve Your Room Today! • Call the hotel dir ectly at 800-2 66-9432 or 506-474- 2009. • Be sure to provide the group name: Reliable Plant Conference. • Make all hotel reserv ation changes or cancell ations direct ly with the Renaissance.

Multiple registrations must be purchased at the same time. Call 800-597-5460 to take advantage of this offer.

Full Conference Registration Includes: • All sessi ons in the 3 co-located co nferences • Conference Proceedings in CD-ROM format • Opening General Session • Exhibition Hall Access (Tuesday-Thursday) • Lunches in the Exhibit Hall (Tuesday-Wednesday) • Daily Refreshment Breaks (Tuesday-Thursday) • Daily Continental Breakfasts (Tuesday-Thursday) • Networking Receptions (Tuesday-Wednesday) • Plus, a FREE $1,195 Noria training coupon. See page 3 for details.

1-Day Conference Registration ....................................$395 1-Day Registration Includes:

• • • • American Airlines is offering discounted fares for attendeesReliable of Plant • 2010. Some restrictions may apply for airline tickets and discounts may not • be available on all fares. For reservations and ticketing information, call Amer- • ican’s Meeting Services Desk at 800-433-1790 from anywhere in the U.S. or Canada and reference Authorization Number: 2780AP

Airlines Air Travel and

Car Rental

Day’s sessi ons in the 3 co-loc ated conferences Opening General Session (Tuesday Only) Exhibition Hall A ccess for One D ay Lunch in Exhibit Hall for One Day (Tuesday-Wednesday) Day’s Refreshment Breaks Day’s Continental Breakfast Day’s R eception (Tuesday and Wednesday Only)

Exhibition Only Registration

Discount fares are valid for round-trip travel on American Airlines, American Eagle, American Connection Service and all oneworld Alliance Partners. The percentage discount may be applied to American and American Eagle flights booked online by visiting www.aa.com and entering the authorization number as the aa.com discount code. Valid group travel dates are August 28 - September 5, 2010.

Car Rental Discounted group car rental rates are available from August 23 September 9, 2010. Reservations can be made by calling 800-331-1600 or visiting www.avis.com. Reference Discount Code J907635 for group discount rates.

Discounted group car rental rates are available from August 24 September 9, 2010. Reservations can be made by calling 800 -654-2240 or visiting www.hertz.com. Referenc e Discount Code CV#04B10002. 16

With Exhibitor Guest Pass......................................................................FREE Without Guest Pass..................................................................................$50

Pre-Conference Workshops One-Day (with Full Conference Registration) ............................................................$375 One-Day (Workshop Only)..............................................................................$450 Workshop Registration Includes: • Course Materials • Opening General Session (Tuesday Only) • Refreshment Break(s) • Exh ibit Hall Access (Tuesday Only)

Spouse/Family Registration..............................................$135 Spouse/Family Includes: • Opening General Session (Tuesday Only) • Exhibition Hall Access • Daily Lunches in the Exhibit Hall (Tuesday-Wednesday) • Daily Continental Breakfasts (Tuesday-Thursday) • Receptions in the Exhibit Hall (Tuesday-Wednesday) For complete conference and expo information and updates, visit conference.reliableplant.com


Registration Nashville, TN - August 31 – September 2

August 31 - September 2 – Nashville Conventio n Center – Nashville, Tennessee

1. Registrant Information

4. Conference Proceedings on CD-ROM

Please print your name clearly. Your name and company will appear on your badge.

With full conference registration . . . . . . . . . . . . . . . . . . . . . . . . . . .Included

PLEASE photocopy this form for an additional registrant.

Purchase without registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .$99

First Name __________________________________________________ Last Name __________________________________________________ First Name for Badge __________________________________________ Title ______________________________________________________

Tota l Paym ent D ue: $ ______________ Payment due upon receipt of invoice and prior to conference. No registration materials will be distributed without full payment. Customers ou tside the U.S.: We accept checks drawn on U.S. banks in U.S. dollars.

Company ____________________________________________________ Address 1 __________________________________________________ Address 2 __________________________________________________ City ____________________________State/Province ________________

5. Method of Payment Payment must be received prior to the conference. Check # _____________ is enclosed or will be mailed Noria Corporation Please make check payable to:

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2. Conference Fees

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Individual Full Conference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .$995

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Register using any of the following:

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Group Discounts

BEST E! VALU

@ Online:

800-597-5460or 918-749-1400 M - F, 8 - 5 (CST)

By Fax:

By Mail:

Fax your completed registration form to: 918-746-0925

Send this form and payment: c/o Noria Corporation 1328 E. 43rd Ct. Tulsa, OK 74105 U.S.A.

Three to Ninefull conference registrations only $550 each Tenoror Morefor $350

each. Group discounts include a 20% discount on pre-conference workshop fees. Group registrations must be purchased at the same time. Call 800-597-5460 to take advantage of this offer.

3. Pre- conference Workshops Monday, August 30

Save With Full Registration

How to Rate and Select Oil Filtration . . . . . . . . . . . . . . . . .$450 . . . . . . .$375 How to Optimize Preventive Maintenance Programs . . . . .$450 . . . . . . .$375

By Phone:

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Cancellations/Substitutions You may cancel a registration before July 31, 2010. Cancellations must be in writing. A $75 cancellation fee will be applied to all cancellations received after July 31, 2010, but you will also receive a $75 coupon good for use against the cost of a Noria training course or conference. This coupon is fully transferable. If you don’t cancel and you don’t attend, you will be charged the full registration fee. Substitute attendees are welcome at no extra charge with written notice prior to the event.

17

Get a Printable Version of This Puzzle Online at: MachineryLubrication.com/puzzle

CROSSWORD PUZZLER 1

2

3

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5

6

7

8

9

10

11

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ACROSS

DOWN

1 Instrument generally used to determine the specific gravity of oil.

1 A common cause of lubricant oxidation (two words).

4 Name of Noria Corporation’s annual conference and exhibition,

2 Product manufactured by company featured in this issue’s

which will be held this year on August 31-September 2 in Nashville (two words).

7 Kinematic viscosity is measured using this type of viscometer (three words).

cover story.

3 Vice president of manufacturing at Jane’s Dough Foods (see cover story). 5 This Nissan vice president will provide the opening keynote address at Noria’s big event in Nashville (two words).

10 These products come in single-point and mutiple-point versions.

6 A method to measure chlorine contamination.

12 Parts per million, in short form.

8 The role of this is to produce a barrier film on oil-wet ferrous

16 Noria’s e-mail newsletter focused on filters and filtration systems (two words).

surfaces to repel water (two words).

9 A fluid that is used as a fire-resistant hydraulic fluid (two words).

18 Fourier transform infrared (FTIR) is used to quantify the presence

11 The Oklahoma city where Noria Corporation is based.

of this within an oil. Product line featured in the WD-40 advertisement in this issue 19 The term for contaminants entering a fluid from an external source 13 (two words). and the resultant generation of contaminants because of wear.

20 Whose Machinery Lubrication column normally ends with the tag line “As always, this is my opinion; I’m interested in yours” (two words).

