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Contents
6
COVER STORY
Machinery
2011 Salary Survey: What Lubrication Professionals Earn
Lubrication
The results of Machinery Lubrication’s recent online survey provide new insight
into the lives of lubrication professionals.
2
AS I SEE IT
November - December 2011
24
PRACTICING OIL ANALYSIS
The Optimum Reference State: Creating an
Engineering Specification for Lubrication Excellence
The Optimum Reference State is a state of preparedness and condition
readiness that enables lubrication excellence. It gives the machine and
its work environment “reliability DNA” as it relates to lubrication.
4
How to Develop an Effective Oil Analysis Strategy
To implement a well-developed oil analysis program, you must ask
the right questions and supply relevant information to the data
analyst. Once this takes place, you can ensure the program will be in
a better position to achieve the desired results.
26
FROM THE FIELD
HYDRAULICS AT WORK
The Dangers of Overgreasing
Invest in Proactive Maintenance
for Your Hydraulic Equipment
While the ideal outcome from any predictive maintenance task is to
find nothing wrong, the discovery of a fault, defect or other cause for
alarm vindicates performance of the task. It essentially turns what
could otherwise be classified as an expense into an investment.
When it comes to regreasing bearings, more is not always the better
option and actually can be a costly mistake. Instead, greasing
should be set on a frequency with proper calculations used to
determine the amount of grease needed at each relubrication.
16
34
18
42
LUBE-TIPS
Our readers provide excellent advice on a host of lubrication-related
issues, including how to handle containers with care, protect metals
with corrosion inhibitors and get more from your reservoir.
INDUSTRY FOCUS
Clopay’s Lippert Reaps the Benefits
of ICML Certification
Personifying the spirit of ICML, Scotty Lippert has garnered industry
recognition for his work in machinery lubrication almost 10 years
after achieving his first certification.
BACK PAGE BASICS
Removing Dissolved Soft Contaminants from Oil
The Basics of Synthetic Oil Technology
Learn how soft contaminants are created, their consequences and how
to detect them, as well as a new and improved method of removing
them utilizing cooling and cellulose depth filter media.
More
CERTIFICATION NEWS
Some confusion has arisen recently regarding the use of the word
“synthetic.” Jeremy Wright explains the types and properties of
synthetic oils as well as the possible advantages and disadvantages.
Editorial Features
Departments
30 GET TO KNOW
32 NOW ON MACHINERYLUBRICATION.COM
14 PRODUCT NEWS
33 CROSSWORD PUZZLER
38 ASTM STANDARDS
39 TEST YOUR KNOWLEDGE
40 PRODUCT SUPERMARKET
Maintenance and Reliability
AS I SEE IT
JIM FITCH NORIA CORPORATION
THE OPTIMUM
REFERENCE STATE
CREATING an ENGINEERING SPECIFICATION
for LUBRICATION EXCELLENCE
These days an increasing number of
companies are trying to achieve a
state of lubrication called “lubrication excellence.” Others might call this “world-class”
lubrication. Most understand the reliability
benefit gained when excellence in lubrication is attained, yet even those who are
professionals in reliability and maintenance
too often have vague ideas of what defines
lubrication excellence.
We all know that machines used in plant
production processes are designed and
built to engineering specifications intended
to achieve a desired level of performance,
efficiency and productivity. Using this same
concept, it is reasonable to write an engineering specification for machine reliability
and lubrication excellence. In the specification
would be an itemized list of critical attributes
needed to achieve the desired state of reliability. It should be noted that only part of the
specification relates to the design and modification of the machine.
In the past, these critical attributes
have sometimes been called “best practice” or the “rights of lubrication,” but
what exactly defines best practice and
these so-called rights? A true engineering
specification must be precisely defined and
purposeful. It needs to not only permit the
desired level of reliability to be achieved
but also be within reach of most reliability
and lubrication teams.
I would like to introduce a new term
called the Optimum Reference State related
to the integrated and collective use of these
Benchmark Assessment Example
Equipment Selecon
Correcve Acon Approach
Sampling Locaon and Hardware
Oil Analysis Program
Management
Sampling Procedure
Training, Skills, Cerficaon
Sampling Frequency
Sampling Hardware
Laboratory Selecon
Data Analysis
Industry Average
2|
Recommended Goal
November - December 2011 | www.machinerylubrication.com
Test Slate
Preferred Pracce
66%
of lubrication professionals say their
plant has not yet achieved lubrication
excellence, based on survey results
at www.machinerylubrication.com
critical attributes. Let me define this important term:
“The Optimum Reference State (ORS) is
the prescribed state of machine configuration, operating conditions and maintenance
activities required to achieve and sustain
specific reliability objectives.”
Note the definition for the ORS does not
state a requirement to “maximize” reliability. This is because a point can be
reached where the incremental cost of reliability exceeds the incremental benefit
(point of diminishing return). Such overspending on lubrication is seen, for example,
when synthetics are used in marginal applications or when lubricants are changed too
frequently. Like many things in engineering
and reliability, there is a “precision” component to good decisions.
Defining Lubrication Excellence
Only after we establish the Optimum
Reference State do we have a way to define
the meaning of lubrication excellence:
“Lubrication excellence is achieved when
the current state of lubrication approaches
that of the Optimum Reference State.”
Noria often uses a spider diagram to
benchmark a plant’s current lubrication
state across 11 categories relative to the
Machinery
Lubrication
PUBLISHER
Mike Ramsey - mramsey@noria.com
Optimum Reference State (represented by
the outer perimeter of the diagram). Each
spoke of the diagram is a cumulative measure
of lubrication performance against critical
attributes within that category. The diagram
gives a convenient snapshot of lubrication
quality at a plant as well as the opportunity
for improvement.
