Machinery Lubrication

Contents 10

COVER STORY Lube Room Challenge

Machinery

Machinery Lubrication’s annual annual Lube Room Challenge showcases exceptional lube rooms submitted by readers who have transformed their lubricant storage and dispensing methods to best practices.

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Lubrication September - October 2011

34

AS I SEE IT Justifying the Cost of Excluding a Gram of Dirt

CERTIFICATION NEWS Eli Lilly’s Wenzel Embodies the Spirit of ICML

ITCH AUTHOR : JIM F ITCH

AUTHOR : SUZY J JAMIESON

Many variables and factors influence the cost of excluding a gram of dirt. However, there are many more costly consequences associated with failing to exclude.

By successfully completing the very first ICML exam 10 years ago, Rendela Wenzel not only became one of the first ICML-certified professionals but also the ver y first ICML ICML-certified -certified female practitioner.

6

HYDRAULICS AT WORK How a Band-Aid Solution Can Fix Your Hydraulics Problems

FROM THE FIELD 6 Steps to Update Your Lubrication Program

44

TEPHEN N SUMERLIN AUTHOR : S TEPHE

AUTHOR : BRENDAN CASEY

There’s a negative negative bias toward toward the BandAid solution in engineering, but there are times when a convenient shortcut is needed. The trick is being able to recognize when a Band-Aid solution is appropriate and when it is not.

24

OIL ANALYSIS Lubricant Analysis in Steam Turbines AUTHORS: BEATRIZ GRACA, JORGE SEABRA, PINTO SOUSA

Discover the potential of analytical ferrography in diagnosing the early stages of sludge and varnish problems so the root cause can be determined and corrective action taken before a catastrophic failure occurs.

More

Editorial Features 20 GET TO KNOW 32 NOW ON MACHINERYLUBRICATION.COM

When updating your lubrication program, it is important to think of every aspect of lubrication. Just working on one area will not yield the results you desire.

LUBE-TIPS

46

Our readers provide excellent advice on a host of lubrication-related issues.

BACK PAGE BASICS Comparing Gasoline and Diesel Engine Oils

48

RIGHT AUTHOR : JEREMY W W RIGHT

While gasoline and diesel engine oils generally have the same anatomy and are formulated from the blending of base oils and additives, they actually are quite different when examining the lubricant’s required performance for each engine type.

Departments 18 PRODUCT NEWS 22 CROSSWORD PUZZLER

30 BOOKSTORE 40 PRODUCT SUPERMARKET 42 TEST YOUR KNOWLEDGE

Contamination Control

AS I SEE IT

JIM FITCH NORIA CORPORATION

JUSTIFYING the COST of EXCLUDING a GRAM of DIRT

For years Noria has been saying, “The cost of excluding a gram of dirt is probably only about 10 percent of what it will cost you once it gets into your oil.” Recently, a Noria training client asked us to document proof of this statement. It reminds me of a widely used quote from Benjamin Franklin: “If you think education is expensive, try ignorance.” Or another familiar one: “Pay me now or a whole lot more later.” Proactively investing in reliability and machine wellness is very often challenged by the need to justify. Management is always asking for financial analysis and to “make the business case.” Conversely, a financial study rarely is produced to obtain funds to repair a failed machine, especially when plant production has stalled. Sadly, I’ve heard maintenance folks say that they’ve quit trying to propose proactive measures to management. They claim it’s easier to just let the machines fail. This is like saying it’s easier to just wait until you have a heart attack than to proactively make the lifestyle changes needed to avoid heart disease (diet, fitness, quit smoking, etc.). These differences are often deeply ingrained in management and business culture. Does your organization have the “here and now” folks or those who “plan and prepare?” On the bright side, an increasing number of companies are led by managers who do “get it.” Much of this has been driven by the growing base of documented success stories from organizations and program leaders who have championed change and happily reported their results. They didn’t need to be beaten over the head but rather took the initiative and captured the benefit.

escalate the ingress. Air typically enters through vents and breathers, past shaft seals, unsealed hatches and cleanout covers, and other unprotected machine openings. New oil is also a source of contamination, as are invasive inspection and repair activities. Hydraulic systems using linear actuators receive a high percentage of their partic les from ingression past worn wiper seals and rod seals. Of course, mechanical wear, corrosion, oil degradation and surface exfoliation are also common sources of solid particles. The cost of contaminant exclusion relates to both retrofitted hardware and routine maintenance tactics for blocking contaminant entry. These costs include such things as transfer cart filtration, proper breathers on machines and lubricant storage vessels, improved seals (labyrinth, for instance), tighter system closures, greater awareness and care during internal inspections and part replacement (education and better procedures/ tools), routine cleaning of

The Cost to Exclude a Gram of Dirt For those wondering what is meant by excluding a gram of dirt, it’s a rather simple concept. First, figure out what the contaminant is (dirt, coal dust, fly ash, etc.) and then determine the point(s) of entry (tank vent, worn seals, hatch, etc.). Some do this by examining particles found in used filters and sump sediment aided by common laboratory tools (XRF, SEM, optical microscopy, etc.). For many machines, the inhaling of airborne contaminants into reservoir and tank headspace is the primary source of contamination. Forced convection of air by thermal syphoning, machine-driven air currents (e.g., movement of gears, plunging oil return-line flow) and cyclical changes in the tank oil level (hydraulic cylinder movement) can 2 | September - October 2011

www.MachineryLubrication.com

Machinery

Lubrication PUBLISHER

Mike Ramsey - [email protected]

machine exteriors and many other similar methods. Depending on the type of machine, this could generate initial costs ranging from $100 to $1,000 per machine. There is also an annual ongoing cost of routine maintenance relating to contaminant exclusion (e.g., replacement breathers).

The Cost of an Unexcluded Gram of Dirt 1. The Cost of Machine Wear Caused by Ingressed, Unfiltered Particles We are all aware that particles make particles. The number of new particles generated from a single ingressed particle depends on many factors, including the type of machine, filtration, settling, number of frictional zones, working clearances and operating speeds. Basically, it relates to how many surface scratches and indentations a particle is allowed to make before it is pulverized, settles to the tank floor or removed by an oil change or filter. If ingressed particles reach the filters fast, there is less damage and few new wear particles are produced. Conversely, if no filtration or poor filtration is the case, this leads to longer particle residence time in the fluid and thus more damage and more production of wear debris. An average ingressed dirt particle (left unremoved in the oil) will generate somewhere between five and 20 new particles (secondary particles). Some of these particle s will make more particles (tertiary particles). The situation is selfpropagating. Additionally, you can imagine that a single scratch mark from a grain of dirt can produce a corkscrew wear particle long enough to crush into five or more particle segments. Take a look at the data below from 17 hydraulic systems (ref. Pall Corporation). The highly filtered five cleanest systems only had 7 percent wear particles (metallic). The destructive dirt was removed quickly, preventing the generation of secondary and tertiary particles. On the other hand, the five dirtiest systems generated

117,768 new particles, representing 42 percent of all the particles in the fluid. If a better filter was then applied, the filter would plug quickly from the high concentration of particles, of which nearly half were formally a part of the machine.

GROUP PUBLISHER

Brett O’Kelley - [email protected] EDITOR-IN-CHIEF

Jason Sowards - [email protected] SENIOR EDITOR

The Costs: The high cost of machine repair and lost production (if no oil filter or poor-quality filters are used) is 10 to 10,000 times the cost of contaminant exclusion.

Jim Fitch - jfi[email protected] TECHNICAL WRITER

Jeremy Wright - [email protected] CREATIVE DIRECTOR

Ryan Kiker - [email protected]

2. The Cost to Remove Ingressed Particles by Oil Filtration In well-filtered, high-ingression systems such as off-road hydraulics, more than 90 percent of the particles found in oil filters are likely to be terrain dust (ingested from the air). For indoor equipment running in a relatively clean environment, the filter might be loaded with 50 to 90 percent metallic particles. By comparison, particles in unfiltered systems such as splash-fed gearboxes might be more than 95 percent metallic due to self-propagating particle generation. Filters cost less to maintain (last longer) when: • Particle ingression is kept in check (seals, breathers, etc.). • High oil cleanliness targets are set and maintained. If you can’t keep ingression in check, you are left with using filtration to stabilize high oil cleanliness targets. This is best done by removing particles quickly. Remember, the longer particles are allowed to stay in the oil, the more secondar y and tertiary particles are generated. Then, they too have to be filtered out (increasing the cost of filtration). One or more of the following methods are the best ways to remove particles quickly: • Locate filters just downstream of ingression sources, such as on a hydraulic return line. • Maintain a high flow rate through filters (to quickly carry particles to filters for removal). • Employ multiple filters. • Use high capture-efficiency filters.

F IV E CL EA NE ST

M ID DL E S EV EN

F IV E DI RT IE ST

Total Particles

980

33,000

280,400 (the cause)

Total Nonmetallic

911

20,643

162,632

Total Metallic

69

12,357

117,768 (the effect)

Percent Metallic

7%

37%

42%

Relative Filtration Cost

1

2

4

GRAPHIC ARTISTS

Steve Kolker - [email protected] Gustavo Cervantes - [email protected] Julia Backus - [email protected] ADVERTISING SALES

[email protected] Phone: 800-597-5460 MEDIA PRODUCTION MANAGER

Rhonda Johnson - [email protected] CORRESPONDENCE

You may address articles, case studies, special requests and other correspondence to: Editor-in-chief MACHINERY LUBRICATION Noria Corporation 1328 E. 43rd Court • Tulsa, Oklahoma 74105 Phone: 918-749-1400 Fax: 918-746-0925 E-mail address: [email protected]

MACHINERY LUBRICATION Volume 11 - Issue 5 September —October 2011 (USPS 021-695) is published bimonthly by Noria Corporation, 1328 E. 43rd Court, Tulsa, OK 74105-4124. Periodicals postage paid at Tulsa, OK and additional mailing offices. POSTMASTER: Send address changes and form 3579 to MACHINERY LUBRICATION, P.O. BOX 47702, Plymouth, MN 55447-0401. Canada Post International Publications Mail Product (Canadian Distribution) Publications Mail Agreement #40612608. Send returns (Canada) to BleuChip International, P.O. Box 25542, London, Ontario, N6C 6B2. 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 or Fax: 866-658-6156. Copyright © 2011 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. CONTENT NOTICE: The recommendations and information provided in Machinery Lubrication and its related information properties do not purport to address all of the safety concerns that may exist. It is the responsibility of the user to follow appropriate safety and health practices. Further, Noria does not make any representations, warranties, express or implied, regarding the accuracy, completeness or suitability, of the information or recommendations provided herewith. Noria shall not be liable for any injuries, loss of profits, business, goodwill, data, interruption of business, nor for incidental or consequential merchantability or fitness of purpose, or damages related to the use of information or recommendations provided.

Award Winner, 2008, 2010 and 2011


September - October 2011

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AS I SEE IT

Of course, all of this costs money, plus the hassle to maintain. In contrast, a filter used as an air breather will hold more particle mass (perhaps two to five times more) than the same filter used to clean oil (same size and micron performance). As a final note on filtration, while many contaminant-exclusion tactics can prevent the entry of particles of all sizes, oil filtration, on the other hand, is selective. It generally only removes particles above the micron rating (say, 10 microns), leaving the smaller particles undeterred and available to do damage to the base oil, additives and the machine. The Costs: The cost to filter your way to clean oil is perhaps 10 times greater than the cost of exclusion.

3. Increased Oil Consumption Due to Uncontrolled Particle Ingression

consumption (from additive depletion and base oil oxidation) and less downtime from oil changes and flushing. We’ve also reported in the past the many hidden costs of an oil change. One consultant (Ken Brown) has estimated that an oil change can cost more than 40 times the cost of the oil and labor. An oil change is disruptive to the machine. It not only can cause downtime but also an internal disturbance that can lead to collateral damage. One common and serious disturbance is called the “fish bowl effect,” which relates to the redistribution of sediment as a result of an oil change. Of course, dirty oil is also a primary cause of oil leakage. Particle contamination abrades seals over time. Some companies have reported more than an 80-percent reduction in leakage as a result of maintaining higher oil cleanliness. The Costs: Oil consumption and associated costs (including seal repairs) may exceed 10 times the cost of contaminant exclusion.

Most people don’t associate particle contamination with lubricant service life, oil change frequency or the overall cost of lubricant consumption. We’ve reported 4. Energy Consumption Losses Due to Particle-induced Wear many times in Machinery Lubrication on how oils age. For instance, one of the wellWear not only leads to machine operaknown drivers of oil oxidation is the presence tional failure but also impedes performance of catalytic wear metals in the oil. Wear in the intervening period leading up to particles don’t get into the oil by themselves. repair or overhaul. During this period there One very common source of wear particles is is usually impaired productivity due to slugparticle-induced wear (secondary and tertiary, gish or erratic machine function. There is as previously discussed). Suspended dirt also increased energy consumption. For particles also provide a site for oil additives instance, when hydraulic pumps and actuato hitch a ride. This ties up these additives, tors wear, they lose volumetric efficiency. which suppresses their ability to perform their This slows work (pumps and actuators move intended function. slower) and increases the consumption of So less dirt ingression means less wear energy (and heat distress to the lubricant). debris production, which means less antioxi- Gears and bearings also consume more dant additive depletion, which means less oil energy as a result of wear.

4 | September - October 2011

Even diesel engines suffer from decreasing combustion efficiency due to wear in the valve train, bottom-end bearings and combustion chambers (rings, piston, cylinder wall, etc.). A corresponding increase in fuel consumption results. Wear in these zones is often associated with particles in the lubricating oil. One simple way to exclude particles from entering the crankcase is to enhance the quality of the induction air filter. The Costs: The cost of lost work and increased energy consumption over the life cycle of the machine may exceed 20 times the cost of contaminant exclusion.

The Tally As you can see, many variables and factors influence the cost of excluding a gram of dirt. However, there are many more costly consequences associated with failing to exclude. The quote at the beginning of this article claimed a 10-to-1 difference. On closer inspection, the actual difference is arguably more than 100-to-1 when taken across the life of the machine.

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 courses 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 jfi[email protected].