14 The type of lubricants featured in the cover story on the Jane’s Dough Foods plant in Columbus, Ohio.

15 A metal often seen on oil analysis reports that comes from the additive ZDDP.

17 The last name of Back Page Basics author Jeremy.

Get the solution on Page 29. 50 July - A ugust 2010



OIL ANALYSIS

A New Technique for Filter Debris Analysis BY SURAPOL RAADNUI

D

ue to the increasing fineness of filter elements in high-precision machinery lubricating oil systems, monitoring of filter debris analysis (FDA) is gaining increased significance for the early failure detection of moving parts. These considerations led to the development of a new method to recover filtered debris particles efficiently, productively and economically.

A Brief Introduction Methods for detecting damage to rotating components in highprecision machinery lubricating systems operate on the determination of types, size, shape and concentration of wear particles in the lubricating oil. Detecting still relies on an oil sample. Apart from the oil sampling technique, however, FDA is increasingly

cleaning of the used oil filter is accomplished by immersing the filter in a suitable solvent and removing entrapped debris by ultrasonic agitation and/or air pulsation. Major drawbacks of conventional FDA are: particle stacking gives an erroneous result, and the method is a fairly cumbersome, time-consuming process. A new FDA approach is proposed in this article. A special particle separating tube (PST) is introduced. Figure 1 shows a typical PST; the component also can be used for separation of solid particles from used lubricants1,2.

growing in acceptance. Filter inspection is a method of long standing, where the chance of detecting damage varies with the method used to recover the particles from a filter element specimen. FDA, in general, can therefore be thought of as consisting of three discrete steps: removal and cleaning of the oil filter, recovery of the removed debris, and examination of the debris. Typically,

Figure 3. Particle Separating Tube (PST) for FDA

Filtersonicgram Maker Procedures Here is a step-by-step walkthrough of the process. Figure 1. Typical PST for Solid Debris Separation

Figure 2. A Filter Element Specimen 52 July - August 2010

1) hydraulic, Coll ect a turbine, used oilengine). filt er (i.e. 2) Remove the fi lter housing with a suitable tool. (Do not use a hacksaw to open up the housing as the metal saw dust will have a significant effect in the solid debris analysis stage.) Figure 4. Put the Sample


into the PST


OIL ANALYSIS

Figure 5. Typical Ultrasonic Washing Machine

Figure 9. Filtersonicgram Slides Have Been Prepared

3) Cut part of the whole filter element as a “specimen” (Figure 2). 4) Put the filt er element specimen into the top c hamber of the PST unit (Figure 3). 5) Pour proprietary solve nt into th e PST unti l the filter e lement specimen is submerged under the solvent (Figure 4). 6) Put the PST(s) into th e fixture in side the ultrasonic washing machine (Figure 5). Figure 6. Insertion of the PSTs into the Fixture

A set of PSTs can be used to extract solid particles in multiple samples simultaneously (Figure 6). 7) The samples are no w ready to be “wa shed” inside the ult rasonic washing machine (Figure 7). 8) Operate the washing machine, which has an intensity of the “ultrasonic wave” approximately at 42 kilohertz for an “appropriate” duration, which depends on the type of filters – i.e. engine oil filter, hydraulic oil filter, turbine oil filter, etc. (Figure 8). 9) Switch off the wa shing m achine and ta ke the P STs out of the unit.

Figure 7. Inside of Washing Machine After the PSTs are Put in Place

10) Up to this stage, the solid p articles have bee n extracted from the used filter element and also have been classified as per their sizes. 11) Remove the drain p lug to get rid of the unwanted solven t (Figure 9).

Figure 8. Utilization of Ultrasonic Washing Machine 54 July - A ugust 2010

12) Disconnect each section of the PST and remov e the “patches” which are now ready to be analyzed under an optical microscope or similar device for debris classification and identification by: size; color; shape; edge detail; thickness ratio; surface texture; response to light (reflected or transmitted light); and response to heat ( the “wire mesh” can be used as a filter patch which can be heated up to certain temperatures, depending on the wire mesh materials). This



process can be used to identify fiber, elastomer and alloy composition (i.e. copper, aluminum, tin, lead). Sample slides are shown in Figure 10. 13) The patch also can be weighed, which can be used to quantify the extracted debris due to their size ranges. 14) Debris morp hology ca n be done in a more comfortable manner as the particle-stacking probl em in the conve ntiona l “filtergram” technique (by the conventional vacuum filtration technique) is partly solved. 15) The wire mesh patch may be reused, if needed.

A Unique Assessment and Examination Tool “Filtersonicgram” is a novel method to recover solid particles trapped in filter elements with the simultaneous utilization of ultrasonic wave and a conventional filtration approach. The recovered particles on the multi-patch filters can be assessed with the aid of a microscope or other device. Careful examination of the debris morphology can give specific information about the condition of the moving parts of precision machine elements from which they were generated, and the wear mode and/or wear mechanism in operation in the system from which they were filtered. This technique is at present being tested in the field and it is the field

operators who will judge the efficacy of solid debris separation and examination by this technique. Acknowledgement The work reported here has been funded by the Thailand Research Fund (www.trf.or.th).

References 1) System and Method for Filter Debris Analysis , International Patent Application (PCT) Number PCT/SG2009/000465, date of filing December 3, 2009. 2) An Apparatus and Method for Particle Analysis , International Patent Application (PCT) Number PCT/SG2009/000264, date of filing July 27, 2009.

About the Author Surapol Raadnui is an engineering faculty member at King Mongkut’s University of Technology North Bangkok in Thailand and works in the school’s Machinery Health Monitoring and Tribology Laboratory. Send your questions or comments via e-mail to Surapol at [email protected] o r [email protected].

Hungry For More Information? The Machiner y Lubr ication Web site is the home for hundreds of technical articles, columns and reports related to lubrication research, solutions and best practices. out www.machinerylubrication .com andCheck learn more.

Figure 10. Typical Filtergram Slides Machinery Lubrication



LUBRICANT STORAGE

Pennsylvania Power Plant Gives Oil Storage Room a Much-needed Makeover BY MICHAEL MALPEZZI, CMRP

T

he oil storage room at the Elrama Generating Station in Elrama, Pa., was located in a separate building specifically made to house the oil at the plant (Figure 1). Oil drums were stocked on racks, and an overhead crane lifted full drums to pour into steel containers that stored the oil for plant distribution (Figure 2). These storage tanks were open to atmospheric conditions and were typically left open as the manually operated oil pump dripped for several hours after use. These tanks were an entry point for contamination into the system. No filtering took place. The lubricant was placed into containers, bottles and buckets – another entr y point for contamination. But, that was then. This is now.

Results Oil analysis indicates that new oil from the supplier is received on site with an average ISO cleanliness code of 18/17/13. This is consistent with the manufacturer’s claims and advertising. This is not something a person can see with the naked eye, so the pictures in Figure 7 have been magnified 100 times to give you a better look. Transferring into the old storage tanks made the oil dir tier than new. Oil samples from these tanks showed an increase in

Current Practice The reconfigured storage room today consists of oil in stacked plastic totes in a quantity representative to the SAP stocking level (Figure 3). Drums are not stored in the room unless an oil analysis is in process. The drums are pumped through 25- and 3-micron filters on a filtering cart into the plastic totes. The totes are seale d from the atmosphere and use a desiccant breather to dry the air that enters the tote when draining the oil into filling bottles. Totes are labeled with the oil manufacturer’s information to prevent pumping into the wrong tote (Figure 4). Color- and shape-coordinated labels also identify the oil type and help prevent cross-contamination (Figure 5). The overall process is shown in Figure 6.