Hydraulics

HYDRAULICS AT WORK

BRENDAN CASEY

HOW a BAND-AID SOLUTION can FIX your HYDRAULICS problems

Last year there was a book on the New York Times bestseller list called Have a New Kid by Friday . It was written by psychologist Kevin Leman and has sold more than 400,000 copies. To capitalize on this book’s success, Leman is hur rying out another titled Have a New Husband by Friday . Leman’s literary success is testimony to the appeal and popularity of the quick (and effortless) fix for a problem. Don’t get me wrong, I have no issue with the concept of a quick fix where one is legitimately available, but as a parent I know you can’t replace a child’s bad behavior with good in seven days. Most parents can’t even read the book in seven days. As a husband, I also know my bad habits won’t be eliminated in seven days. My wife may well be able to replace me in seven days but not change me. Any thinking person knows instant results for anything but the simplest of problems are an illusion, but this is not to say that the notion of a quick fix or even a Band-Aid solution doesn’t have its place. Last week I had a conversation with a longtime client who’s been having a long-running battle with the manufacturer of a hydraulic machine he purchased three years ago. The machine has never

91%


of people have used a BandAid solution for a problem, according to a recent survey at www.machinerylubrication.com

The trick is being able to recognize when a Band-Aid solution is appro priate and when it is not. performed to either my client’s satisfaction or the manufacturer’s advertised specifications. This client is an owner/operator, which means his machine is his livelihood. And he’s had enough. So now he’s taking the machine’s manufacturer to court — a decision he hasn’t taken lightly. Although he didn’t consult me directly about this issue, I was aware of the problems he was having and the way in which the equipment manufacturer was responding to them. The crux of the issue, and one which will now be argued in court, is the machine model my client bought was marketed as a “professional” version, meaning it was designed to be used a minimum of eight hours a day, five days a week. This is in contrast with hobbyist or weekender use of typically a couple of hours in a stretch, a couple of days a week. The trouble is, when the “professional” model my client purchased was operated continuously for more than a couple of hours, its performance dropped off dramatically. The primary reason for this, which was blatantly obvious to me, was insufficient install ed cooling capacity, or more accurately, no cooling capacity at all. Not only did I share this assessment with my client, but because I’d done work for him before and didn’t want to see him lose work and income as a result of the machine’s obvious design flaw, I presented him with a Band-Aid solution — switch to a high-VI synthetic oil. Now don’t get me wrong. I’m all for doing things right. The correct solution to this issue was to install a heat exchanger of sufficient capacity to maintain an appropriate and stable operating oil temperature and therefore viscosity. But in this case, there were two major barriers to this happening. The first was the compact nature of the machine, which allowed for little or no space to retrofit a hydraulic oil cooler. The second was my client quite rightly expected the machine’s manufacturer to do this under warranty, which meant they first had to admit the machine had a design flaw.

81%

of people view Band-Aid solutions negatively, based on survey results from www.machinerylubrication.com www.MachineryLubrication.com

HYDRAULICS AT WORK

Switching to a high-VI synthetic oil would do nothing to address the issue of insufficient cooling capacity, but it would help the machine cope with it. So in this respect, it definitely qualified as a Band-Aid solution.

The Best Kind of Solution In his book, The Tipping Point , author Malcolm Gladwell describes why Band-Aid solutions should be viewed in a positive light. “But that phrase (Band-Aid solution) should not be considered a term of disparagement. The Band Aid is an inexpensive, convenient and remarkably versatile solution to an astonishing array of problems. In their history, Band-Aids have probably allowed millions of people to keep working or playing tennis or cooking or walking when they would otherwise have had to stop. The Band-Aid solution is actually the best kind of solution because it involves solving a problem with the minimum amount of effort and cost. We have, of course, an instinctive disdain for this kind of solution because there is something in all of us that feels that true answers to problems have to be comprehensive, that there is virtue in the dogged and indiscriminate application of effort, that slow and steady should win the r ace. The problem , of co urse, is that t he indiscri minate a pplicati on of effort is something that is not always possible. There are times when we need a convenient shortcut, a way to make a lot out of a little...”


Unfortunately, my client didn’t act on this advice. Maybe it was because, despite the apparent widespread popularity and seductive appeal of the quick fix, we have been conditioned to think of Band-Aid solutions in negative terms. This negative bias toward the Band-Aid solution in engineering is particularly strong, and in many situations, rightly so. For example, there’s no way a Band-Aid solution is appropriate for the recent problems of the Rolls-Royce Trent 900 engines fitted to the Airbus A380. But if you have a mini-digger with a chronic overheating problem that is not easily corrected, being open to a Band-Aid solution can be very constructive. As mentioned earlier, I’m all for doing things the right way, and I consider quick-fix, silver-bullet, magic-pill, cure-all solution-seeking as lazy and unrealistic. But as author Malcolm Gladwell says, “There are times when we need a convenient shortcut…” The trick is being able to recognize when a Band-Aid solution is appropriate and when it is not. I wish this client the best of luck with his lawsuit. He deserves to win. But more than that, having declined the Band-Aid solution, now he has to win.

About the Author Brendan Casey is the founder of HydraulicSupermarket.com and the author of Insider Secrets to Hydraulics, Preventing Hydraulic Failures, Hydraulics Made Easy and Advanced Hydraulic Control . A fluid power specialist with an MBA, he has more than 20 years of experience in the design, maintenance and repair of mobile and industrial hydraulic equipment. Visit his Web site: www.HydraulicSupermarket.com.




Machinery Lubrication recently issued its annual Lube Room Challenge for readers to submit exceptional lube rooms that incorporate best-practice features. Several readers met the challenge with

evidence of how their lubricant storage and dispensing methods have been transformed. The following entries showcase how designing a proper lube room is one of the first steps to achieving lubrication excellence.

Agrium Tim Johnson at Agrium’s Conda phosphate operation in Soda Springs, Idaho, was just waiting for a chance to show the improvement that had been made to his plant’s lubrication program. The photos below illustrate just how far the company has come in a relatively short period of time. r e f o B e

r e f o B e

One of the company’s previous lube rooms used typical barrel racks, no desiccant breathers or oil filtration. Oil inventory space was small, forcing some stock to be left outside exposed to the elements.

The old-style lube room required all oil drum delivery from vendors to be done outside and then moved through a narrow doorway, exposing personnel to hazardous conditions.

r t e A f

The new oil filtration and dispensing room allows oil to be delivered directly to the inside of the room, avoiding hazards and exposure to the elements. This room is climate-controlled and large enough to fit all oils that are used in the plant’s equipment . r t e A f

r t e A f

The view from the inside of the new oil filtration and dispensing room shows oil filter units, dispensers, desiccant breathers and oil inventory. Instructions for the operating filter system are available on the bulletin board. The floor is covered with a nonslip epoxy coating, which improves the safety of personnel and is tough enough for the heavy loads from the oil drums. Desiccant breathers are installed on all oil barrels when put into service. When an empty barrel is replaced, the new oil is allowed to multi-pass in the filter system for two hours before dispensing. This results in typical ISO-rating improvements from 20/17/14 at the beginning of multi-pass to 15/14/13 when complete.

This is a close-up of the oil dispenser. Each type of oil has been tagged on the on/off switch, fill piping and at each drum filter. The dispenser tray is engineered to hold more than 55 gallons in the event of an upset. Also, the floor is designed to contain all oil stocked inside this room in case of accidental spills.



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COVER STORY

Cargill Cargill’s facility in Newark, Calif., follows best practices by filtering and dispensing in designated containers. Previously, lubricant was dispensed in whatever container was available. Now color-coded containers with like-colored tags are posted at each piece of equipment. r e f o B e

r t e A f

The Cargill facility uses colorcoded containers with like-colored tags that track when the oil and filters were last changed.

enabling all the new oil and fluids to be filtered. Hydraulic fluids are filtered to an ISO 4406 cleanliness standard of 17/15/13. Motor oil and transmission fluids are kidney-looped with 10-micron filters for a period of up to 24 hours. Fluids are then dispensed through Graco pumps and separate 10-micron filter assemblies. Transfer carts are also equipped with the same quick couplers, and they receive the same filtering process before they are used. To minimize contamination, the vents from the IFH tanks are independently plumbed to a centralized overflow container system, which is vented with a desiccant filter. Transferring the fluids consists of a sequence that uses different types of pumps specific for a type of fluid being pumped. Hydraulic and specialty fluids are dyed to specified colors for easy identification. EWEB uses a series of containers that are also color-coded and labeled for the same specific fluids. Spill containment is utilized for all storage tanks and racks. The lube room also includes spill clean-up materials, spill dikes and absorbent wipes. The room has been equipped with an emergency shower and eye-wash station. The facility is certified in Oregon as an Eco-Biz facility, meaning that it has reached the highest standards in minimizing its environmental impact. EWEB employees have taken pride in implementing proper material-storage methods and hazardous waste-management techniques within the lube room.

Eugene Water and Electric Board The Eugene Water and Electr ic Board (EWEB), Oregon’s lar gest public utility, is no stranger to promoting sustainable practices. Its lube room is no exception. It consists of two double-walled storage tanks that are used for synthetic-blended motor oils. It also entails a modified IFH storage and dispensing system that handles hydraulic and transmission fluids, as well as Rhino Tuff poly tanks for coolant and washer fluids. The room features concrete walls, a sealed floor, a fire sprinkler system and an automated climate-control system that maintains the room at a consistent temperature throughout the year. Through lab testing of incoming oils and fluids, EWEB identified that in many cases the oil and lubricants that were purchased were filthier than the fluids that were being removed. Because of this, EWEB equipped all of its storage tanks with quick couplers,

EWEB’s lube room consists of two double-walled storage tanks for synthetic-blended motor oils, a modified storage and dispensing system that handles hydraulic and transmission fluids, as well as tanks for coolant and washer fluids.

…in many cases the oil and lubricants that were purchased were filthier than the fluids that were being removed. The EWEB lube room also has an emergency shower and an eye-wash station.



COVER STORY

r e f o B e

MillerCoors M MillerCoors first upgraded its lube room in Golden, Colo., several years ago with some significant changes. Although the more recent upgrades are minor in comparison, t hey are still important in the company’s journey to world-class lubrication. The MillerCoors lube room now has an exhaust ventilation system, fire-protection system and explosion-proof lighting fixtures. A training room has been created specifically for lubrication with a 3-hour class offered. A bi-weekly “Lube-Tips” style e-mail is sent out to all the packaging teams on best lubrication practices and lubrication safety issues. The e-mails provide a great way t o keep people thinking about lubrication and its importance to the reliability of the equipment. r e f o B e

Oil drum transfer pumps were often left in poor environments (left) where they could be exposed to contaminants. A storage drum for the pumps was provided to keep them cleaner and in one place (right). There are also separate hoses to avoid cross-contamination of lubricants. Both the pumps and the hoses have identification tags.

r t e A f

This old drum pump setup (left) had basic transfer pumps. Although breathers were later installed on each dr um, the oil was still not being filtered, and the operators had to hook up an air hose to the pumps. No 5-S visuals were in place. The picture on the right shows the new pump systems with 10-micron filters and 5-S visuals on the floor with oil identification placards on the wall behind each drum.

r e f o B e

r t e A f

These color-coded grease guns (left) help with easy identification of grease types. They also have the health hazard tags included on them. The guns pictured were just out of the box and had not yet been fitted with coupler tip covers that are used for contamination control. MillerCoors also carries different sizes of disposable funnels (right) and tries to promote their use.

r t e A f

This old wooden workbench (left) was being used for filling Oil Safe secondary containers and for cartridge replacement of grease guns. It was replaced with a stainless-steel table (right) similar to those used for food preparation in restaurants. It provides a cleaner setting to do this work.

Utilizing Oil Safe secondary containers helps in the identification of the many lubricants being used as well as contamination control. Although a lubricant identification system was in place, MillerCoors’ Richard David came up with new identification cards that also incorporate symbols to go along with the color coding. Between the two systems, it is almost impossible to mix up lubricant types. David’s lubricant identification cards also promote good visual factory practices.


Although this area is not inside the MillerCoors lube room, it is a big part of the company’s lubrication efforts. Realizing the importance of proper lubrication, the management team allowed for the creation of a training room specifically for lube training. A 3-hour class is offered that covers basic lubrication best practices, the importance of lubrication and how it is instrumental to the reliability of the equipment. The Noria DVD “Lubrication Basics for Machinery Operators” is used to reinforce much of what is covered in the class.


Georgia-Pacific Initially, the oil storage room at the Georgia-Pacific mill in In Muskogee, Okla., needed a lot of attention. When the room was overhauled, an HVAC unit was installed to maintain room temperature, the entire room was cleaned and repainted, new lighting was installed, new cabinets for equipment filters and oil transfer pumps were put in, press filters wer e added to clean the oil before it enters storage totes, new oil containers were purchased and proper labelling was instituted.

The plant plant’s ’s next steps towar towardd achie achieving ving lubr lubricati ication on exce excel-llence will be to change from a 10-micron filter to a 5-micron filter to improve particle counts, implement monthly preventive maintenance, train all operations and maintenance staff on the fundamentals of lubrication, revise the sampling program and install proper oil sampling ports on the equipment. r t e A f

r e f o B e

Before overhauling its lube room, the Georgia-Pacific mill faced a significant challenge challenge to meet its cleanlines cleanliness s objectives.


After the lube room was modified, the condition of the storage room and its contents were dramaticall dramatically y improved.


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COVER STORY

Power Partners Power Partners Inc. in Athens, Ga., never really had a lube storage room, but company officials thought they were fine until they read a few articles i n Machinery Lubrication and attended a Reliable Plant Conference. They quickly realized they had a big problem. The company has come a long way over the last 14 months. While there are a few more things they want to accomplish, they are extremely proud of their efforts. With the new lube room and enhanced policies and procedures that go with it, Power Partners Partners has realized an annual cost savings of more than $28,000. Factor in the other reliability programs they have implemented in the shop, and the annual cost savings total more than $46,000. Rio Tinto transfers oil from 55-gallon barrels into totes, which are then filtered and fitted with desiccant breathers.

r e f o B e

The original Power Partners lube room featured metal funnels out in the open along with buckets and barrels everywhere. r t e A f

At the new Rio Tinto lube room, all oil is dispensed into color-coded containers, which are cleaned after use.

Temple-Inland

The company’s new lube storage room has dedicated storage totes, a communications corner, clear grease guns with calibration stickers, an oil matrix that details which oil goes in which machine, and oil transfer jugs that are tagged and color-coded.