Figure 1. Here’s a snapshot of the old lubricant storage area. It was not set up to achieve lubrication excellence. 56 July - August 2010


Figure 2. This is a visual diagram of the previous practice used to store and distribute oil.

Figure 3. Today, oil is stored in stacked plastic totes. Machinery Lubrication




LUBRICANT STORAGE

Figure 5. Labels have a color and shape system Figure 4. Totes are labeled to show oil type and the manufacturer.

to prevent misuse.

Benefits

Using a life extension table created by Noria Corporation to compare machine oil cleanliness, we saw that a three-level reduction in cleanliness code extends the life of gearboxes by a factor of 1.5 and journal bearing machines by a factor of 1.8 times. The Noria chart makes a couple of assumptions in that you must maintain the oil cleanliness level at that level for the life of the machine, which is very difficult and almost never practical. It does show, however, that if the oil is cleaner (and all other variables are equal), longer equipment life will be the result. The question you should ask yourself is, “How much of your budget do you use to repair oil-lubricated machines?” If that amount is greater than $100,000 per year, then cleaner oil would be a huge benefit to your bottom line. An additional benefit of starting with cleaner oil is that oil change intervals can be extended if the reason for changing the oil is high particle counts. If you extend oil change intervals, your plant will Figure 6. This is a visual diagram of the current practice consume less oil during any measured period. This will result in an used to store and distribute oil. overall savings and increased profit margin. If you extend the oil change intervals on average by 20 percent and the annual plant oil the ISO cleanliness code to 19/18/14, or 50 percent dirtier than expenditure was $100,000, the savings would be $20,000 in reduced when we first purchased the oil (Figure 8). Using this oil oil purchases, plus the cost of labor for those oil changes, which following an oil change, we would never meet recommended could easily double that amount, for a total savings of $40,000 per cleanliness targets. Meeting these targets would maximize equipyear. I won’t account for any benefit that a machine sees with ment and component life. extended life because of the number of variables that exist. Installation of the new storage totes and filtering the oil before placing it into the tote dropped the cleanliness code by 2/2/2 from the drum and 3/3/3 from the old storage system. The amount of Further Improvements particles in this oil is 87 percent lower than before. This allows for Best practices indicate that setting individual machine cleanliextended equipment life and maximized oil life. ness targets should be followed to maximize the life of lubricated

Figure 7. Pictures of oil samples taken from a fresh oil drum (left), after transferral into the old storage tanks (center) and after the changes. 58 July - A ugust 2010



ISOCode >4 Micron >6 Micron >14 Micron Micron >50 >100 Micron

18/17/13 2446 951 72 3 0

16/15/11 461 179 13 0 0

filter larger oil reservoirs, such as boiler feed pumps and pulverizer gearboxes. Storage totes come in many different sizes, from 65 to 240 gallons. Some oil storage areas have their own spill containment units. The cost to filter and store four different lubricants for a gas turbine plant may be in the $5,000 to $15,000 range, and the cost to filter and store 10 different lubricants at a coal-fired plant may be in the $30,000 to 45,000 range.

19/18/14 3349 1302 99 4 0

Investment Return

We conservatively calculate $40,000 as the annual benefit from extended oil changes. This doesn’t take into account lost margin from any unit derate or outages, nor does it take into account benefits from reduced maintenance due to extended machinery life. We Figure 8. What oil do you want protecting your machines? also conservatively calculate $45,000 for costs on an oil storage area, with 12 percent as a discount rate and a 20-year life expectancy. The net present value (NPV) is calculated at $208,778.

Acid#mgKOH/g Water %

Rollerbearing Journal bearing Industrialgearbox Mobilegearbox Dieselengine Steamturbine

0.013 Neg

0.03 Neg

0.17 Neg

An Air-Tight Case for Change

16/14/12 17/15/12 17/15/12 17/16/13 17/16/13 18/15/12

New oil arrives on site in varying degrees of cleanliness. It easily can be improved with the use of sealed storage tanks and by filtering the oil before storage. A minimum removal of 75 percent of all particulate contaminates can be expected with filtering. New oil is not clean enough to use if cleanliness targets are implemented and maintained. The NPV shows a positive figure of $208,788 for a 20-year life cycle; the benefit-to-cost ratio is 4.6 Figure 9. Here is a sampling of base cleanliness targets forwhen a discount rate of 12 percent is used. These storage tanks should be used at every power plant facility. common machines and machine elements. This is a case of proactive maintenance contributing to machine surfaces. Figure 9 represents targets for common machines and reliability and the company’s bottom line. machine elements. If any of these targets are followed, then filtering the oil from the About the Author drums is mandatory since the new drum oil will not meet any of Michael Malpezzi, CMRP, is a reliability engineer at Reliant Energy’s Elrama Generating Station in Elrama, Pa. Elrama is a fully scrubbed, fourthese targets. Clean oil storage hardware and techniques are the unit, pulverized coal-fired generating station located on a 44-acre site key components to keep these targets low.

Costs The cost of the Elrama oil storage tanks was $45,000. The cost of your lube room is dependent on a number of factors. How many lubricants do you use on site? Do you need spill protection? Are you going to use filter carts or individual rack-mounted pumps with filters? Filter carts give you the added flexibility to roll around the plant and


along the Monongahela River, 25 miles southwest of Pittsburgh. Elrama operates as a baseload facility and has a net demonstrated capacity of 465 megawatts. Units 1,2 and 3 were commissioned in the early 1950s, while Unit 4, the largest unit at the facility at 175 net megawatts, began commercial operation in 1960. The flue gas desulfurization (scrubber) system, one of the first full system retrofits of its kind, was installed in the mid-1970s and removes more than 80 percent of the sulfur dioxide produced during the combustion process.



WEB PREVIEW

Get Even More Information at machinerylubrication.com and reliableplant.com very day, thousands of industrial professionals from around the world visit our Web sites. See what makes these sites so popular and so informative. Visit us today and every day at www.machinerylubrication.com and www.reliableplant.com.

E

Lube Storage & Handling Tips for World-Class Contamination Control Developing and implementing a world-class contamination control program is a sizable undertaking, and it usually requires significant modifications to machinery as well as changes in procedures and methodologies. However, one component of contamination control can affect the entire plant: the storage, handling and application of new lubricants. This is a good place to start improving your program. Find this in the White Papers section on the ML site. 10 Pointers for Off-line Filtration of High-viscosity Lubricants Follow the expert maintenance advice found in this article from Noria Corporation. Here’s one of the tips: When selecting filtration for high-viscosity gear oils, you should first determine the optimum target cleanliness level for that specific gearbox and ensure adequate breathers are fitted, as any attempts at cleaning the oil will be lost quickly. Find this article in the Web Exclusives section on the ML site or type in “Filtration Pointers” in the ML Search bar. A Discussion on Desiccant Breather Use & Application Preventing the ingress of dirt and water into the lubricant is the most effective, yet least fully utilized method of controlling contam-

We’re Your Source for Free White Paper R eports MachineryLubrication.com is the place to turn for free white paper reports on a host of maintenance and reliability topics. Here’s just a sampling of some of the white papers currently available for download. • “Cost-Effectiveness of Automatic Lubricators” • “Industrial Food-Grade Lubricants Guide” “Automatic Lubrica tors: WhatProgram” You Need to Know” “EngineeringGrease an Effecti ve Oil Analysis “Elements of a Good Preventi ve Maintenance Program” “Controlling Gearbox Lubricant Contam ination” “Choosing the Correct Oil or F uel Purification System for W ater Contamination Removal” • “Hidden Benefits of Lubricant Consolidation” Check out the full list of white papers. Visit www.machinerylubrication.com and click on the “White Paper” link on the home page. 60 July - August 2010

protection and reliability optimization. Find this article it by typing “Breathe” in the Search bar on the ML Web site.

Also

Articles & White Papers

• • • • •

ination. High-performance desiccant breathers enable front-end

Term Glossaries Nearly 100 lubrication and oil analysis terms are defined in the Glossary on the ML Web site. Maintenance, reliability and lean terms are defined on the RP Web site. Just click on the “Glossary” link on the top of each home page. Watch Videos More than 160 free videos, vodcasts and slideshows on lubrication and oil analysis topics are available for viewing on the ML Web site. Simply click on the “Videos” box on the ML home page. More than 1,500 videos on maintenance, reliability, lean and manufacturing topics can be found on the RP site. Industry News Stay informed by reading news stories posted most every day. Check out the “Industry News” box on the home page. Write a Blog We are looking for industry pros to write for a new blog section of our Web sites. If you wish to be a blog author on the subject of machinery lubrication or oil analysis, e-mail [email protected]. E-mail Newsletter Sign up for Lube-Tips and Filtration Tips, Noria’s free lubricationrelated e-mail newsletters, which contain helpful articles, tips, trivia and more. Just click on the “Newsletters” link at the top of the ML home page. Additional newsletters are available via the “Newsletters” link on the RP home page. Subscription Services Ensure that you will continue to receive award-winningMachinery Lubrication magazine by filling out the free subscription form. Simply click on the “Subscribe” link at the top of the ML home page. Education On The Road Get all the details on Noria’s industry conferences, seminars and other educational events, including new and expanded Machinery Lubrication and Oil Analysis courses. Just click on the “Events” link found at the top of the ML and RP home pages.



CERTIFICATION NEWS

The Importance of Experience in Attaining ICML Certification BY SUZY JAMIESON, ICML

I

t is standard practice in the field of personnel certification to outline qualification requirements as part of the certification process. In addition to such qualification requirements, there also is commonly an element of assessment of such qualification to confirm the knowledge base in question has been adequately acquired. In common terms, this is where the certification examination comes in. Regarding qualification in preparation for the assessment – or in other words, fulfilling the requirements in preparation for successful examination – people in industry have ease in understanding the need to have received training in the body of knowledge of a specific certification program prior to attempting the exam. It tends to be against human nature to attempt examination in something on which you have not been previously trained. However, training is but one facet of the qualification process in most certification programs, with experience normally being a major component. Field experience is where the knowledge base you’ve been exposed to in training takes shape, is tested and finetuned, thus completing the learning curve. This, too, is logical, as most education systems, courses, even life skills, need to be put into practice before anyone truly masters the skills in question. Yet with the case of many certification programs working alongside theory-based training programs, at times an expectation on the part of candidates exists that attendance to this or that training course would lead to successful certif ication. In the particular case of the International Council for Machinery Lubrication, most programs require one or two years of experience in the f ield for which certification is sought. Even in the case of the Machine Lubricant Analyst Level I program, following ISO 184364, where the minimum requirement of years of experience is based on 16 hours per month, ICML still strongly suggests full-time expe-

professionals they are, after proving their skills and attaining worldrenowned credentials. It is natural in the process of “sorting through the grapes” that the exam be challenging and target passing rates be maintained. In ICML’s case, an overall passing rate of approximately 60 percent of the candidates is right on target. With a prestigious credential that carries a fair, yet challenging examination component, the role played by field experience becomes even greater. It is evident that people with greater experience in the subject areas being tested will tend to do better in the exams, especially considering the practical nature of the certification program’s exam questions – the core of the program is the “where”, “when” and “how” of proper machinery lubrication and oil analysis. Thus, it is logical that if one hasn’t had much chance to witness first hand, by the machine, where, when and how

rience in analysis, during the same period length as outlined, before attempting examination.

Knowledge and Experience Increase Chances

Training Doesn’t Guarantee Certification

It is very important that training is chosen to match the subject areas covered in the body of knowledge of the equivalent chosen certification program. It is crucial that the experience requirements outlined be viewed as minimum requirements; also, that experience be based on best practices after proper training, not on one year of doing things the wrong way repeated many times

ICML certification programs were created with a very important mission, that of dignifying the profession of lubrication technicians and oil analysts, ensuring practitioners are respected as the skilled 62 July - A ugust 2010

processes and procedures are properly carried out, such person will be at a disadvantage when it comes to approval ratings in the exam, independent of any training course undertaken. While training is a key component of the qualification and as such a requirement – not only for certification, but even for qualification as an exam candidate – experience plays a very important part. Training is but one aspect of the qualification process and a very useful tool when viewed properly. It is important that candidates taking training as part of a certification program’s qualification process understand that training is just one of the requirements for sitting the exam and that no person should expect to simply attend a course as a means of guaranteed approval. Training, if appropriate and in the relevant body of knowledge of the exam, is a great starting point to expose candidates to the subject areas they will need to master in order to pass the exam; it’s also a great refresher tool for the experienced professional.



over. Lastly, it is very important that candidates understand the correlation between the greater the proper, knowledgeable experience, the better chances at approval on examination, vs. the myth that training programs increase approval ratings. A good, solid course of instruction in the exam’s body of knowledge is very important, but it is not a sole requirement or sure shot at certification. Seek a high-quality training program, apply the knowledge acquired during training in field experience at your workplace, and then and only then, pursue testing. About ICML The International Council for Machinery Lubrication (ICML) is a vendor-neutral, notfor-profit organization founded to facilitate growth and development of machine lubrication as a technical field of endeavor. Among its various activities, ICML offers skill certification testing for individuals in the fields of machine condition monitoring, lubrication and oil analysis. ICML is an independently chartered organization consisting of both paid professional staff members and volunteer advisors. It provides lubrication and oil analysis standard development support, scholarship, skill-based testing and certification, and recognition of excellence. For more information about ICML, visit www.lubecouncil.org.

Need to take an exam? ICML regularly holds exam sessions throughout the United States and the world. Upcoming dates and locations for ICML exams can be found at www.lubecouncil.org




CONTAMINATION CONTROL

Five of the Most Common Filter Cart Mistakes BY JARROD POTTEIGER popularity of portable filtration units, often referred to as TJusthefilter carts, has increased dramatically over the past few years. a decade ago, filter carts were primarily used by service providers to decontaminate large systems or flush new equipment. Now, it is uncommon for a plant not to have at least one filtration unit. The biggest reasons for this change are most likely education and availability. Through education and training, maintenance professionals have become aware of the tremendous value presented by portable offline filtration. This awareness created a rapidly expanding market for such equipment, and the makers of lubrication and contamination control products responded with a wide array of equipment to meet the demands of most applications. But while most plants use filter carts, they don’t always use them in the most effective way. There are unfortunately several common mistakes that diminish the value or effectiveness of filter carts. The good news is that they are easy to fix.