The Tem Temple-Inland ple-Inland lube room in Cumberland City, Tenn., boasts drums with air-powered pumps and 5-micron filter s, sample ports and quick disconnects on the drums and Oil Safe containers. Oil is filtered as the Oil Safe containers are filled, fil led, and the lids do not need to be removed to fill. The pumps can also be utilized to polish the oil before use. r e f o B e

Rio Tinto The lube room at Rio Tinto Minerals in Boron, Calif., was built in 2007 and has been maintained thanks to the hard work of the lube crew and support from upper management. The company transfers oil from 55-gallon barrels into totes using dedicated filter carts. The totes are then filtered to achieve the desired ISO standard and fitted with desiccant breathers. Oil samples are taken monthly to verify continued compliance. All oil is dispensed into color-coded containers, which are cleaned after being used. 16 | September - October 2011 2011

These photos show the Temple-Inland lube room before changes were made.


r t e A f

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At Temple-Inland’ Temple-Inland’s s new lube room, oil i s filtered as the Oil Safe containers are filled.

Cerveceria Bucaramanga The init T initiati iative ve to mod modify ify the lub lubee roo room m of Cervec Cerveceria eria Buc Bucaraaramanga, a SABMiller plant in Colombia, began after company personnel read an article in Machinery Lubrication on the advances of Clopay Plastics’ lube room. They felt encouraged to improve their lube room and received advice from Noria Latin America as well as a lot of training, which was important to their success. They also have included several practices from the Oil Analysis Basics book book by Noria Corporation. With the improvements, Cerveceria Bucaramanga now has an oil cleanliness level of ISO 4406 (14/12/8) on its oil storage tanks. The lube tasks also are ergonomic and easier to perform, having been optimized by more than 15 percent. The workers feel proud of this and take great care to maintain this goal and even improve upon it.

After strategic improvements were made, the new lube room at Cerveceria Bucaramanga in Colombia includes a used oil storage area and dedicated filters for intermediate oil c ontainers.

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These photos show the old Cerveceria Cerveceri a Bucaramanga lube room before the improvement project began.



| 17

MOTOR OIL

S W E N T C U D O R P

Valvoline’s NextGen motor oil features a new formula made from 50-percent recycled oil to deliver 100-percent engine protection . Developed through years of research, technology and innovation from scientists coupled with improvements in the oil re-refining process, NextGen motor oil is good for engines and the environ ment, exceeding industry specifications with reduced environmenta l impact compared to non-recycled motor oil. Valvoline www.valvoline.com 800-832-6825

FILTER PACK

FOOD-GRADE LUBRICANTS The new UltraLube food-grade lubricants not only meet NSF standards but also offer four times the natural lubricity of petroleum-based oils. These bio-based oils instantly penetrate into areas where lubrication is needed most and create a long-lasting bond to metal and plastic surfaces. Specifically formulated with EP additives to provide protection under heavy shock loads, UltraLube H1 Food Machinery Grease is ideal for lubricating bearings, gears and machine slides. It also offers superior adhesion and protects all ferrous metal components from rust and corrosion.

The new FilterPak from Y2K Fluid Power incorporates a sturdy diamond-plate aluminum frame, a milled-aluminum grip and a 1-hp Viking pump with a capacity of 2.5 to 5 gallons per minute. It also sports a visual indicator with 50 psi bypass, a 10-foot swivel discharge hose, a 7-foot swivel suction hose, a 3-foot electrical cord and an on/ off switch. Y2K Fluid Power www.y2kfluidpower.com 888-925-8882

UltraLube www.UltraL ube.com 800-545-1689

FOOD-GRADE PENETRATING OIL

PORTABLE LUBRICATION SYSTEM

The new Food Grade Penetrating Oil from CRC is an effective and efficient non-silicone lubricant for use on all food-processing equipment. The highly refined white mineral oil is colorless, odorless and tasteless to meet NSF and FDA standards. The general-purpose penetrant can be used to loosen rust, scale and corrosion around fasteners and hose fittings on food-processing equipment.

The new mobile lubrication system fr om the IFH Group provides storage and dispensing of lubricants for industrial plants requiring lubrication maintenance at multiple locations over a large area. The new system is delivered on a pallet that allows it to be placed in the bed of a truck for mobility anywhere within the plant. It includes two 50-gallon and two 25-gallon steel containers with PVC sight gauges. Air-operated piston pumps provide a 5-to-1 pumping ratio, while filters on the side remove any dirt or small particulates. Startup is quick and easy with the onboard gas-operated air compressor.

CRC www.crcindustr ies.com 800-556-5074

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The IFH Group www.if hgroup.com 800-435-7003 www.MachineryLubrication.com

METAL-WORKING FLUID Developed for use in high-pressure applications, the new Cimperial 1072-HFP fluid from Cimcool is recommended for all metals and heavy-duty machining operations including turning, drilling, tapping, reaming, gear cutting and broaching. It prevents, controls and reduces foam even when fluids are used in high-pressure delivery systems. Cimperial 1072-HFP also provides excellent lubricity, extends fluid life, is operator and machine friendly and helps prevent corrosion on parts and machine components. Cimcool www.cimcool.com 888-246-2665

PRESSURE SWITCH SKF’s new DSB1 pressure switch for monitoring centralized lubrication systems is designed to attach directly to the lubricant line. This position is in contrast to conventional pressure switches that branch off to a cul-de-sac where grease is never mixed, which can form a blockage, harden and render the pressure switch ineffective. The new DSB1 pressure switch is installed before the last distributor, where the grease consumed by the distributor constantly flows past the switch, eff ectively preventing blockage. SKF www.skf.com 267-436-6000

MARINE ENGINE OIL

FOOD-GRADE COMPRESSOR LUBRICANTS Ultrachem has developed a new line of Omnilube food-grade rotary screw and reciprocating air-compressor lubricants with improved wear, oxidation and lubricity. These fully synthetic compressor oils are formulated from high-quality polyalphaolefin (PAO) base oils with a proprietary additive package to achieve long life. The oils meet all of the requirements of the USDA and FDA H-1 regulations, and conform to NSF requirements. They are also approved for Kosher use.

Royal Purple’s new line of multi-vis 30-weight and 40-weight four-stroke High Performance Marine (HPM) engine oils promise to give boaters better protection for their engines. These new oils feature Royal Purple’s advanced additive lubricant technology, Synerlec, which creates an ionic bond that adheres to metal parts to provide continuous protection and strengthens the oil for better performance. It also has high film strength that prevents contact between metal parts and improves sealing inside the engine for more complete combustion and reduced wear. Royal Purple www.royal- purple-i ndustria l.com 888-382-6300

Ultrachem www.ultrachem inc.com 302-325-9880 www.MachineryLubrication.com


19

M L

GET TO KNOW

Christensen Directs Lube Crew at

Kennecott

Utah Copper

Name: Jan Christensen Age: 60 Title: Lubrication Technician 2 Company: Kennecott Utah Copper Location: Magna, Utah Years of Service: 10 years

Jan Christensen began working on heavy equipment as a mechanic in 1973. He started with Fluor Industrial Services working at Kennecott Utah Copper’s smelter in 2002 as a mechanic. He joined the lube team in November 2006 and has worked in several important roles for the lube team, providing valuable input and overseeing key projects since that time.

Q What made Rio Tinto and Kennecott Utah Copper (KUC) decide to put more emphasis on machinery lubrication?

lubricators, replacing faulty or empty units as needed, check and maintain oil levels, and inspect desiccant breathers and replace them as needed.

A At the KUC smelter, we implemented changes that led toward improving reliability, including hydrocarbon management in 2001 Q What lubrication-related items are you currently and 2002. This improvement was aided by Rio Tinto’s corporate working on? drive toward improved reliability and hydrocarbon management A I am working on installing a head space-management system for during the same timeframe. The rate of improvement increased our bulk oil totes in an effort to improve our new/bulk oil cleanliwhen Rio Tinto placed additional focus on these ar eas in 2004. ness. I am also gathering data to set up electric motor grease routes throughout the plant. Q How did you get your start in machinery lubrication? A I have been working at the KUC smelter since January 2002. Prior Q How does your company view machinery lubrication in to working at the smelter, I worked on heavy equipment for 30 years. terms of importance, strategy, etc.? I also purchased lubricants and did oil sampling. I came to this job A Our six-man crew works for Fluor Industrial Services, the in the lube group in November 2006 under the direction of the reli- company KUC contracts to perform maintenance at the smelter. ability group and have been with the group since then. The lube group reports to the reliability group. Both of these groups Q What types of training have you taken or been involved with? What about future training?

are highly motivated to make sure the equipment is l ubricated properly and with the correct lubricant. Rio Tinto and KUC have high HCM standards, which we are working hard t o meet.

A Before working for KUC, I had several hydraulic and electrical training classes on cranes and other heavy equipment. Since coming Q What have been some of t he biggest lubrication project to KUC, I have had oil analysis level I, II and III and machinery lubri- successes in which you have played a part? cation level I training from Noria, as well as training from suppliers. A We have installed new poly totes with kidney-loop systems I have also been involved in several Rio Tinto internal human capital used to store new bulk oils, as well as a lube trailer to be used management (HCM) program assessments. on some of our remote equipment for oil changes. We have also Q What is the range of equipment that you service through installed several kidney-loop systems throughout the plant and lubrication tasks at the smelter? implemented filter cart routes. I have also been involved with peer A We service pumps, fans, conveyor belts, compressors, feeders, review/peer assist HCM assessments at the smelter and other agitators, ball-and-roller mills and other smelter-processing equipment. plants within KUC. Q What do you see as some of the more important trends Q What is a normal work day like for you? A We have a six-man lube crew that is dedicated to grease and taking place in the lubrication and oil analysis field? oil-related issues. On any given day, you could find us doing any A We are seeing oil companies being pushed to become more of the following: oil changes, grease routes, oil routes, oil sample accountable for their products, and we have been getting more routes and filter cart routes. On these routes, we check automatic on-site oil analysis testing equipment. 20 | September - October 2011


M L

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

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ACROSS 1 A process for treating raw extracted base stocks with

hydrogen to saturate them for improved stability. 7 The degree of opacity of a fluid. 8 A failure generally associated with a valve whose movements

are restricted due to small particles that have wedged in between critical clearances. 10 The sum of atmospheric and gauge pressure. 13 The most common type of grease today. 14 Wear phenomena taking place between two surfaces having

oscillatory relative motion of small amplitude. 16 Particles added per unit of circulating fluid volume. 17 A form of wear in which seizing or tearing of the gear or

bearing surface occurs. 18 The addition of fatty oils and similar materials to

lubricants to impart special properties.

DOWN 2 A measure of the total acidity or basicity of an oil. 3 An engine design in which oil is not retained in a pan beneath

the crankshaft. 4 The brown or black viscous residue from the vacuum

distillation of crude petroleum. 5 Ability of a lubricant to resist natural degradation upon

contact with oxygen. 6 Capable of being mixed in any concentration without

separation of phases. 9 A unit of kinematic viscosity. 11 Ability of a fluid to dissolve inorganic materials and polymers,

which is a function of aromaticity. 12 The relationship of flow per unit area to differential pressure

across a filter medium. 15 A container for storage of liquid in a fluid power system.

Get the solution on Page 29.



OIL ANALYSIS BY: BEATRIZ GRAÇA , INEGI; J ORGE SEABRA, FEUP; AND PINTO SOUSA, PORTUCEL

Lubricant

Analysis in Steam Turbines T

Turbine oils are subjected to a wide range of conditions — extreme heat, entrained air, moisture, contamination by dirt and debris, inadvertent mixing with different oil, etc. — that degrade the integrity of the hydrocarbon base stock and deplete the additive chemistries, causing irreversible molecular changes. There are two primary degradation mechanisms in turbine applications — oxidation and thermal degradation. Oxidation is a chemical process where the oxygen reacts with the oil molecules to form a number of different chemical products, such as carboxylic acids. The rate at which this occurs depends on a number of factors. Temperature is perhaps the most critical one, since the rate of oxidation doubles for every rise of 10 degrees C. The temperature above which this occurs is influenced by the oxidation stability of the oil and the presence of catalysts and pro-oxidant conditions such as water, air, certain metals, fluid agitation and pressure. Thermal degradation is the breakdown of the oil molecules by heat (high temperature), forming insoluble compounds that frequently are referred to as soft contaminants. Typically, thermal degradation occurs as a result of micro-dieseling, electrostatic

n o i t a d a r g e D l i O

s O i l p I u o G r The majority of phenols have depleted Gr oup II & III Oils Time

Degradation trend of different base stock oils

24


spark discharge and hot spots. Micro-dieseling is the combustion of imploding air bubbles creating adiabatic compressive heat (often exceeding temperatures above 1,000 degrees C). Electrostatic spark discharge results from the internal molecular friction that generates high-voltage electric charges such as where oil passes through very tight clearances at high flow rates, producing temperatures over 10,000 degrees C. Over time, it has become clear that the oxidation performances of the different base stock classes are quite different. The high natural oxidative resistance of Group II turbine oils combined with specific antioxidants employed (usually based in phenol and amine compounds) provide a non-linear behavior in terms of their molecular degradation over time. As a result, the majority of standard oil analysis tests offer little to no warning as the lubricant starts to degrade and generate system deposits. Instead of degradation occurring in a linear and predictable fashion, many of the modern turbine oils f ail rapidly. Changes in the oil’s molecular structure due to additive depletion and the development of insoluble particulates are among the first oil degradation conditions that affect equipment performance. The sequential process will be the formation of sludge and varnish, which are common occurrences in tu rbo-generators. Besides these oxidation and thermal degradation byproducts being the main contributors for the development of varnish and deposit problems in turbines, they interfere with other important properties in steam turbine lubricants, such as demulsibility and the detrainment of air. Therefore, it is vital that appropriate diagnostic analysis be performed to detect these conditions in critical and sensitive lubrication systems.

Ferrography Analysis Ferrography is a technique that provides valuable information about wear evolution in machinery through analysis of a representative lubricant sample. Developed by Vernon Westcott at www.MachineryLubrication.com

OIL ANALYSIS

the U.S. Navy in the 1970s as a conditionmonitoring technique, it has been applied by hundreds of worldwide users to all kinds of lubricated systems. The potential of ferrography is not only limited to predictive maintenance strategies. Its important contribution to tribology studies, by assisting in a better understanding of the wear mechanisms and of the lubricant effects on the contact surfaces, turns this versatile technology into one of the most powerful diagnostic tools to assess machine health, providing valuable information about the past, present and future condition of the machine’s lubricated components. The test procedure is lengthy and requires the skill of a well-trained analyst. As such, there are significant costs in performing analytical ferrography not present in other oil analysis tests. However, if time is taken to fully understand what analytical ferrography uncovers, most agree that the benefits significantly outweigh the costs and elect to automatically incorporate it when abnormal wear is encountered.