Mistake No. 1: Not Properly Fitting the Filtration Unit to the Reservoir If a reservoir is not fitted with suitable couplers to connect with the filter cart, it will be difficult to efficiently or effectively decontaminate the oil. One of the first steps in a good contamination control strategy is to identify the equipment modifications necessary to facilitate sound lubrication practices. Opening a hatch on a

reservoir and inserting hoses into the oil is not a good way to attach a filter cart. Even if the hoses are inserted through an open port, there still will be ample opportunity for further contamination. In addition to further contaminating the oil, the effort required to connect a filter cart to a sump which has not been modified can make the task quite cumbersome. Any lube oil reservoir or sump with which a filter cart may be used should be properly accessorized. This process is often as easy as attaching inexpensive hydraulic fittings to the drain port for suction and an available port at or above the oil level as a return. For those occasion s where there is no available fill port or there are fewer ports than accessories, a number or combination fittings are commercially available that will allow a sample port, breather and quick-connect to easily attach to one port.

Mistake No. 2: Using the Same Filter Cart for Different Lubricants While it is certainly permissible to use the same f iltration unit for different types of oil, it usually is not the best practice. If done properly, switching lubricants requires a significant amount of flushing, which generates an unnecessary waste of oil and, more importantly, time. You don’t have to save that many man-hours to pay for a new f ilter cart. As maintenance staffs continue to suffer cutbacks, any opportunity to improve efficiency should be investigated. At the very least, f iltration units should be dedicate d to particular types of oil (such as one for gear oils, hydraulic oils, etc.). Switching viscosity grades is not as problematic as switching formulation types. Develop the best strategy for your budget and include filter carts in your lubricant identification scheme. The use of an effective color-coding system to identify lubricant-handling equipment for different products is widely accepted as a best practice.

Mistake No. 3: Buying the Wrong Filter Cart for Your Applications All too often, maintenance professionals procure a f ilter cart for a particular application only to find out that it doesn’t work. It is imperative to consider the following criteria when selecting a filter cart: – What is the viscosity of the fluid to be filtered under normal conditions? Remember to consider the fluid’s viscosity for the temperature at which the f luid will be f iltered. 64 July - A ugust 2010



– What flow rate is desired for the systems to be filtered? The minimum flow rate should at least be able to accommodate the entire sump volume once per hour. The ideal flow rate would be at least several times this amount. – How clean are you trying to get the oil? If you want to clean the oil to 15/13/10, you won’t get there with a 10-micron filter. The filter pore size should be chosen based on the cleanliness requirements for the machine, and the beta rating should be at least 75,

The two most common sources for particle contamination in the average system are ingested air and new oil. This method of oil transfer eliminates contamination from new oil and reduces airborne ingression by maintaining a sealed system.

although 200 would be better. – How will you power the filter cart? Most filter carts are available with electric or air motors. In some facilities, power outlets are not as common as air supply. – Where is the unit to be filtered? Is it at the top of a ladder? How reasonable is it to transport the filtration unit to the equipment? Filter carts do come in many sizes. This list doesn’t cover ever y issue. The best way to ensure that a product will work in a certain situation is to work closely with your supplier to make sure all of the primary specifications are correct.

use filter carts, so they buy them; however, they don’t have proper procedures in place to implement their use. A strategy should be developed that identifies when, where and how filter carts should be utilized. Some systems should be filtered on a periodic basis. Some should be filtered when their condition requires it. Others may need permanent offline filtration to achieve cleanliness goals. Whatever the case may be, it is essential that the use of this type of equipment be a documented part of the lubrication program.

Mistake No. 4: Not Realizing All of the Uses of Filter Carts Portable offline filtration units were srcinally designed to decontaminate large systems, and they do work well for that application. However, there are many other uses for filter carts. Probably the best use for a filter cart is as an effective means to transfer oil to lubricated equipment or pre-filter new oil before it is dispensed. Not only does this practice help to ensure that new oil additions are clean, it also makes the job more efficient.


Mistake No. 5: Not Using the Filter Cart at All Believe it or not, this one is quite common. Plenty of program managers know they should

Keep These in Mind There are probably dozens of less common mistakes made with the application of portable filtration technology, but these are the big ones. To make it simple, just remember to decide when and where toyour use the equipment, theaccessorize unit will work for applications, andensure properly the machine sumps to facilitate the task. About the Author Jarrod Potteiger is the product and educational services manager for Des-Case Corporation, which specializes in contamination control products for industrial lubricants. For more information on the company’s products and services, visit www.descase.com or call 615-672-8800.



BACK PAGE BASICS

Telltale Signs and Tips to Tame Machinery Vibration JEREMY WRIGHT NORIA C ORPORATION

V

ibration analysis, when properly done, allows you to evaluate the health of equipment. By finding inherent failures before they become catastrophic, maintenance personnel can minimize unplanned downtime. In simplest terms, vibration in motorized equipment is the backand-forth movement, or oscillation, of machines and components, such as drive motors, driven devices (pumps, compressors and so on), and the bearings, shafts, gears, belts and other elements that make up mechanical systems. Vibration in industrial equipment can be both a sign and a source of trouble. Other times, vibration just “goes with the territory” as a normal part of machine operation, and should not cause undue concern. This article focuses on those machines that are designed to operate with minimal vibration.

When V ibration is a Problem Most industrial devices are engineered to operate smoothly and avoid vibration, not produce it. In these machines, vibration can indicate problems or deterioration in the equipment. If the underlying causes are not corrected, the unwanted vibration itself can cause additional damage.

Most Common Causes of Machine Vibration Vibration can result from a number of conditions, acting alone or in combination. Keep in mind that vibration problems may be caused by auxiliary equipment, not just the primary equipment. The following are some of the major causes of vibration. A “heavy spot” in a rotating component will cause vibration when the unbalanced weight rotates around the machine’s axis, creating a centrifugal force. Imbalance could be caused by manufacturing defects (machining errors, casting flaws) or maintenance issues (deformed or dirty fan blades, missing balance weights). As machine speed increases, the effects of imbalance become greater. Imbalance can severely reduce bearing life as well as cause undue machine vibration. Vibration can result when machine shafts are out of line. Angular misalignment occurs when, for example, the axes of a motor and pump are not parallel. When the axes are parallel but not exactly aligned, the condition is known as parallel misalignment. 66 July - A ugust 2010

Misalignment may be caused during assembly or develop over time, due to thermal expansion, components shifting or improper reassembly after maintenance. The resulting vibration may be radial or axial (in line with the axis of the machine) or both. As components such as ball or roller bearings, drive belts or gears become worn, they may cause vibration. When a roller bearing race becomes pitted, for instance, the bearing rollers will cause a vibration each time they travel over the damaged area. A gear tooth that is heavily chipped or worn, or a drive belt that is breaking down, also can produce vibration. Vibration that might other wise go unnoticed may become obvious and destructive if the component that is vibrating has loose bearings or is loosely attached to its mounts. Such looseness may or may not be caused by the underlying vibration. Whatever its cause, looseness can allow any vibration present to cause damage, such as further bearing wear, wear and fatigue in equipment mounts and other components.

Effects of Vibration The effects of vibration can be severe. Unchecked machine vibration can accelerate rates of wear (i.e. reduce bearing life) and damage equipment. Vibrating machinery can create noise, cause safety problems and lead to degradation in plant working conditions. Vibration can cause machinery to consume excessive power and may damage product quality. In the worst cases, vibration can damage equipment so severely as to knock it out of service and halt plant production. Yet there is a positive aspect to machine vibration. Measured and analyzed correctly, vibration can be used in a preventive maintenance program as an indicator of machine condition and help guide the plant maintenance professional to take remedial action before disaster strikes.

Characteristics of Vibration To understand how vibration manifests itself, consider a simple rotating machine like an electric motor. The motor and shaft rotate around the axis of the shaft, which is supported by a bearing at each end. One key consideration in analyzing vibration is the direction of the vibrating force. In our electric motor, vibration can occur as a force applied in a radial direction (outward from the shaft) or in an axial direction (parallel to the shaft). An imbalance in the



BACK PAGE BASICS

motor, for instance, would most likely cause a radial vibration as the “heavy spot” in the motor rotates, creating a centrifugal force that tugs the motor outward as the shaft rotates through 360 degrees. A shaft misalignment could cause vibration in an axial direction (back and forth along the shaft axis) due to misalignment in a shaft coupling device. Another key factor in vibration is amplitude, or how much force or severity is encompassed in the vibration. The farther out of balance our motor is, the greater its amplitude of vibration. Other factors, such as speed of rotation, also can affect vibration amplitude. As rotation rate goes up, the imbalance force increases significantly. Frequency refers to the oscillation rate of vibration, or how rapidly the machine tends to move back and forth under the force of the condition or conditions causing the vibration. Frequency is commonly expressed in cycles per minute or hertz (CPM or Hz). One Hz equals one cycle per second, or 60 cycles per minute. Though we cal led our examp le motor “si mpl e”, eve n this machine can exhibit a complex vibration signature. As it operates, it could be vibrating in multiple directions (radially and axially), with several rates of amplitude and frequency. Imbalance vibration, axial vibration, vibration from deteriorating roller bearings and more all could combine to create a complex vibration spectrum.


Prevention through Understanding Vibration is a characteristic of virtually all industrial machines. When vibration increases beyond normal levels, it may indicate only normal wear – or it may signal the need for further assessment of the underlying causes or for immediate maintenance action. Understanding why vibration occurs and how it manifests itself is a key first step toward preventing vibration from causing trouble in the production environment. About the Author Jeremy Wright is a cer tified Machinery Lubricant Analyst (ML A) Level I and Level II and Machinery Lubrication Technician (MLT) Level I by the International Council for Machinery Lubrication (ICML). In addition, he is a Certified Maintenance and Reliability Professional (CMRP) by the Society for Maintenance and Reliabili ty Professional s (SMRP). Contact Jeremy at [email protected].


SEE WHAT’S NEW IN LUBRICATION

The Lubrication Excellence conference is one of 3 co-located events at RELIABLE PLANT 2010 in Nashville, TN. See page 33 or visit conference.reliableplant.com for details.


Who Will Benefit? • All Maintenance Professionals • Lubrication Technicians • Craftsman or Millwrights • Equipment Operators • Laboratory Anal ysts • Lubrication Engineers • Maintenance Managers • Maintenance Supervisors • Manufacturing and Industrial Engineers • Operations Managers • Predictive Maintenance Technicians

You’ll gain practical new skills that you can use right away: 1

• Reliability Engineers

What Industries Will Benefit? • Aerospace • Automotive Manufacturing • Earthmoving • Food Processing • General Manufacturing • Municipal Utilities • Petrochemical • Power Generation • Primary Metals • Process Manufacturing • Pulp and Paper • Transportation

• Process Pumps • Rolling Mills • Steam Turbines

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This course will empower you with the knowledge to understand important lubricant properties and strategies to select the correct lubricant for each machine application.

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The best practices for lubricant storage, handling and dispensing. Learn how award-winning maintenance programs design lube storage areas, dispensing stations and transfer carts.

3

The four Rs of lubrication.

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Grease gun or lethal weapon? In the hands of an untrained operator, a grease gun

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Effective oil analysis with precision oil sampling.

If You Use Any of These Machines, This Training is a Must: • Blowers/Fans • Compressors • Diesel Engines • Final Drives • Gas Turbines • Gear Boxes • Hydraulic Systems • Hydrostatic Transmissions • Motor Bearings • Paper Machines

The secrets of lubricant selection.

Right lubricant, right time, right quantity and right place. If these four basic elements aren’t properly addressed, you could be doing your equipment more harm than good. Learn the newest methods for implementing the best lubrication practices.

can deliver pressure up to 15,000 psi. That’s 30 times what a typical bearing seal can handle. Once the bearing seal is broken, the bearing is on its way to early failure. This class will teach you proper grease gun practices.

Learn how to get data-rich oil samples, exactly where to install oil sampling ports, and what sampling equipment should and shouldn’t be used.

We Guarantee Results! With our no-risk satisfaction guarantee, Noria Corporation proudly stands behind its public courses 100 percent. We guarantee you’ll be thrilled with the vital skills, powerful techniques and important insights provided – or we’ll give you your money back in full. You have nothing to lose and a wealth of hard-hitting machinery lubrication know-how to gain!

ENROLL TODAY! Call toll free 800-597-5460 or visit www.noria.com

A special note from Noria’s President

Satisfied Customers Say it Best… “The information from this course could save my company as much as $20,000 in monthly oil costs.”

Jeff Smith, Maintenance Planner, Mueller Copper Tubes career success) ce Professional, (and yo ur own s es cc su n’s Dear Maintenan ult. tio res za i ed an g sir or de e ur th yo e, and with To a large degre s done – on time “Packed with powerful information that iques, guideability to get thing u the proven techn yo ing br to – ve in ti depends on your se ti e ur can be applied with measureable results. co mp co ble y lua ta s va is of th ns rely on to This is the focus ic for um to This course provides the right training to -class or ganizatio teg rld tra s wo d t a an th ul f e ies ur se is a purpos co lines and strateg is influence a cultural change in mainteTh t. e rk ma manding actices. today’s highly de ation excellence pr nance and operation organizations.” ric lub t en em pl im urse: Brian Baldwin, Reliability Engineering Manager, teach you how to wer ful training co Dynergy Midwest Generation of what you’ll learn in this po s ys tem g mple lin sa nd a t ha d jus s an re’ e He lubricant storag s as -cl rld wo a xcellence • How to set up “ABSOLUTELY AWESOME! Should ving lubrication e nef its from achie be ial nc ina f e Th ls • va reduce downtime 25 to 50 percent.” ter in ain dr ze and extend oil Scott Gilreath, Lube Tech, UNICCO es • How to optimi tur x mi se rea g le incompatib ing id vo a or f s tip •7 ty problems “I believe the knowledge I have now me leakage stabili • How to overco n oil analysis tests will reduce downtime 50 percent.” mo m co t s mo 11 e d f ittings Johnny Dominquez, Mechanic, • When to use th of grease guns an the maintenance or f es Phelps Dodge Mining tic ac e pr t nc s ma • Be or f r pe t an ric at enhance lub th s ve ti di ad y e k • 14 ce culture ad “I think the information I learned can m your maintenan you char t your ro • How to transfor strategies to help d an improve our hydraulic systems by 40 es iqu hn tec ther tips, Plus, dozens of o percent.” lp organhe to w ho on as al tips and ide Vernon Player, PDM Tech, tic to ac ed pr map to success. ne t n u yo ese s pr ol designed to the proven to International Paper This training was n. We’ll give you to-date the compe ti tio work armed wi th the mos t upre to mo rn izations get the edge on jo d tu an re ve ll re producti the b. You’ “This course has provided me an inre conf ident, mo face challenges on tr y, making you mo us ind e th in n depth view on how to create a d an ts informatio h ig e valuable ins r. world-class lubrication program.” to benef it from th d. es k ten valuable than eve ta t t a i to all y t t’s a ni tu attend. Th iss this oppor Dennis Hill, Facility Engineer, Alcoa m t n’ Do er. Register now and f f o ul training has to f r we po is th ills new sk