Oil Flow

Slide Magnet Large particles deposit at entry point where the magnetic pull is the weakest.

Smaller particles deposit along the slide as the magnetic pull strengthens.

Analytical ferrography deposited patterns

In analytical ferrography, the solid debris suspended in a lubricant sample is separated and thoroughly deposited onto a glass slide while passing across a bipolar magnetic field. When the sample flow is completed, a solvent “wash” cycle removes any lubricant remaining on the substrate, resulting in a “ferrogram,” where the particles are all arranged by size and permanently attached to the slide for optical analysis using a biochromatic microscope. The particles are then examined and classified by size, shape, 26


A steam turbo-generator at a cellulose industry plant

concentration and metallurgy. This information carried by the wear particles is valuable for the identification of the wear mode and mechanism.

Steam Turbine Monitoring This case study is about the condition monitoring of the lubricant in a steam turbo-generator at a local cellulose industry plant. The turbine is a 26 MW Siemens G 800-2. It has been in service for 22 years, operating continuously, with a lubricating oil reservoir holding 8,500 liters of ISO VG 46 oil to lubricate and cool bearings, gears and oil shaft seals and to act as a hydraulic medium for operation of the governor and steam control valves. Since its initial operation in 1988, this turbine worked with solvent-refined base stock oil (Group I). However, due to a manufacturer upgrade, this oil was replaced by a hydrocracked base stock (Group II) in 2002. In the meantime, about 6,000 liters of makeup fluid was added, along with a few periodic oil reservoir fill-ups, making the circulating fluid a blend of these two base stocks. The turbo-generator was operating and performing normally, and no occurrences of anomalous functions of the lubricated components had been recorded. Nevertheless, a close monitoring of the oil condition was ensured by analyzing the turbine oil periodically.

Turbine Oil Analysis A lubricant analysis program was applied quarterly, taking two samples from the oil reservoir and sending it to independent laboratories. The standard methods used at one of the laboratories to assess the condition of the turbine oil were: • Kinematic viscosity at 40 degrees C (ASTM D445) • Water by Karl Fisher (ASTM D6304) • Insoluble particulates (ASTM D4898) • Acid number (ASTM D664) • Neutralization number (ASTM D974) • Elemental spectroscopy (ASTM D5185) • Rust (ASTM D665-A) • Demulsibility (IP 19) • Foam (ASTM D892) • Flash point (ASTM D92) • Air release (DIN 51636) • Cleanliness code (ISO 4406) • Linear sweep voltammetry (LSV), (ASTM D6971) Simultaneously, at another laboratory, ferrography and Fourier transform infrared (FTIR) analysis were performed along with other techniques. These analyses allowed a complemented diagnosis not only of the condition of the oil but also of the turbine wear rate conditions. In this case study, among all the standard test results obtained, those that showed some indications of fluid www.MachineryLubrication.com

ANALYTICAL RESULTS FROM STANDARD TESTS DATE

Jan-10

Oct-09

Jul-09

May-09

Jan-09

REFERENCE

PHYSICAL PROPERTIES Viscosity@ 40°C [cSt] 41.4-50.6 Acid Number [mgKOH/g] 0.3 Demulsibility [s] 300 Air Release [min.] 5 Foam, seq. I [ml/ml] 450/0 Flash Point [°C] >185 CONTAMINATION Water Content [ppm] 100 Insolubles [mg/100ml] 10 ISO CODE 18/16/12 VARNISH POTENTIAL Amine % RULER >25 Phenolic % >25

45.9 0.14 606 3.2 400/0 242

45.8 0.08 442 4.4 50/0 238

44.3 0.12 368 4.2 300/0 229

45.9 0.1 305 8.4 190/0 232

46.6 0.06 >1200 2.4 470/0 210

<0.05 7 23/21/17

147 3.7 22/19/16

65 5.8 22/19/16

179 9.5 23/23/22

<0.05 7.5 23/21/18

95 <10

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62.2 19.7

67 4

70 -

Analytical results from standard oil tests show the oil viscosity and acid number are within the range over the time period.

degradation were the demulsibility, air release, particle count and LSV. As can be seen in the table above, the oil viscosity and acid number are within the range over the time period. Water contamination and foam tendency are maintained low. However, the particle contamination is high for all the evaluated period, the phenolic content falls below critical in some samples and the demulsibility is also affected significantly. The sequential events in the oil degradation produces an eventual depletion of the antioxidant additives. The aminic/phenolic antioxidant mixtures actuate as a complex system. The aminic inhibitor works to neutralize the free radicals that cause oil oxidation, but it is then regenerated by phenolic, which is a good free-radical trap. When phenolic levels fall below a critical level, the oil is in danger of rapid degradation, resulting in the formation of soft contaminants and varnish. Soft contaminants are typically less than 2 microns in size and cannot be removed through standard mechanical filtration. They are insoluble and polar in nature, and are unstable in a non-polar oil environment, such as hydrocracked base oil (Group II). The high ISO Codes obtained, mainly in terms of small particles (less than 4 microns), can be related with this turbine oil degradation process. Demulsibility is also compromised by the presence of polar contaminants. For the lubrication of turbo-generator bearings, the cleanliness level with respect to particles in the oil is of the utmost importance. Consequently, a proactive action is taken through periodical on-line oil purification (filtration during 24 hours) to achieve the system cleanliness in accordance with OEM recommendations (ISO www.MachineryLubrication.com

18/16/12). However, a swift increase of the ISO Codes is consistently verified during the operation of this turbine. The ferrography analysis completed for the same period revealed valuable information on the oil’s solid contamination. In all ferrograms, the presence of soft contaminants that resulted from oil thermal degradation and additive depletion was observed. This information is essential to identify the reason for the persistent high ISO Codes obtained in particle counting. Although soft particulates are not harmful in terms of wear, they contribute to the generation of surface deposits, as detected through ferrography. Figure 1 shows two photomicrographs of these particles deposited on a ferrogram as observed under white/green light and polarized illumination. The polarized light allows the identification of non-metallic particles (crystalline and amorphous materials, for instance) by the brightness of light reflected. Note the brown pattern evidenced by some of these particles. The particles in the ferrogram of Figure 2 are very small in size, and due to polarity, they easily aligned along the magnetic field of the ferrograph. These particles have the tendency to form agglomerates, which when overstressed with the

Figure 1. These two photomicrographs show turbine oil crystalline contaminants (1,000x magnification).


27

OIL ANALYSIS

oil, form a large coherent structure by a molecular polymerization. The varnish Figure 2. Particles build-up seems to aligned on the ferrogram to the be a consequence magnetic field of this physicochemical process, as can be realized by the photomicrographs in Figure 3, obtained in different oil samples. All these kinds of particulates have polar affinities and high molecular weight and tend to be adsorbed onto dipolar metallic surfaces as a sticking matter, which in turn captures hard contaminants as they flow within the system. They are capable of shutting down a turbine or causing serious damage, which is frequently related to bearings and servo applications. Another technique employed to monitor the oil condition was FTIR, which is used to measure organic molecular components, monitor additive depletion (antioxidants) and identify organic degradation byproducts (oxidation). The monitoring of specific antioxidant depletion in used lubricants is still considered a relatively new research

Figure 3. Ferrogram photomicrographs of the turbine oil particles in different samples (1,000x magnification)

area. However, some studies show that the rate of antioxidant depletion is related to lubricant degradation or affected by the antioxidant mix or base stock type used to produce the lubricant. Used oil samples are complex mixtures of different chemicals, including compounds derived from the formulation of the base oil and its additives, and from oil degradation products and contaminants. As a result, a used oil spectrum is complex and essentially the net sum of the spectra of all the individual compounds making up the sample. In fact, because of this complexity, the used oil spectrum alone is of limited value and must be compared against the spectrum of the unused oil to be of significant analytical value. Figure 4 shows transmittance spectral snapshots of the new and used turbine oil. The black spectrum is that of t he new oil (new base stock – Group II), while the red spectrum is from the blend oil in service, which still contains a small percentage of Group I base stock oil. Nevertheless, the spectra revealed identical functional groups. In analyzing the spectrum overlays, you can clearly see relative molecular changes in the oxidation peaks, as well as thermal degradation of the oil through the signs of nitration. Another molecular alteration is observed where the phenolic antioxidants are characterized. The type of decomposition detected in the used oil spectrum is commonly observed in FTIR analysis of fluids where thermal breakdown took place.

Used Oil

phenol inhibitors (depletion)

New Oil oxidation and thermal degradation

Figure 4. FTIR spectra in transmittance/wavenumber (cm-1) of new and used turbine oils

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Filter Analysis Static-generated sparks are very common incidents in the filtering systems of turbo-generators. This is a phenomenon of molecular friction occurring as oil flows through small clearances, such as the filter media. Since oil and filter media are both dielectric, this electrical energy builds until a limit is reached, and then sparks are released in the lubrication system in the direction of the ground. These electrical arcs can have an extremely high, localized temperature (about 20,000 degrees C), instantly cracking the hydrocarbon molecule. Since spark discharges generated on filters and other locations are a key root cause of varnish, and some of the previous oil analysis results confirmed that (through additive depletion and high particle counts), one of the duplextype filters was dismantled and analyzed through an optical microscope. Evidence of electric discharge can be easily seen through microscopic inspection of the filter media, filter core, filter meshes and from debris carried away from the filter. Figure 5 shows one of the plugged filters changed in a periodic maintenance action due to a plugged filter alarm, with a microscopic view of the filter mesh. As can be seen, black and brown shiny deposits (sludge and varnish) are present in high concentrations, clogging the filter mesh. The solvent used for cleaning the filter mesh was collected and used to prepare a ferrogram where significant amounts of ferrous spherical wear particles were identified (Figures 6 and 7). One source of spherical ferrous debris is the er osion wear activated by electrical discharges. The high temperatures attained by the sparks on the steel surface thermally liquefy the steel debris, which acquires a spherical shape due to rapid cooling under the action of surface tension. The microscopic analysis of the filter core surface showed several small, circular burned holes left by the high-temperature spark discharges on the metal surfaces. In conclusion, turbine oils must be well-maintained to extend their service life www.MachineryLubrication.com

characteristics, and these small air bubbles are adiabatically compressed, causing varnish to appear. In this case study, it was recognized that only the following techniques used to monitor the condition of the turbine oil were efficient in predicting eminent problems related to the generation of varnish and sludge:

Figure 5. Plugged filter from the turbogenerator and filter mesh with black and brown shiny residue (200x magnification)

and simultaneously provide the maximum turbine performance. However, the recent upgrade in the turbine oil formulations has caused some controversy. The older analytical techniques are no longer the predictive tools able to monitor the real condition that they once were. The generation and presence of soft contaminants are among the main consequences of the actual turbine oil degradation process. There are four likely reasons for this: • Unlike old-generation base oils (Group I), the type of base oil currently used (Group II) does not hold varnish precursors in suspension. These insoluble particles may form deposits. • Group I and Group II turbine oils possess significantly different oxidation properties and failure mechanisms. • The antioxidants precipitate as they are preferential oxides generating insoluble particulates. • The new generation of anti-foam additives has less effective air-release

• Particle counting (ISO Code) was effective in monitoring particle contamination. This was in spite of the fact that most particle counter s are not sensitive to the small size of the polar particles (less than 2 microns). The reason for their efficiency was that the particles have a tendency to form agglomerates, increasing the size of the particulates and thus allowing particle counting to detect them. • The demulsibility of the oil was a critical characteristic to evaluate since it is affected by the presence of polar particles. The alteration of this property could be a signal of extreme particle contamination. • The LSV technology and FTIR are both already recognized as important techniques to monitor the condition of modern turbine oils. They efficiently monitor the condition of the antioxidant package and the creation of soft contaminants. • Analytical ferrography was effective in the detection of soft contaminants and in the identification of their nature. In the hands of a skilled analyst, analytical ferrography is a powerful technique to identify turbine oilrelated problems, providing a root cause based on the morphology and characteristics of the insoluble particles, as well as monitoring the progressive mechanism of varnish formation. From Page 22 H Y D R O F I

Figure 6. Photomicrograph showing high concentration of ferrous spheres (1,000x magnification)

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E R O T S K O O B

Welcome to Machinery Lubrication’s Bookstore, designed to spotlight lubricationrelated books. For a complete listing of books of interest to lubrication professionals, check out the Bookstore at store.noria.com.

How to Select a Motor Oil and Filter for Your Car or Truck

Author: Jim Fitch Publisher: Noria Corporation Before spending any more money on oil changes, synthetic oils, premium filters, engine flushes or oil treatments, learn what leading lubrication expert Jim Fitch recommends. With these sound recommendations, you’ll know exactly what to do next time you change your oil — for about the pric e of an oil change. How ow to Grease a Motor Bearing earin Training Video

Format: DVD Fo Publisher: Noria Corporation Anyone responsible for the maintenance, operation and reliability of electric motors will benefit from this training video. It provides plant personnel with an overview of the best practic es for lubricating electric motor bearings. You can use the video to train operators, lubrication technicians, mechanics, electricians and maintenance personnel for years to come.

Machinery Oil Analysis — Methods, Automation & Bene fi ts

Author: Larry A. Toms This book uniquely presents the entire practice of oil analysis as a condition-monitoring tool for machines. The in-depth analysis describes the what, when, where and how-to for machinery lubrication, machinery failure and maintenance concepts, oil sampling and testing, statistical analysis and data interpretation.

Lubrication Fundamentals — Second Edition

Authors: D. M. Pirro and A. A. Wessol This newly revised and expanded reference book emphasizes the need for lubrication and careful lubricant selection. Thoroughly updated and rewritten, the Second Edition of Lubrication Fundamentals discusses product basics, machine elements that require lubrication, methods of application, lubrication, lubricant storage and handling, lubricant conservation and much more.

Industry Practices for Electric Motor Bearing Lubrication

Publisher: Noria Corporation Discover what works for motor bearing lubrication while benchmarking your lubrication program to 200 plants. Noria Corporation researched electric motor bearing lubrication at 200 North American plants and condensed the results into this valuable research analysis report.