Sincerely,

Jim F itch ation Noria Corpor

ductivity and e in increased pro s for years to com a.com or by end ori vid w.n di w w you g y tin y visi ining will pa 800-597-5460, b ling tment in this tra cal ves y b in y r a You tod . P.S our place ve Pa y ge 6. professional ef fectiveness. fReser istration orm on reg the in g ilin ma

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“Vendor-neutral makes a difference!” Maintenance Technician, Kawneer Company


Presented by:

© Copyright 2010

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Introduction to Machinery Lubrication and Oil Analysis Course Outline • Financial benefits from achieving lubrication excellence • Don’t attempt reliability-centered maintenance (RCM) without the 5–I lubrication method • Five equipment maintenance strategies, and when each applies • Important implementation steps to lubrication excellence • 10 roadblocks to achieving lubrication excellence

• • • •

Six important functions of lubricating oils How oils and greases are formulated and why it is important How friction is generated in lubricated machinery The importance of oil film thickness and critical clearances

• • • •

How lubricant properties irreparably change Seven important physical properties of a base oil The importance of API’s five base oil categories When to select one of the six most commonly used synthetic base oils • How to use temperature to determine the right base oil for your machine • How to select grease thickeners for your application

• 14 key additives that enhance lubricant performance • Understanding viscosity grades, measurement, and reporting • Why Viscosity Index is important and how it improves your work • Lubricant performance tests and reporting – what you need to know • How water contamination generates other contaminants • How to control and eliminate aeration problems

• Seven tips for avoiding incompatible grease mixtures • Advantages and disadvantages of centralized lubrication systems • Best practices for greasing motor bearings • How to calculate greasing intervals and quantity • Best practices for ultrasonic/sonic-based greasing • Important tips for working with your motor rebuild shop

• • • • •

Overview of oil lubrication methods and devices How to use oil mist and other automatic lubrication methods Using pressure spray methods for gearboxes Best practices for the maintenance of grease guns and fittings Overview of single-point direct lubrication systems

• • • • • • • • •

Journal and rolling-element bearings Open and closed gears Gas engine and gas compressors Air compressors Hydraulic fluids Steam and gas turbines Process pumps Multipurpose grease Oil mist lubricants

• • • • • •

How to optimize and extend oil change intervals Interval vs. condition-based oil change How to monitor lubricant consumption Best practices for oil changes How and when to perform a flush Selecting appropriate cleaning and flushing procedures

Meet your trainer, Jim Fitch, Drew Troyer, or Mark Barnes Jim Fitch

• World-class strategies for accessorizing equipment for lubrication excellence • Seven critical accessories for inspection and sampling • Seven critical accessories for contamination control prevention • Eight essential lubrication accessories • What your breather is telling you about your machine

• • • •

• Building reliability through contamination control • Seven most destructive contaminants and how to control them • Three steps to proactive maintenance • Understanding the ISO Solid Contaminant Code • 10 ways to maximize filter cart usage

• Important USDA requirements and government regulations for food-grade lubricants • What you need to know about food-grade additives, base oils and grease thickeners • Advantages and disadvantages of food-grade lubricants

• How to set up a world-class lube room • How to optimize lubricant selection/procurement • How to implement a lubricant consolidation program and select suppliers • Best practices for inspecting/testing new lubricants • Used lubricant storage, handling, and disposal best practices

What oil analysis can tell you Types and categories of oil analysis Applications for oil analysis Overview of oil analysis tests

• 11 elements of a successful oil analysis program • How clean should sample bottles be? • How to find the best sampling locations • Sampling valves and hardware recommendations • A quick method for optimizing sampling intervals • An oil sampling technique that ruins trending • The importance of primary and secondary sampling points • How to properly sample circulating systems • Safe, effective high-pressure sampling from hydraulic systems • Best practices for sampling splash-, collar-, and ring-lubricated systems

• • • •

12 questions your filter will answer about your machine Which visual inspections can provide big results Used filter inspections Quick tips for using scent, sound, and touch to inspect lubricants

Got a Group to Train? We can customize Introduction to Machinery Lubrication and Oil Analysis – or any of our other courses – to meet your unique needs. We’ll provide expert instruction at a time and place most convenient

Drew Troyer

for your group. Want to know more? Call Brett O’Kelley at 800-597-5460 ext. 112. Whether you have 5 or 500 people to train, Noria is the answer.

Mark Barnes

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Join this list of world-class companies who have benefited from Noria training 3M 76 Lubricants Air Products Akzo Nobel Alabama Power Alcoa Allied Signal Alumax Ameren Arco BHP Copper BP Amoco Bristol Myers Boeing Boise Cascade

Borg Warner Cargill Castrol Caterpillar Centralia Mining Chevron Citgo Clopay ConocoPhillips Destec Energy Detroit Edison Dow Chemical Dow Corning Duke Power DuPont

Eastman Kodak Eli Lilly Entergy ExxonMobil First Energy Florida Power Ford Motor Co. Formosa Plastics General Electric General Motors Geneva Steel Georgia Pacific Georgia Power Goodyear Great Lakes Chemical

Harley-Davidson HB Zachry Holcim Intel Houston Metro Transit International Paper John Deere Kinder Morgan Koch Industries LaFarge Canada Lockheed Martin Lubrication Engineers Lukens Steel M&M Mars MillerCoors

Michelin Northern States Power Nova Chemicals Owens Corning Oxy Chem Pacific Gas & Electric Peabody Coal PPG Industries Procter & Gamble Reliant Energy Rio Tinto Seattle Times Seminole Electric Shell Oil Southern Companies

Sun Company Temple-Inland Texaco Texas Instruments Texas Utilities U.S. Army U.S. Navy U.S. Postal Service Via Rail Canada Westinghouse Weyerhaeuser Whirlpool Willamette Industries Wyeth

Get Certified! Why Certify? Certification is an important part of the training process because it confirms you possess the skills to do the job. Combining training with certification creates a knowledgeable and valuable employee.

Which Certifications? This course is designed to help you prepare for the following ICML certification exams: • Level I Machine Lubricant Analyst (MLA) • Level I Machine Lubrication Technician (MLT) Find out more about these ICML certification exams at the ICML web site: www.LubeCouncil.org

What is ICML? The International Council for Machinery Lubrication (ICML) is a vendor-neutral, not-for-profit organization founded to facilitate growth and development of machine lubrication as a technicalield f of endeavor. Among its various activities, ICML offers skill certification testing for individuals in the fields of machine condition monitoring, lubrication, and oil analysis.

How to Certify evel I following MLT and the Leveltraining. I MLA certification testing will becertification held the LFriday To register for the ICML exam, go to www.LubeCouncil.org or call 918-259-2950 for more information. S av more e than

*By policy, ICML does not endorse training events or study aids as preparation for the examination.