Oil Sampling Procedure Posters

Publisher: Noria Corporation This set of three posters visually displays step-bystep oil sampling procedures for in-service lubricants and hydraulics. Each poster includes a list of required equipment necessary to follow the procedure. The procedures featured in the set are for high-fluid pressure systems, low-fluid pressure systems and systems at atmospheric pressure.

For descriptions, complete table of contents and excerpts from these and other lubrication-related books, and to order online, visit: store.noria.com or call 1-800-597-5460, ext. 204 30


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MachineryLubrication.com

Every day, thousands of industrial professionals from around the United States and around the world visit the Noria Corporation Web sites. See what makes these sites so popular and informative. Visit us today and ever y day at www.machinerylubrication.com.

Automated Lubrication — Benefits and Design Options While grease guns and manual lubrication seem to get the job done for many maintenance operations, their benefits often cannot compare to those provided by an automated lubrication system in terms of productivity, environmental issues and worker safety. An automated lubrication system helps to prevent bearing failure by providing the right amount of the right lubricant at the r ight time to the right place. Find this article in the Bearing Lubrication section on the ML site.

How Infrared Thermography Predicts Failures This video offers expert analysis of how infrared technology can predict equipment failures. Access this 9-minute, 11-second video at www.machinerylubrication.com.


Demystifying Sludge and Varnish You could tar your roof with it. It stick s to everything. It spreads like cancer. You thought you were getting rid of it with the oil change and flush, but it is back again, lurking in your oil and gripping the insides of your machine. Maybe you have it now . . . sludge and varnish. Do you know what causes it and how to stop it from spreading? Discover the destructive potential of sludge and varnish as well as how to prevent it from coming back by reading this article on the ML site.

Hydraulic Gear Motors and How They Work Get a detailed look at the interior of a motor, its gears and body. Watch how oil is pushed into the inlet port and through the outlet, traveling between the gear te eth and the gear housing, generating the rotation of the shaft. Access t his 2-minute, 11-second video at www.machinerylubrication.com.

Managing the Risk of Mixing Lubricating Oils Today’s high-performance lubricants are specifically formulated with a carefully selected balance of performance additives and base stocks to match the lubrication requirements of the equipment in which they are used. When lubricants are mixed, this balance is often upset. Mechanical problems leading to shorter equipment life can occur, sometimes catastrophically. Read this article on the ML site to learn why mixing lubricants is fraught with danger to your equipment, your business and your wallet. www.MachineryLubrication.com



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CERTIFICATION NEWS

ELI LILLY’S WENZEL EMBODIES the SPIRIT OF ICML BY SUZY JAMIESON, ICML

Ten years ago, ICML held its ver y first examination session in Biloxi, Miss., changing the course of the machinery lubrication industry. In the small pioneering group of only six practitioners stood Rendela Wenzel, who took it upon herself to be part of the very first group of ICML candidates. By successfully completing that first ICML e xam, she not only became one of the first ICML-certified professionals but also the very first ICMLcertified female practitioner. In celebration of ICML’s 10th anniversary, we wanted to tell Wenzel’s remarkable story. Wenzel remains one of a still few female reliability engineers and machinery lubrication practitioners. Although part of an ICMLaward-winning team, she was one of the people ICML recognized at the 2011 Reliable Plant Conference in Columbus, Ohio, as embodying the spirit of ICML in the area of certification. Wenzel is currently the corporate lubrication technical team leader for Eli Lilly. She has 14 years of experience in maintenance and operations, troubleshooting maintenance issues, implementing

Rendela Wenzel (center) and her team from Eli Lilly were the recipients of the 2008 John R. Battle Award.


solutions to these problems and supervising skilled trades. Wenzel has a level II certification in both lubrication and vibration analysis, and a level I certification in both infrared thermography and ultrasonic analysis. A Six Sigma Green Belt and a certified maintenance and reliability professional (CMRP), she has a bachelor’s degree in mechanical engineering and a master’s degree in business administration. Wenzel is also a member of ICML and the Society of Maintenance and Reliability Professionals (SMRP). She began her career at the Chr ysler Foundry in 1997 as a process engineering intern in the core delivery area. After a few months, Wenzel became the team leader for operations and mainte nance for the cleaning area. “All engineers at Chrysler start out on the floor to gain experience working with the people and equipment that they support and redesign,” Wenzel says. “This was an excellent opportunity for me to be able to see the struggles that workers have with equipment and learn how to design those issues out with mechanical solutions. I also learned to work with people of various backgrounds in a union environment and still be able to be effective at implementing those solutions.” Wenzel then moved to Inter national Truck and Engine (Navistar) in 1999 as a maintenance engineer over the crankshaft line for the steel business unit at the Indianapolis engine plant. “I was tasked with developing a job description for a maintenance engineer and a predictive maintenance program for the entire site,” she recalls. “Navistar knew that this was a new role in industr y, and they needed individuals to go out and get trained on how to implement it in their facilities. This is where I learned about Noria and the ICML.” Wenzel’s task was to develop a lubrication program and implement it in a union environment. “I went to Oil Analysis I and II training from Noria and became MLA I certified through ICML in January 2001,” she says. Wenzel took the information she learned back to her facility and developed a robust and highly successful lubrication program, www.MachineryLubrication.com



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CERTIFICATION NEWS

Along with Kurt Bittner of PSEG Nuclear and Scotty Lippert of Clopay Plastics, Wenzel was honored at the 2011 Reliable Plant Conference in Columbus, Ohio, as representing the spirit of ICML.

which was later replicated at Melrose Park and also the Huntsville, Ala., facility. She was able to transform the culture of reactive maintenance into a proactive environment that valued reliability activities and wanted them integrated into t heir PMs and daily operator tasks. “I took the structure of the existing vibration program as a model and integrated an oil and thermography program into the PM tasks and jobs of the craftsmen,” Wenzel notes. “This was a daunting task in a union environment. Oil analysis was an extra task for the machine repairmen, and thermography was an extra task for the electricians.” Oil analysis became something that Wenzel and her team did routinely over the next three years to diagnose many potential failures, which resulted in greater uptime. “I implemented the changes in ver y small increments, including oil leak-detection devices such as a UV light and dye that could find oil leaks,” she says. “One leak in our facility equated to more than $42,000 per year in savings. I decreased oil consumption by 25 percent and eliminated time-based oil changes. I added proper sampling ports, revamped our lube room and instituted an operator machine-cleaning program. The production on our bottleneck step increased by 10 percent, which eliminated one shift per week of overtime.”


Wenzel then had the opportunity to obtain her master’s degree in 2003 and wanted to broaden her experience base by switching industries. She started with Eli Lilly in 2003 as a reliability engineer in the insulin side of the business. Her role was to be the reliability engineer over the Humalog product line in B130. “I took the knowledge from my Noria training and replicated my efforts in B130 to establish a robust and successful oil analysis program,” she says. “My building was certified by the corporate lubrication technical team as world class in the fall of 2003 and was the first manufacturing facility to be certified by the corporate team. This was a great achievement only being with the company five months.” For a minimal investment of $5,000, Wenzel took the shell of a lubrication program and turned it into the pilot plant for the rest of the company to follow. After replicating this program for the remaining manufacturing facilities at Eli Lilly, the corporate team applied for the ICML John R. Battle Award. “Our team decided to use my area for the application, and we were the 2008 John R. Battle Award recipients,” Wenzel says. “I took over the reins of the corporate lubrication technical team from Wayne Ferguson in 2009. Since then, we have maintained the 12 areas of the company that are world-class certified, established two lubrication courses (basic and advanced lubrication fundamentals) at Lilly for all engineers, supervisor s and crafts, and are in the process of replicating all these policies and procedures to all our sites.” To date, more than 900 Eli Lilly and contract employees who come into direct contact with critical machinery have been trained in lubrication fundamentals. When asked to think back to Jan. 26, 2001, the day she took that first ICML exam, and about her journey until now, Wenzel offered a gracious response that demonstrates why she is one of the best examples of the spirit of ICML. “The last 10 years have been a very rewarding journey for me through three different types of industries, learning the cultures, designing and implementing lubrication programs, and developing policies and procedures to ensure the longevity of the programs,” she adds. “I feel very blessed to have been put in the situation to be able to make a difference by helping make equipment safer, more reliable and easier to maintain.”




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CERTIFICATION NEWS

RECENT RECIPIENTS OF ICML CERTIFICATION The International Council for Machinery Lubrication (lCML) would like to congratulate professionals worldwide who have recently achieved certified status through ICML’s certification programs. ICML offers certification in the areas of oil analysis and machinery lubrication. The following is a list of recently certified professionals in the area of machinery lubrication who have attained their status as a certified Machine Lubricant Analyst (MLA), Machine Lubrication Technician (MLT) or Laboratory Lubricant Analyst (LLA). Azman BinBadron, MLT I Eduardo Bruschi, MLT I Claudio Marcos Madureira Martins, MLT I Humberto Mozer Carvalho, MLT I Brittany J. Russo, MLA I

Acerias Paz del Rio S.A. Jaime Augusto Rodriguez Orozco, MLT I Aerospace Testing Alliance Joo D. Reynolds, MLA II Al Bedaya Consultancy & Marine Survey LLC Khaled Aly Matar, MLA I Alcoa Cheyene Robert Buse, MLT I Jennifer Lynn Cheaney, MLA I & MLT I Joseph F. Clayton, MLA I & MLT I Jonathan A. Fulton, MLA I & MLT I David T. Gainer, MLA I & MLT I Allen Hohl, MLA I Nathan Jones, MLA I & MLT I Neil Kennedy, MLA I Robert Koehler, MLA I & MLT I Shawn L. Mayo, MLA I & MLT I David Michael Patterson, MLT I Ben Robak, MLT I Robert C. Rockhill, ML A I & MLT I Dave A. Swindell, ML A I & MLT I Yi-Hsien (Ti m) Yang, MLA I & MLT I Allegheny Technologies Brandon Gaskey, MLA I & MLA II Dale L. Jones, MLA I, MLA II & MLT II Allied Reliability John M. Trulli, MLT I Apache Corporation Keith Madsen, MLT I Arauco Jaime Bohme Fuentealba, MLT I Alfredo Boett cher Schell, MLT I ATI Wah Chang Boyd Koehler, MLA I Jim Scofield, MLT I Jon Walberg, MLA I AV Technology Ltd. Carl Dawson, MLA I Tim Wilkinson, MLA I Birmingham Water Works Board Jonathan Malloy, MLA I Cargill Inc. Jessie Barlow, MLT I Steve Brantley, MLT I Terry Wayne Brewer Jr., MLT I Rodolfo Cabrera, MLT I Daniel M. Dicke, MLT I Jimmy Goff, MLT I Kevin Gorski, MLT I Dave Horn, MLT I Thomas Edward Jackson, MLT I Harrison W. Joyce, MLT I Joe Lemer, MLA II & MLT I Chris M. Lindgren, MLT I Michael S. Moore, MLT I


David J. Peraza, MLT I Mark Resendez, MLT I John Reyes, MLT I Troy Rooney, MLA II Jeremie D. Walker, MLA II

Cariboo Pulp & Paper Company Don Edwards, MLT I Brent Janischewski, MLT I Steve Logan, MLT I York Malner, MLT I Cameron McPhedran, MLT I James R. Porter, MLT I Scott E. Richardson, MLT I Rob Rolfe, MLT I Jason Phillips-Watts, MLT I

Energy Northwest Jeff Scott, MLA II Entergy, Inc. James R. Fraser, MLA II Exelon Corporation Steven Wood, MLA I Filtramax Francois Lepine, MLA I First Energy Corp. James E. Black Jr., MLA II Scott K. Graton, MLA II Florida Power & Light David LaGuardia, MLA II

Chevron Hilary A. Fernando, MLT II Aimee Hawkins, MLT II Sorasak Saengwanit, MLT II Alexander William Stephenson, MLT II

Flow Dynamics and Automation Phillip Scrimpshire, MLT I

Cia. Vale do Rio Doce Luis Orlando Pino Delgado, MLA II

Georgia-Pacific Greg Van Camp, MLT I Shawn M. Day, MLT I Dennis R. Leach, MLT I Alex Moses, MLT I William R. Nichols, MLT I Wayne Noakes, MLT I William Paul Terrell, MLT II Jason Vance, MLA I & MLT II

Cliffs Natural Resources John Freiberg, MLT I Cloud Peak Energy Jeffrey Biegel, MLA III Compañia Teck Minera Quebrada Blanca S.A. Rodrigo Gonzalez C., MLT I Cristian Jesus Parra Rios, MLT I Roberto Joaquin Ramos Hernandez, MLT I Conauto Jorge Fernando Calero Mejia, MLT I Del Monte Phils., Inc. Cirilo Amoy, MLT I Eleazar S. Orina Jr., MLT I Diavik Diamond Mines George M. Fancy, MLA II Dave Frederick Forster, MLA I & MLA II J. David Monchuk, MLA I & MLA II Alexander Shank, MLA I Anand Sharma, MLA II Jim Simmons, MLA II Jim A. Strickland, MLA I Dubai Aluminium Co. Ltd. Shajeev Puthalath, MLA I

GenOn Energy Ryan Bailey, MLT I

Greenlub Lubrificantes Ltda. Rogerio Zadra, MLT I Hedcor Inc. Niel Cabang, MLT I Dennis Miranda, MLT I Holcim Inc. Jason Frankiewicz, MLT I Charles E. Gibbs, MLT I Alvin Chester C. Oreiro, MLT I Pete Oviedo Jr., MLT I David “Coop” Towle, MLT I The Hurt Company, Inc. Newton Hopkins, MLT I Roy M. Christoffel, MLT I Industrial Oils Unlimited Danny “Mike” Toney, MLT I Insight Services Eric Ambrose, MLA II Monika Malcolm, MLA I Dwon Ruffin, MLA I

DuPont Erica R. Cross, MLT I Larry E. Kunze, MLA II Richard Lipscomb, MLT I Aaron P. Moore, MLT I John Edward Nesselroad, MLT I Brian Thompson, MLT I

IPM David Williams, MLT I

Eastman Chemical Earl F. Edens, MLA III

Japan Atomic Power Co. Atsuya Tsuruzono, MLA III

EMA Lubricants Co. Syed Sadath Hussain, MLT I

Jimah O&M Sdn Bhd Sofian Bin Sahat, MLT I Mohd Fauzi Bin Hamin, MLT I

Emirantes Aluminium Mohammed Yousef Abusheikha, MLA I

ITW Polymex Ricardo Joel Duarte Loperena, MLT I Aldo Guatemala, MLT II Edgar Guzman Lopez, MLT I

JM Huber Dana Rowan, MLT I

The JM Smucker Co. Patrick Lalor, MLT I James Robert Pant, MLT I Kanden Plant Corp. Kazuyoshi Hagane, MLA II Yoshitaka Nakano, MLA II Tomohiro Sanda, MLA II Kennecott Copper Kirk Dittmar, MLT I Lubrication Engineers Inc. Patrick R. Bilberry, LLA I Larry Boyle, MLT I Bruce A. Bruner, MLA II James Cowles, MLA II & MLT II Jacob Bryant Davisson, LLA I & MLA II Mike Hall, MLT I Sarah Hall, MLT I Berle Hartman, MLT I Caleb D. Hayes, MLT I Eric Ndegwa, LLA I Brian L. Nelson, MLT II Stan Nelson, MLT I Sam R. Quakenbush, MLT I Daniel Roberts, MLT I Birju Shah, MLT I Chris Shelly, MLT I Bob Sodergren, MLT I Gregory Spiers, MLA I & MLT I Derek Taylor, MLT I Bernie A. Thomsen, MLT I Matthew Valentine, MLA I & MLT I

David William Niebergall, MLA II Derek Rice, MLA II Kelly Therrien, MLA II Reid Foley Williams, MLA II Shaun K. Wright, MLA II Greg A. Zimmer, MLA II

MRG Labs Richard N. Wurzbach, LLA I Newmont Mining Corp. Brett Eugene Morton, MLA I NextEra Energy Jerry Lee Barske Jr., MLA II Nissan Chad Crane, MLT I David Gross, MLT I Noria Latin America Francisco J. Paez Alfonzo, MLA III Norske Skog Tasman Grant Carncross, MLT I Eric Horwood, MLT I Rhys Drayson, MLT I NRG Energy Inc. Joshua Shewan, MLA I OCI Wyoming L.P. Dean Kendall, MLT I

Lubrication Systems Company Osmari Chacon, MLA III

Oil-Dri Donald K. Everett, MLT I Kim Robert Jaynes, MLT I Mitchell Jon Schalk, MLT I Jim Warden, MLT I

Luminant Power Jeremy Layne Swanson, MLA III

Overlake Oil Paul Hawkes, MLT I

Machine Evaluation Michael E. Thornton, MLT I

Owens Corning Andrisa Jefferson, MLT I

Matzan Reliability Engineering Matt Arndt, MLA II

Pemex Gas & Petroquimica Basica Alejandro Castillo Lazaro, MLT I Carlos Alberto Dominguez Osuna, MLT I Ramiro Fernandez Martinez, MLT I Javier Garcia De Leon, MLT I Juan Enrique Germanos Otero, MLT I Francisco Javier Gonzalez Juarez, MLT I & MLT II Octavio J. Guerrero Hernandez, MLT I Wilberth Guillermo Herrera Osorio, MLT I Jorge Higa Arvizu, MLT I Roberto Martinez Bustos, MLT II Miguel Martinez Luria, MLT I Erick Martinez Ramirez, MLT I Medardo Melo Sanchez, MLT I & MLT II Gabriel Olan Gonzalez, MLT I Jose Manuel Perez Sosa, MLT I Raymundo Rodriguez Romero, MLT I Omar Valdivia Maza, MLT I & MLT II Edgar Genaro Vega De Leon, MLT I Gabriel Zavala Gomez, MLT I

Mecoil Diagnosi Meccaniche Srl Giacomo Mariani, MLT I Michelin Tires Corporation Jerry Gibson, MLT I Micron Technologies David A. Peck, MLT I Mighty River Power Ltd. Allan Heath, MLT I Peter Martin, MLT I Mike Ranger, MLT I Andre Richards, MLT I Peter Smith, MLT I Jeremy Wilson, MLT I MillerCoors Brewing Company Thomas Lloyd Davis, MLT I MinePro Chile S.A. Marcos Castro, MLA II

Carlos Tomas Mondaca Lopez, MLA II Mosaic Company Rodney E. Bernath, MLA II Kelly M. Chalus, MLA II Brad L. Gabrielli, MLA II Garrett Matthew Kuntz, MLA II

Petrobras Julio Cesar L. Alves, MLT I Solange Virilo Borbily, MLT I


Mario Roberto Leao Burle, MLT I Cesar Figueiredo, MLT I Sergio Peixoto Augusto Junior, MLT I Marcos Thadeu Giacomin Lobo, MLA I Vinicius Moia Monte Alegre, MLT I Rosana Villela Santos, MLT I

Petronas Gas Berhad Gladwyn Bacena, MLT I Muhammad Effirdaus Bin Abdul Hakim, ML A II Pilipinas Shell Petroleum Corp. Kerchieval G. Balingit, MLT I Donna Christine Enriquez, MLT I PQ Corporation Stuart Hensley, MLT I William M. Ledbett er, MLT I Praxair, Inc. Matthew Thomas, MLA I Progress Energy Larry E. Barnett, MLA II PT Newmont Nusa Tengarra Neka Damartha, MLA I Queensland Nickel Pty. Ltd. Andrew Camp, MLT I James Leslie Filmer, MLT I Anthony Philip Greinke, MLT I Tak Sam Lee, MLT I Russell Vernon McIntosh, MLT I Angelo Nobile, MLT I Matthew Joseph Paulger, MLT I Craig Pegg, MLT I Risto Reissenberger, MLT I Cameron Smith, MLT I Dane Tappenden, MLT I Jason Bradley Townsend, MLT I Daniel Vogler, MLT I Bill Weston, MLT I

Charles Arthur Lewis, MLA I Heidi A. Marshall, MLA I Charles James Pence, MLT I Matthew T. Platek, MLA I Craig Alan Schrowang, MLA I Richard D. Segovich, MLA I Gordon L. Seymour, MLA I Carol Jean Straub, MLT I David S. Thompson, MLT I Jimmy L. Uhde, MLA I Craig William Walker, MLT I Reggie R. Wulff, MLT I

Samsung Everland Dae Keun Kang, MLA II Sungil Park, MLA II Hyun Gyu Yang, MLA II San Roque Power Corp. Leo V. Tibayan, MLT I Sarawak Shell Berhad Chow Kim Vui, MLA II SaskPower Mark Crooks, MLA I Saudi Aramco Rabi M. Hakeem, MLA I SeaTec UK Limited Ajay Arora, MLA II Stanly George, MLA II Shell Markets Middle East Sandeep Banerji, MLA I Shikoku Electric Power Co. Yuji Yano, MLA III Siemens Power Operation Inc. Edmund M. Castro, MLT I Elena Kristine A. Javal, MLT I Sandy L. Uson, MLT I

R.J. Reynolds Tobacco Co. Michael D. Cornett, MLT I Joseph Scott Poindexter, MLT I

SKF del Peru Roy Felix Cabezas Jara, MLA I Ronald Vidal Ravelo, MLA II

Right Flow Reliable Solutions Inc. Dawn April Lumbas, MLT I

SKF Maintenance Products Gustavo Yesid Sabogal Rozo, MLT I

Rio Tinto Morgan Hall, MLA I Brendan Moffat, MLA I Brian Wagstaff, MLA I

Solvay Advanced Polymers Michael D. Dye, MLA II & MLT II Southcoast Petroleum Ltd. Oleksandr Bodnya, MLT I

Robinson Nevada Mining Michael Sean Farrell, MLT I Justin Shalako Pope, MLT I

Southern Company Neal Mac Namara, MLA II

Roquette America, Inc. David Chandler, MLT I MarceyMarcey Lonning, MLT I

Sterling Steel LLC Michael Kyarsgaard, MLA II & MLT I Jeff Trancoso, MLA II & MLT I

Sabic Innovative Plastics Adam E. Ball, MLA I Norman Bulloch, MLA I Christopher M. Corbitt, MLA I Joseph Lee Dean, MLT I Dennis R. Dick, MLT I Lance Foreman, MLA I Gerald Goebel, MLA I Jeff C. Hutcheson, MLT I

Taylor Enterprises Thomas J. Loar, MLA II Teck Highland Valley Copper Mark Baker, MLA II Shane Kozoriz, MLA II Mark Mulroy, MLA II Temple-Inland Forest Products William Scott Davis, MLA II

ICML Certifications LLA I = Laboratory Lubricant Analyst Level I MLA I = Machine Lubricant Analyst Level I MLA II = Machine Lubricant Analyst Level II MLA III = Machine Lubricant Analyst Level III MLT I = Machine Lubrication Technician Level I MLT II = Machine Lubrication Technician Level II www.MachineryLubrication.com

Tenaga Nasional Berhad Venoth Kumar Govindasamy, MLA II Thomas Petroleum Ricky Edward Cantrell, MLT I James Grant Clark, MLT I Dee Harold Draper, MLT I Brandon S. Ford, MLT I Rodolfo J. Gonzalez Jr., MLT I Kimbery A. Gregory, MLT I Chris Dewain Harris, MLT I Mark Wesley Hudson, MLT I James C. LaBeff, MLT I Dennis G. Maietta, MLT I Nicole Martin, MLT I Ronnie Wayne Pewitt, MLT I Ricky Roden, MLT I David L. Sanchez, MLT I Frank Eidin Slaugh, MLT I Garrick Ashley Thomas, MLT I Thunder Bay Coal Co. Michael Siegert, MLA II Tohoku Electric Power Co. Takuya Saito, MLA II Masayuki Shimada, MLA II Nobuhiko Umeki, MLA II TSNZ Pulp & Paper Maintenance Ltd. Selwyn Pryor, MLT I Unicco Aaron Chad Abbott, MLT I James R. Anderson, MLT I Charles Mettler, MLT I Brian Keith Miles, MLT I Valero Energy Corporation Allan R. Thibodeaux, MLA II Jimmy Thomson, MLA II & MLT I Verso Paper Edwin W. Ames, MLT I Caleb Bell, MLA I Stephen P. Blair, MLT I Reginald A. Cloutier, MLT I Robert Allden Downes, MLT I Scott Dyar, MLT I Thomas Henry Heywood, MLT I James H. McClure, MLT I Michael D. Michaud, MLA I Terry Arlene Ring, MLT I Travis C. Veilleux, MLT I We Energies Mark J. Smith, MLA II WesTrac Pty. Ltd. Philip De Wet, MLA II Xstrata Luis Angel Romero Carlos, MLA II & MLT I Yonden Engineering Co. Keiichi Shimomoto, MLT I

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 September - October 2011

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T E K R A M R E P U S T C U D O R P

Ensure protection from live parts and arc flash - Safety Plugs allow technicians to quickly connect/disconnect electrical equipment. Exclusive features protect from electrical hazards and simplify NFPA 70E compliance. FREE samples available.

Escalator Chain Lube is a synthetic lubricant; it excels in lubricating the chains of escalators, moving sidewalks & elevator doors. Its high-film strength improves equipment reliability while reducing lubricant consumption.

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.

Royal Purple, Inc.

Cannon Instrument Company

Meltric Corporation

www.royal-purple-industrial.com 888-382-6300 [email protected]

www.cannoninstrument.com 800-676-6232 [email protected]

www.meltric.com 800-433-7642 [email protected]

Maximize productivity and reduce costs with the power of Castrol High Performance Lubricants. • Gear Oils • Greases • Hydraulic Oils • Way Lubricants • Compressor Oils • Chain Oils. Only Castrol Industrial has the technology inside. Contact us [email protected] Castrol Industrial North America Inc.

877-641-1600

Know when to lubricate with UE Systems Ultraprobe® 201 Grease Caddy. Sensing ultrasound, Grease Caddy isolates bearing sounds making it easier to listen in noisy plant environments. Wear on a holster or attach to grease gun. UE Systems, Inc.

www.uesystems.com 800-223-1325 [email protected]

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The SureSample utilizes a patented vacuum technology that eliminates the need for sample pumps. Simply affix the length of tubing to the SureSample bottle, insert into a reservoir or sample port, and let the bottle do the rest.

Krytox ® Fluorinated Greases and Oils are chemically inert, insoluble in common solvents. Temperatures range from -103° to 800°F. Compatible with plastics, rubber, ceramics and metals. Nonflammable, oxygen compatible, no silicones or hydr ocarbons. H-1/H-2 Food Grades available.

Analy sts, Inc.

Miller-Stephenson Chemical Company, Inc.

www.analystsinc.com 800-655-4473 [email protected]

www.miller-stephenson.com 203-743-4447

Summit Varnasolv will alleviate problems from varnish and carbon in y our rotary screw or rotary vane compressor. Clean your compressor while it is running, no need to disassemble. Use Varnasolv to clean heat transfer systems, high temperature chains and gearboxes.

Isn’t it time you streamlined your fluid handling?

Summit Industrial Products

www.klsummit.com/varnasolv.pdf 800-749-5823 [email protected]

The IFH Group, Inc.

www.ifhgroup.com 800-435-7003 [email protected] www.MachineryLubrication.com

PAID A DVERTISING SECTION

BELL ULTRA’s formulation substantially reduces friction in hydraulic systems by resurfacing metal surfaces, resulting in LOWER OPERATING TEMPERATURES AND POWER INPUT and LONGER COMPONENT LIFE. Cornerstone Controls

Valve reduces sampling time by 80% Plus - Unique 360° rotating spout allows easy one hand samp ling. Stainless steel chain and clip. NEW higher flow for low pressure applications. NEW rugged spout design with easy to grip knurled cap.

www.ccisupply.com/BellUltra 352-291-2300 flpwr@cfl.rr.com

Checkfluid, Inc.

Hornche Corporation

www.checkfluid.com 866-652-8728 info@checkfluid.com

www.easylube.com [email protected]

One Eye Industries for all your magnetic and industrial filtration needs. Our filtration solutions have applications in all industries. We manufacture an extensive product line utilizing new magnet technology.

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 customerspecified grease or oil.

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.

One Eye Industries, Inc.

PLI LLC

www.oneeyeindustries.com 877-888-8727 [email protected]

www.memolub.com 800-635-8170 [email protected]

Maintain your fluid cleanliness from storage to point of use with the PROFILL portable fluid transport container. PROFILL provides sealed, reliable, and efficient, transport and accurate dispensing of your critical fluids.

Inolex Chemical Company synthesizes premium 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.