$

75

From our Resource Center… The Level I MLT / Level I MLA Study Packet This Study Packet is designed to be used for both ICML Level I MLT and Level I MLA certification. More than 385 flash cards designed as a study aid for preparing for both ICML Level I MLT and Level I MLA certification. is written for beginners who are starting in the grease field or for practitioners who would like to broaden and deepen their knowledge of lubricating grease. discusses lubricant basics, machine elements that require lubrication, methods of application,

lubrication, lubricant storage and handling, and lubricant conservation. is the No. 1 book in the lubrication industry and makes oil analysis for machinery condition monitoring easy to understand. Once you start reading this book, you probably won’t stop until you finish it. It is that easy to read. You’ll find understandable explanations of how lubricants work, what they’re made of and how they break-down. Topics ranging from engine lubricants to industrial oils and hydraulic fluids are covered. Retail Price: $410.95

$335

$12 for shipping will be added to all study packet orders

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Registration Form Introduction to Machinery Lubrication and Oil Analysis 1

Training Course Course City: _____________________________________________ Course Date: ____________________________________________

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Who Will Be Attending Mr./Ms.: ________________________________________________ Job Title:________________________________________________ E-mail: _________________________________________________

Training Schedule The phone numbers and codes below are for booking hotel reservations only. To register for the course call 800-597-5460 ext 143.

July 27-29, 2010 Mayflower Park Hotel 405 Olive Way Seattle, WA 98101 206-623-8700

October 5-7, 2010 Renaissance Riverview Plaza Hotel 64 South Water Street Mobile, AL 36602 800-922-3298

August 10-12, 2010 Hyatt on Capitol Square

November 9-11, 2010 Hyatt Regency Louisville

75 E. State St. Columbus, OH 43215 888-421-1442

320 West Jefferson Street Louisville, KY 40202 800-421-1442

(Please list additional registrations on a separate sheet and attach)

Company Information Organization: ____________________________________________ Address: ________________________________________________ Mail Stop: ______________________________________________ City: ________________________ State/Province: ____________ Country: ____________________ Zip/Postal Code:___ _________ Phone: ______________________ Fax: _______________________ E-mail: _________________________________________________

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September 21-23, 2010 Platinum Hotel 211 E. Flamingo Road Las Vegas, NV 89169 877-211-9211

Check Noria.com for more dates and locations

Industry Information

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Agricultural Automotive Manufacturing Aviation, Rail, Maritime, Trucking Chemicals & Allied Products Construction & Allied Products Consulting/Services/Training Food Process Manufacturing

General Manufacturing or Other Government/Military Laboratory Mining/Metals Petroleum Products & Refining Pharmaceutical Plastics & Allied Products

Pulp & Paper, Lumber Textiles & Apparel Tire/Rubber Tobacco Utilities (Electric, Water, Gas, Waste)

Other

Phone 800-597-5460 Or 918-749-1400

Certification Study Packet

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4 Ways to Register

Fax 918-746-0925

Quantity

The Level I MLT/MLA Certif ication Study Packet - $335

______

$12 for shipping will be added to all study packet orders.

Method of Payment

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(Certification exams are optional and not included in the training price. Contact ICML at 918-259-2950 or lubecouncil.org to make arrangements to sit for the exam.) ❑ ❑

Noria Corporation ATTN: Training 1328 East 43rd Court Tulsa, OK 74105

❑❑

❑

Card Number: __________________________ Expiration Date: ________________________ Name on Card:__________________________ Signature: ______________________________ ❑

Purchase Order attached: # ____________________________________

Mail Online Noria Corporation www.noria.com ATTN: Training 1328 E. 43rd Court Tulsa, Oklahoma 74105

Registration Information Introduction to Machinery Lubrication and Oil Analysis $1,195 8:00 am to 4:00 pm daily. Check-in begins at 7:30 am. For fast registration, call 800-597-5460 ext. 143 toll-free between 8:00 a.m. and 4:00 p.m. central time Monday through Friday. Or, fax your registration form to 918-746-0925 at any time. The fax line is open 24 hours a day, 7 days a week. We will send a confirmation of your registration via email. If your confirmation does not arrive within 48 hours please contact us to process your registration immediately. In lieu of cash, check and credit cards are preferred when paying at the training site. Your fee provides you the best training around, a comprehensive manual, a free package of training materials, continental breakfast, lunch each day and refreshments. You may cancel your registration prior to the course date or send a

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Emergency Contact Name:__________________________ Phone: __________________

substitute. If you cancel, we will refund your entire payment, cancel your invoice or, if you prefer, apply your payment to a future Noria course.

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Food Allergies

Certification testing is offered by the ICML the morning following this training course at the same hotel. Please contact the ICML to register for the certification exam or register online at their web site:

(Please list any food allergies so that we can better serve you.)

__________________________________________________________________________ __________________________________________________________________________

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Certification Exams

Phone: (918) 259-2950• Fax: (918)259-0177 Email: [email protected] • Online: lubecouncil.org

BOOKSTORE

Welcome to Mach iner y Lubrication ’s Bookstore, designed to spotlight lubrication-related books. For a complete listing of books of interest to lubrication professionals, check out the Bookstore at www.noria.com.

Lubricating Grease Guide Author: NLGI This guide ser ves as a source of basic inform ation on lubricating grease and is a handy quick-reference book. Written for the beginner or for the practitioner who wants to broaden knowledge. It includes a grease application guide for beginners. You’ll know when to select the right grease for your machinery and easily determine which greases are compatible.

How to Grease a Motor Bearing Training DVD Format: DVD Publisher: Noria Corporation How to Grease a Motor Bearing provides plant personnel an overview of the best practices for lubricating electric motor bearings. Anyone responsible for the maintenance, operation and reliability of electric motors will benefit. Use electricians it to train operators, lubrication technici for ans, mechanics, and maintenance personnel years to come. The product has three main benefits: • Lubrication te chnicians will have a clear understanding of why proper motor bearing lubrication is critical.

Practical Lubrication for Industrial Facilities

• You’ll reduce motor failures, downtime , rebuilds and replacement costs.

Author: Heinz Bloch Helps reliability professionals, mechanics, machinists or lubrication specialists understand what matters most in a lubricant, and to distinguish mere sales talk from relevant facts. It is intended to assist the professional in ensuring The Practical Handbook that machinery operates at optimum performance levels with a minimum of costly downtime.

Oil Analysis Basics

• You’ll replace old-time lubrication procedures with vendor-neutral, bestpractice procedures that work.

of

Machinery Lubrication Author: L. Leugner If you want to establish yourself as the lubrication expert in your company, this book is a must-read. Once you pick it up, you won’t put it down until you’ve finished it. It’s that easy to read.

Publisher: Noria Corporation Written by the editors

Introduction to Lubrication Fundamentals Training DVD

of Machinery Lubrication magazine, Jim Fitch and Drew Troyer, this boo k is a great resource for anyone involved in oil analysis or lubrication. Oil Analysis Basics makes oil analysis for machinery condition monitoring easy to understand. You will learn everything from how to take a proper oil sample to how to

Format: DVD Publisher: Noria Corporation The Int roduc tion to Lubr ica tion Fun dam ent als training DVD teaches lubrication basics through highquality animation and video. DVD training makes learning fun and convenient while helping employers provide standardized training for every employee, every time.

select a test slate for your applications.

For descriptions, complete table of contents and excerpts from these and other lubrication-related books, and to order online, visit:

www.noria.com July - August 2010

or call 1-800-597-5460, www.machinerylubrication.com

ext. 104 Machinery Lubrication

Machinery Lubrication July-August 2010

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