FLUIDALL Solutions

Inolex Chemical Company

www.FLUIDALL.com 800-849-0591 [email protected]

www.inolex.com 800-521-9891 [email protected]


The Easylube RFID Patrol Management Automatic Lubrication System provides precision bearing lubrication and condition monitoring in one system. Easily calculate and manage greasing quantities and intervals using our software.

Harvard Corporation

www.harvardcorp.com 800-523-1327

Fundamentals of Machinery Lubrication provides more than 24 hours of foundational training on best practices for machinery lubrication and oil sampling. It lays the groundwork for establishing a world-class lubrication program and is a Level I certification prep course.This online training format allows 24/7, anywhere accessibility. Noria Corporation

store.noria.com 800-597-5460 September - October 2011

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TEST YOUR KNOWLEDGE

This month, Machinery Lubrication continues its “Test Your Knowledge” section in which we focus on a group of questions from Noria’s Practice Exam for Level I Machine Lubrication Technician and Machine Lubricant Analyst. The answers are located at the bottom of this page.

1. Benefits generally associated with the use of synthetics include:

GARZO Model 108B controllers maintain oil levels in engines and compressor crankcases to prevent equipment damage and save oil. The standard valve assembly works with atmospheric tanks or up to 15 psig oil supply pressures.

A) B) C) D) E)

Better oxidation resistance Better compatibility with elastomers (seals) Less toxicity Higher cost Better paint compatibility

GARZO, Inc.

www.garzoproducts.com/108.html 713-466-8679 [email protected]

2. The concentration of wear debris: A) B) C) D) E)

Always increases throughout the oil circulating system Varies throughout the oil circulating system Always decreases throughout the oil circulating system Is constant throughout the oil system Varies with the pressure in the oil system

3. Which maintenance strategy is based strictly on tasks performed at specific time intervals?

Equip your Lube Room of the future with FLUIDALL Lubrication Storage Solutions. Reliable, Clean, Cost Effective, and Space Efficient fluid storage systems available in bulk and portable gravity fed and pump/filtered configurations.

A) B) C) D) E)

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5. Which component generally requires the cleanest oil?

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A) B) C) D) E)

High-pressure hydraulics Gears Engines Turbines Journal bearings

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42



Lubrication Programs

FROM THE FIELD

STEPHEN SUMERLIN

6 STEPS to UPDATE your LUBRICATION program

In today’s culture of looking for high returns on investments, there are not many that can compare to a comprehensive lubrication program. Tremendous financial savings can be enjoyed by eliminating poor lubrication practices from an organization. Numerous financial losses are attributable to poor and inadequate lubrication programs and techniques, and most of the losses are not going to jump out at you. This is why it is important to think of every aspect of lubrication. Just working on one area will not yield the financial results you desire. It is all or nothing. This article will offer valuable guidance as to why and how to look at the big picture when updating your lubrication program.

1

Benchmarking

To understand where your lubrication program needs to be, you must first find out where it currently stands. In order to accomplish this, an in-depth benchmarking process must be performed to compare your current program to industry best practices in key areas of lubrication. Without having a metric to compare your program to, it becomes the blind leading the blind. All successful programs start with a clear picture of how much work they need to do to become world class and what they need to do to get there. Transitioning a lubrication program is not like turning on a light. It takes understanding, clear vision, dedication, champions, time and financial resources to make it happen.

2

Design and Engineering

During the design and engineering phase, look at every lubrication point and determine what actions need to be put into place. These actions can range from equipment modifications and routine inspections to one-off inspections, etc. They are usually dependent upon the equipment type, criticality, reliability needs, financial benefit, safety consequences and other factors that affect the bottom line. Based on these factors, you should create clear, concise and specialized procedures for each lubrication point. These procedures will be used to modify equipment for contamination control, provide standards for oil analysis and coach the lubrication technician on proper lubrication techniques (i.e., top-ups, drains, filtr ation and oil sampling). During this phase, you also should make sure the correct lubricant is being used in each lubrication point. This process involves checking the OEM recommendations for a baseline and then performing certain calculations for proper viscosity selection, 44 | September - October 2011

lubricant type, performance properties, re-lubrication volumes, re-lubrication frequencies, etc. Re-lubrication volumes and frequencies often are left out of procedures, and a “shoot-from-the-hip” method is used. Not understanding how much and how frequently the lubricant should be supplied to an application, especially greaselubricated bearings, can cause frequent lubrication-related failures.

3

Lubricant Consolidation

Many times, as a byproduct of the design and engineering phase, lubricant consolidation occurs. This is important on many levels, as it allows for a clearer pictur e of what products need to be purchased, which reduces purchasing costs, eliminates unnecessary or unused products from inventory, decreases the likelihood of lubricant cross-contamination and helps the lubrication team understand which products they need and why. As the specialized procedures are created during the design and engineering phase, each lubrication activity should have the correct lubricant specified. This will help ensure that the technician is using the right product in the right place.

4

Storage and Handling

Once all of the necessary lubricants are identified, it is time to think about your storage and handling practices. Proper storage and handling techniques are essential in developing a successful lubrication program. You can perform all of the equipment modifications for contamination control, but if you can’t get the lubricant from the storage room to the application without introducing contamination, all of those modification efforts were in vain. This is why it is so critical to have a proper lube room with dedicated receiving filtration, storage systems, filter carts, stored filtration, dispensing equipment and a safe and clean environment for the lubricants to be stored. Lubricant labeling is another frequently missed opportunity. Labeling should be a high priority when thinking of execution. Lubricant-specific labels should be created and placed on stored lubricants, top-up containers, grease guns, filter carts and the equipment. This makes lubrication tasks much more efficient and reduces the likelihood of the wrong lubricant being used in the wrong application. If technicians can clearly see the label on the equipment, go back to the lube room and find the matching label on the filter cart, top-up container or grease gun, their jobs become much easier and safer. www.MachineryLubrication.com

5

Implementation

After designing and engineering a lubrication program, the next step is to implement what you have developed. Many times this is where organizations fail to execute and never see the value of all their previous efforts. Implementation is not a one- or two-day exercise but a multi-month commitment based on available resources. Complex types of equipment such as hydraulic systems will necessitate multiple modifications in order to be considered best practice, requiring a substantial financial commitment. The modifications can include breathers, sight glasses, dedicated sampling ports, quickconnects for periodic decontamination, filters, etc. This is where all the time spent developing the specialized procedures from the design and engineering phase pays off. Every modification activity for each piece of equipment should have its own dedicated specialized procedure to instruct the labor force on how to perform the modification correctly. Other less complex types of equipment such as grease-lubricated bearings may not have any modification procedures but only routine lubrication procedures. These applications do not require as much of a financial or labor commitment to implement, and once the specialized procedure is written, the technician can start with the needed tasks immediately.

6

Re-benchmarking and Continuous Improvement

After your newly revamped lubrication program has been up and running for a while, it is time to re-benchmark your program with industry best practices to see where your program is now compared to where it was during the initial benchmarking. This is where all of the hard work in the previous steps will show the financial rewards and re-enforce that the decision to develop a real lubrication program was worth the financial commitment. As with any change of culture, management and workforce, a lubrication program needs constant refinement and continuous improvement. It is easy to slide back to the old ways of doing things if not careful, especially if the organization has a high turnover rate in the labor force. This is why it is so important to have developed the specialized procedures during the design and engineering phase, as they make it easier to train new members of the lubrication team and define how to do things correctly and accurately the first time, which promotes a sustainable culture change. www.MachineryLubrication.com


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M L

LUBE TIPS

Readers

Supply Super Solutions and Sound Suggestions

The “Lube Tips” section of Machinery Lubrication magazine features innovative ideas submitted by our readers. Additional tips can be found in our Lube-Tips e-mail newsletter. If you have a tip to share, e-mail it to us at [email protected]. To sign up for the Lube-Tips newsletter, visit www.machinerylubrication.com and click on the “Newsletters” link at the top.

Use Crackle Test to Detect Water Contamination If an oil is looking cloudy, the problem could be water contamination. The crackle test can generally be relied upon to confirm the presence of water.

same time degrade another. When specified concentrations of additives become unbalanced, overall oil quality can be affected.

Oil Reclaiming vs. Oil Re-refining Although definitions var y, the general difference between oil reclaiming and oil re-refining is: • Reclaiming removes solids, water, gas and other impurities extractable by vacuum dehydration and filtration. • Re-refining removes both soluble and insoluble impurities and most additives, effectively bringing the used oil back to a pure base stock. It would then need to be readditized.

Check Your Records to Control Oil Losses If you decide to implement a program to control oil losses, one of the first steps you can take is to check historical records of the amount purchased compared with the amount sent for disposal. Try to account for the difference by looking for leaks, products consumed in the process, evaporative losses and products wasted due to contamination or misapplication.

Know the Pour Point The pour point is the lowest temperature at which an oil will flow. This property is crucial for oils that must flow at low temperatures. A commonly used rule of thumb when selecting oils is to ensure that the pour point is at least 10 degrees C (20 degrees F) below the lowest anticipated ambient temperature.

What You Should Know When Using Additives Regarding the use of after market additives and supplemental oil conditioners, keep in mind that some base oils respond well to additives while others may not. Also, increasing the percentage of a certain additive may improve one property of an oil while at the 46 | September - October 2011

Avoid Additive Leaching Particle contamination in a lubricating or hydraulic system is widely known as one of the most devastating contaminants. One effect of particle contamination that is rarely discussed is additive leaching. Many additives attach to particles and are removed along with the particle by filtration.

Oil Sampling Strategies When sampling new oil deliveries for testing, one strategy is to pull the sample from just above the drum or tanker compartment bottom — where contamination is most concentrated. Dispensing lines from bulk transports may also be a good choice (the first and last fluid out). www.MachineryLubrication.com

Automotive Lubrication

BACK PAGE BASICS

JEREMY WRIGHT | NORIA CORPORATION

Comparing GASOLINE and DIESEL ENGINE Oils

I’ve been instructing the Fundamentals of Machinery Lubrication course for a few years now, and many times the course has been the birthplace of the articles I’ve written. The questions and discussions in the course are very representative of what the average maintenance professional is curious about. Most tend to like the discussions about passenger car and truck oils because they not only affect them at work but also at home. In fact, I use this curiosity to my advantage. If I ever notice a subject is starting to bore an audience, I’ll find a way to incorporate an automotive twist to it. Soon all the ears seem to perk up. This article is no different. I plan to explore the similarities and differences between gasoline and diesel engine oils to appease your curiosity.

Getting the right viscosity is of the utmost importance. In the broadest sense, gas and diesel engine oils have the same anatomy or makeup. They are formulated from the blending of base oils and additives to achieve a set of desired performance characteristics. From this simple definition, we start to diverge when examining the lubricant’s required performance for each engine type.

Emissions and the Catalytic Converter A catalytic converter is a housing that contains porous metal filler located between the engine and muffler in the exhaust system. Its role is to convert toxic emissions coming from the engine to stable byproducts before they enter the atmosphere. Some of the byproducts of combustion (lead, zinc and phosphorus) can severely cr ipple the converter’s ability to perform this job. Therein lies the first major difference between the oils. Diesel engine oils have a higher anti-wear (AW) load in the form of zinc dialkyldithiophosphate (ZDDP). The catalytic converters in diesel systems are designed to be able to deal with this problem, while the gasoline systems are not. This is one of the main reasons you don’t want to use a diesel engine oil in your gasoline engine. If your automobile was built prior to 1975, there is a good chance it does not have a catalytic converter, and thus the above statements do not apply. 48 | September - October 2011

Viscosity Viscosity is the single most important property of a lubricant. When I am working as a consultant and designing a lubrication program, one of the first steps I take is to calculate required viscosities. Getting the right viscosity is of the utmost importance. The selected viscosity needs to be pumpable at the lowest start-up temperature while still protecting the components at in-service temperatures. Typically, diesel engine oil will have a higher viscosity. If we were to put this higher viscosity in a gasoline engine, several problems might arise. The first is heat generation from internal fluid friction. I’ve covered before how this heat affects the life of an oil. A good rule of thumb is that for every 10 degrees C you increase the temper ature, you cut the life in half. The second problem is the low-temperature pumpability of this higher viscosity. During cold starts, the oil may be very thick and difficult for the oil pump to deliver to the vital engine components in the lifter v alley. This most certainly will lead to premature wear, as the components will be interacting without the benefit of lubrication.

Additive Levels Diesel engine oil has more additives per volume. The most prevalent are overbase detergent additives. This additive has several jobs, but the main ones are to neutralize acids and clean. Diesel engines create a great deal more soot and combustion byproducts. Through blow-by, these find their way into the crankcase, forcing the oil to deal with them. When you put this extra additive load in a gasoline engine, the effects can be devastating to performance. The detergent will work as it is designed and try to clean the cylinder walls. This can have an adverse effect on the seal between the rings and liner, resulting in lost compression and efficiency. So how do you know if an oil has been designed for gasoline or diesel engines? When reading a label, look for the API (American Petroleum Institute) doughnut. In the top section of this doughnut will be a service designation. This designation will either start with an “S” (service or spark ignition) for gasoline engines or a “C” (commercial or compression ignition) for diesel engines. www.MachineryLubrication.com

Level 1 Certification Preparation

“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

Noria Skills Training

Fundamentals of

MACHINERY LUBRICATION Learn Precision Lubrication Skills Precision Lubrication Skills For Maximizing Machine Reliability Maximizing Machine Reliability Here’s a Sample of What You’ll Learn: How to build a safe and effective lubricant storage and handling program How to rate filters and select the right filtration for the job Lubricant labeling and coding systems -what works and what doesn’t Industry’s best procedures for greasing electric motor bearings How to get the right lubricant in the right place at the right time and in the right amount

Presented by

Enroll Today!

isit Noria.com or call 800-597-5460 Noria Corporation

Apply What You Learn And Reap The Benefits Who Should Attend? • • • • • • • • • • • •

All Maintenance Professionals Lubrication Technicians Craftsmen or Millwrights Equipment Operators Laboratory Analysts Lubrication Engineers Maintenance Managers Maintenance Supervisors Manufacturing and Industrial Engineers Operations Managers Predictive Maintenance Technicians Reliability Engineers

An Organized And Safe Lubricant Storage Room Solve Water-In-Oil Problems Reduce Electric Motor Failures and Replacement Costs

What Industries Will Benefit?

Stop Pesky Oil And Hydraulic Fluid Leaks

• • • • • • • • • • • • • • • •

Leakage is a festering sore to a machine maintenance program. It is often the symptom of a host of other problems. If left unchecked, reduced machine performance is imminent. Eliminating leakage involves the lubrication and oil analysis programs and should be a principal goal.

Aerospace Automotive Manufacturing Earthmoving Food and Beverage General Manufacturing Lumber and Wood Municipal Utilities Petrochemical Pharmaceuticals Power Generation Primary Metals Process Manufacturing Pulp and Paper Rubber and Plastic Textile Transportation

If You Use Any Of These Machines, This Training Is A Must: • • • • • • • • • • • • •

2

Electric Motors Compressors Diesel Engines Final Drives Gas Turbines Gearboxes Hydraulic Systems Hydrostatic Transmissions Paper Machines Process Pumps Rolling Mills Steam Turbines Blowers/Fans

Effectively Troubleshoot Lubricant-related Machine Failures Stop Costly Bearing Failures Compare And Select The Best Lubricants For The Job

Extend Machine Life By Up To

10X

Squeeze Maximum Life From Lubricants Lubricants and hydraulic fluids can have infinite life when specific operating conditions are stabilized. The rising costs of new lubricants and the disposal costs of used fluids are directives for change. Learn a proven action plan for extending fluid life.

Improve Health And Workplace Safety

A More Effective Oil Analysis Program When the goals of a lubrication program are in sync with the oil analysis program objectives, oil analysis becomes far more effective. Learn how to align the programs for maximum results.

Reduce Energy And Fuel Costs Create More Effective Lubrication PMs

With hundreds of lubricant types, base stocks, additive packages and viscosity grades to choose from, how can a person decide which lubricant is right for a machine? The options are endless… synthetic or hydrocracked?… EP or AW?… naphthenic or paraffinic?… ISO VG 32 or 68?

Solve Annoying Hydraulic System Problems

Improve Equipment Meantime Between Failures

Spend Less On Lubricants And Filters – Not More

Enroll Today! Visit Noria.com or call 800-597-5460

Take The Guesswork Out Of Machinery Lubrication If you aren’t using the correct lubricant at the right time in the right quantity and in the right place, you could be doing your equipment more harm than good. Modern lubrication programs have changed considerably from “old school” methods that have been passed down through generations. This course contains a strategic collection of the very best practices for applying and managing lubrication that you can take home and begin using right away.

You’ll Gain Practical New Skills That You Can Use Right Away: The Secrets Of Lubricant Selection. This course will empower you with the knowledge to understand important lubricant properties and strategies to select the correct lubricant for each machine application .

The Best Practices For Lubricant Storage, Handling And Dispensing. Learn how award-winning maintenance programs design lube storage areas, dispensing stations and transfer carts .

Satisfied Customers Say It Best… “Packed with powerful information that can be applied with measureable results, this course provides the right training to influence a cultural change in maintenance and operation organizations.” Brian Ba ldwin, Reliabili ty Engin eering M anager, Dyner gy

“ABSOLUTELY AWESOME! Should reduce downtime 25 to 50 percent.” Scott Gilreath, Lube Tech, UNICCO

“Until I attended this training, I had no idea how poor our best practices were. Improvements will be easy. Justifications will be easy. Recouping the cost of this class will take about a week!” Tim Pendley, Mechanical Engineer, Westlake Chemical

The Four Rs Of Lubrication. 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 .

“Implementing the basic principles taught during this training would prevent premature failure of most all of our rotating machinery!” Brittany Russo, Reliability Engineer, Braskem

Grease Gun Or Lethal Weapon? In the hands of an untrained operator, a grease gun 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 course will teach you proper grease gun practices .

“I think the information I learned can improve our hydraulic systems by 40 percent.”

Effective Oil Analysis With Precision Oil Sampling.

“This training set a good foundation of knowledge to make a measurable difference in our lubrication program.”

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 .

What You Get When You Attend • Case Studies • How To’s • Worksheets

• Checklists • Look-up Charts

When you leave this course, you’ll consider your course manual an indispensable on-thejob reference for years to come .

Vernon Player, PDM Tech, International Paper

David Hull, Reliability Supervisor, Holcim, Inc.

“This course has provided me with an in-depth view on how to create a world-class lubrication program.” Dennis Hill, Facility Engineer, Alcoa

“Vendor-neutral Makes A Difference!” Alfredo Romaro, Maintenance Technician, Kawneer Company


3

Fundamentals Of Machinery Lubrication

Course Outline How Lubrication Affects Machine Reliability

Join This List Of World-class Companies That Have Benefited From Noria Training 3M Alabama Power Alcoa Alumax Ameren American Electric Power ArcelorMittal Archer Daniels Midland Barrick Goldstrike BHP Boeing Boise Cascade BP Cargill Castrol Caterpillar Centralia Mining Chevron Citgo Clopay ConAgra Foods ConocoPhillips Constellation Energy Dow Chemical Dow Corning DTE Energy DuPont Dynegy 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 Holcim Honeywell Intel

4

Heinz Houston Metro Transit International Paper Invista John Deere Kinder Morgan Koch Industries Lockheed Martin Lukens Steel M&M Mars MillerCoors Michelin Mosaic Noranda Aluminum Nova Chemicals Owens Corning OxyChem Pacific Gas & Electric Peabody Energy Pfizer Powder River Coal PPG Industries Procter & Gamble Progress Energy Reliant Energy Rio Tinto Seattle Times Seminole Electric Shell Oil Southern Company Temple-Inland Texaco Texas Instruments Toyota TXU Energy Unilever U.S. Army U.S. Navy U.S. Postal Service USG Corporation Verso Paper Via Rail Canada Westinghouse Weyerhaeuser Whirlpool Willamette Industries

• Financial benefits from achieving lubrication excellence • Four equipment maintenance strategies and when each applies • Important implementation steps to lubrication excellence Lubrication Fundamentals

• 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

Lubricating Grease Application Methods

• How to protect against incompatible grease mixtures • Advantages and disadvantages of centralized lubrication systems • Best practices for greasing motor bearings • How to control pressure when greasing bearings • The unique problems caused by over-greasing – specific steps to eliminate • 3 critical instructions to give your electric motor rebuild shop • Comparing single- and multi-point lubrication options • How to calculate greasing intervals and quantity • Best practices for ultrasonic/sonic-based greasing

Understanding Additives, Base Oils And Grease Thickeners

Lubricating Oil Application Methods

• How lubricant properties irreparably change • Seven important physical properties of a base oil

• How to use oil mist and other automatic lubrication methods

• The importance of API’s five base oil categories

• Using pressure spray methods for gearboxes

• What causes grease to dry out and 18 ways to prevent it

• Best practices for the maintenance of grease guns and fittings

• How to detect the root causes of lubricant oxidation

• How to protect against problems caused by constant-level oilers

• When to select one of the six most commonly used synthetic base oils

• Overview of oil lubrication methods and devices

• Overview of single-point direct lubrication systems

• How to use temperature to determine the right base oil for your machine

Journal Bearing Lubricants

• How to select grease thickeners for your application

• The 8 most common journal bearing lubrication problems

Lubricant Performance Properties

• How to select journal bearing viscosity based on speed

• Key additives that enhance lubricant performance • Viscosity grades, measurement and reporting • Why Viscosity Index is important • What causes oil viscosity to change and how to set monitoring limits • Lubricant performance tests and reporting – what you need to know • How water contamination generates other contaminants • How to control and eliminate aeration problems

Rolling-element Bearing Lubricants

• The nine critical factors affecting rolling-element bearing lubricant selection • How to convert required operating temperature viscosity to ISO viscosity grades Gear Lubricants

• 5 key requirements for gear oil • How to select the best viscosity for a gear lubricant

Food-grade And Environment-friendly Lubricants

• Best practice guidelines for storing spare gearboxes – lubrication matters!

• Important USDA requirements and government regulations for food-grade lubricants

• 10 conditions that may require synthetic gear lubricants

• What you need to know about food-grade additives, base oils and grease thickeners

• Lubrication best practices for enclosed gears – a 12-point checklist

• Guidelines for food-grade lubricants

• Mastering the challenges of open gear lubrication


Fundamentals Of Machinery Lubrication

Automotive And Mobile Equipment Drive-line Lubricants

• Guidelines for controlling machine surface fatigue and extending machine life

• How to read a motor oil label – what really matters

• The No.1 cause of machine wear and how to manage it

• The six critical objectives a motor oil must accomplish • How to set realistic cleanliness levels for lubricants • Understanding API service classifications for engine and gear oils • The No.1 reason automatic transmission fluids fail and how to protect against it

• Effective lubricant contamination control strategies for extending machine life • 4 ways water contamination attacks lubricant additives

• Service classifications for automotive greases – how • How to set limits for water-in-oil contamination to select • Managing the root causes of foam and aeration • Extending engine life – surprising engine oil filter • Best practices for excluding and removing study results contaminants

• Portable oil transfer and filter cart selection advice • How and where to store oil transfer and filter carts • Understanding and managing lubricant storage life • Keeping grease fresh – best practices for storage Design And Inspect for Lube Excellence

• World-class strategies for accessorizing equipment for lubrication excellence

• The right way to control contamination in tanks and • Seven critical accessories for lubricant inspection and sampling sumps • Steps you can take right now to combat compressor • The right machine accessories for effective • How oil filters are rated lubricant failure contamination control • Calculating the clean-up rate for portable filters • The most common compressor lubricant stressors • Best practices for removing water contamination • When to use synthetic compressor lubricants Used Oil Sampling And Analysis from oil and why Fundamentals • The unique problems created by varnish – how to • What oil analysis can tell you remove and stop it Steam And Gas Turbine Lubricants • Types and categories of oil analysis • Why turbine/generator lubricants are the No.1 Oil Drains, Flushing And Reservoir • Applications for oil analysis contributor to forced outages Management • Overview of oil analysis tests • Comparing steam and gas turbine oils – how they differ • How to optimize and extend oil change intervals • Elements of a successful oil analysis program Compressor Lubricants

• Checklist for best practice steam turbine lubrication

• Interval vs. condition-based oil changes – pros and cons

Hydraulic Fluids

• Metrics for monitoring lubricant consumption

• How to select the ideal hydraulic fluid viscosity for gear, vane and piston pumps

• Best practices for oil changes

• Nine key hydraulic fluid requirements and why they matter

• The best procedures for oil draining and refilling

• Know how and when to perform a flush

• Specific conditions that may require a synthetic hydraulic fluid

• How and when to use the bleed-and-feed strategy for extending oil drains

• Fire-resistant hydraulic fluids – what you need to know

• Selecting the right cleaning and flushing procedures

• Hydraulic system maintenance best practices – 21-point checklist

Storing, Handling And Managing Lubricants

Contamination Control

• Strategies for building reliability through contamination control • The seven most destructive contaminants and how to control them • Specific steps for managing a proactive lubricant management program

• How to set up a world-class lube room

• How clean should oil sample bottles be? • How to find the best sampling locations • Oil sampling valve 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 • Advice for sampling hard-to-reach machines • How to properly sample circulating systems • Safe, effective high-pressure sampling from hydraulic systems

• How to know when to reject a new oil delivery

Essential Field Inspections

• How to optimize your lubricant selection and procurement process

• 12 questions your oil filter will answer about your machine

• How to implement a lubricant consolidation program and select suppliers

• Visual inspections you can get big results from right now

• Used lubricant storage, handling and disposal best practices

• Quick tips for using scent, sound and touch to inspect lubricants

• The ISO Solid Contaminant Code – understand it, track it

• Bulk lubricant storage do’s and don’ts

• 10 ways to get more mileage out of portable filter carts

• Lubricant dispensing options and what you must avoid

• How dirt, metal particles and soot mechanically destroy machine surfaces

• Lubricant coding and identification systems – what works and what doesn’t

• Guidelines for storing and handling drums

Take This Course Online! Get Started Now Visit LubeIQ.com


5

Trainers Get Certified! Level I certification testing will be held on the Friday following the training by the International Council for Machinery Lubrication . How To Certify

There are two ways to register for a certification exam. Online:www.LubeCouncil.org Phone: 918-259-2950 Which Certifications?

Jim Fitch Jim Fitch, a founder and president of Noria Corporation, is a highly sought-after consultant and trainer described by his clients as “insightful, dynamic and thorough.” He has advised hundreds of companies on developing their lubrication and oil analysis programs and has taught more than 400 training courses in more than 20 countries.

Jeremy Wright Jeremy Wright, a Noria senior instructor, provides a lively interactive forum for learning at his courses. As a consultant, Jeremy has helped numerous Fortune 500 companies develop lubrication procedures, benchmark to best practices and implement world-class lubrication programs.

Bob Scott

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

From Our Resource Center...

What Is ICML?

The Level 1 Study Packet

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 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 .

On-Site Training We can customize Fundamentals of Machinery Lubrication – or any of our other courses – to meet your unique needs. We’ll provide expert instruction at a time and place most convenient for your group. Want to know more? Call 800-597-5460. Whether you have 5 or 500 people to train, Noria is the answer.

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Bob Scott brings to his courses a wealth of “in the trenches” experience. His practical “how to” advice and engaging teaching style consistently receive top scores from audiences. You’ll reap the benefits from his 25+ years of experience with lubricants, lubrication and oil analysis and come away from the training with solid, practical skills.

The Level 1 MLT / Level 1 MLA Study Packet Includes: Flash Card Pack 385 flash cards to help you prepare for both

ICML Level I MLT and Level I MLA certification. 125-Question Practice Exam This multiple-choice practice

test is a great self-assessment tool and helps you prepare for both ICML Level I MLT and MLA certification. Licensed for use by one person.

Preparation Tools For ICML Level 1 MLT And Level 1 MLA

How To Take A Multiple-Choice Exam Includes advice from professionals who have

passed ICML certification exams as well as helpful hints for the night prior to the exam, steps to take before entering the exam room, techniques to manage your time during the exam and advice for handling different types of questions. Lubrication Fundamentals Discusses lubricant basics, machine elements that require lubrication,

methods of application, lubrication, lubricant storage and handling, and lubricant conservation. Oil Analysis Basics Presents the fundamentals of oil analysis for machinery condition monitoring

in an easy-to-understand for mat. You’ll learn everything from how to take a proper oil sample to how to select a test slate for your applications. The Practical Handbook Of Machinery Lubrication 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

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Machinery Lubrication

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