The ORS is a state of preparedness and condition readiness that enables lubrication excellence.
It gives the machine and its work environment
“reliability DNA” as it relates to lubrication. Let’s
take a look at some of these enabling attributes
of the ORS:
• People Preparedness. People are trained to
modern lubrication skill standards and have
certified competencies.
• Machine Preparedness. Machines have the
necessary design and accouterments for
quality inspection, lubrication, contamination control, oil sampling, etc.
• Precision Lubricants. Lubricants are correctly
selected across key physical, chemical and
performance properties, including base oil,
viscosity, additives, film strength, oxidation
stability, etc.
• Precision Lubrication. Lubrication procedures, frequencies, amounts, locations, etc.,
are precisely designed to achieve the reliability objectives.
• Oil Analysis. This includes optimal selection
of the oil analysis lab, test slate, sampling
4 Features of ORS
Critical Attributes
Critical attributes of the Optimum Reference State (ORS) are similar to dynamic balance
and precision alignment in rotating equipment.
These necessary precursors to reliability are
selected and measured by scientific and engineering methods. Each attribute must be:
1. Precise and definable (e.g., a specific
lubricant sump level),
2. Measurable (e.g., a specific viscosity) or
verifiable (e.g., a sample port location),
3. Controllable (by modification) and
sustainable (by program continuity),
4. Able to achieve the desired reliability
objectives related to the financial benefit,
safety and machine readiness.
frequency, alarm limits, troubleshooting
rationale, etc.
Critical attributes are the building blocks of
the Optimum Reference State. These can be
broken down into primary and secondary attributes. A primary attribute directly enables a
desired level of machine reliability (e.g., the lubricant contaminant level will not exceed ISO
16/13/10). A secondary attribute supports or
indirectly enables a primary attribute (e.g., a
machine with a high-performance filter). The
sum total of all lubrication ORS attributes in a
plant is an engineering specification for lubrication excellence.
Moving toward the Optimum Reference State
is nearly always a process of modification and
transformation. For many plants, this may
require more of an intervention. Sometimes the
best time for transformation is immediately after
a crisis, such as after a costly business interruption from a machine failure.
The modifications needed to enable the ORS
can be numerous depending on the type and size
of the plant. These include modifying people,
machines, procedures, PMs and inspections, as
well as condition-based maintenance activities.
Plants approaching the Optimum Reference
State might see asset utilization numbers
increase from 5 to 10 percent and maintenance
cost reductions as high as 10 to 50 percent. Of
course, this depends on industry and many
operating conditions.
Over the years, Noria has monitored and
observed top performers worldwide in the lubrication field. We’ve looked for unique traits that
set these companies apart. We’ve found differences that are measurable, verifiable and
controllable. These constitute the Optimum
Reference State. The benefits are real, and so too
are the opportunities to achieve them.
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 jfitch@noria.com.
GROUP PUBLISHER
Brett O’Kelley - bretto@noria.com
EDITOR-IN-CHIEF
Jason Sowards - jsowards@noria.com
SENIOR EDITOR
Jim Fitch - jfitch@noria.com
TECHNICAL WRITERS
Jeremy Wright - jwright@noria.com
Matt Spurlock - mspurlock@noria.com
Josh Pickle - jpickle@noria.com
CREATIVE DIRECTOR
Ryan Kiker - rkiker@noria.com
GRAPHIC ARTISTS
Steve Kolker - skolker@noria.com
Gustavo Cervantes - gcervantes@noria.com
Julia Backus - jbackus@noria.com
ADVERTISING SALES
Tim Davidson - tdavidson@noria.com
800-597-5460, ext. 224
MEDIA PRODUCTION MANAGER
Rhonda Johnson - rjohnson@noria.com
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: jsowards@noria.com
MACHINERY LUBRICATION Volume 11 - Issue 6 November-December
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
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SUBSCRIBER SERVICES: The publisher reserves the right to accept or
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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
November - December 2011
|3
Hydraulics
HYDRAULICS
AT WORK
BRENDAN CASEY
INVEST in PROACTIVE
MAINTENANCE for
your HYDRAULIC
EQUIPMENT
I recently purchased a used SUV with the plan to do some
traveling with the family. It’s a big trip, starting with a
journey across the Nullarbor Plain from the west to east coast of
Australia. If you spend 12 hours a day in the car driving, you can
cover the distance in four days.
However, the Nullarbor is a desolate place. There’s not much out
there. You’re lucky if you see a kangaroo or emu between gas stations, and
they’re hundreds of miles apart. It’s certainly not somewhere you want to
break down. This would be even more unacceptable for me, being a
preventive maintenance guy and knowing if something goes wrong with
the vehicle that I’m really going to hear about it from my wife.
To minimize the possibility of any nasty (and embarrassing) surprises
in the middle of the desert, I took my newly acquired but pre-loved SUV
down to the automobile association for a thorough workshop inspection. I dropped it off in the morning, and when I arrived to collect it later
that day, I could see it was still up on the hoist.
3 Steps Toward Proactive Maintenance
1
2
3
4|
GOALS
Set Cleanliness Targets
1
1
Target cleanliness level should
reflect reliability goals.
Take Specific Actions
to Achieve Targets
1. Reduce ingression
2. Improve filtration
Measure Contaminant
Levels Frequently
1. What gets measured gets
done (Step 2)
2. Post control charts of
measured results
November
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b 2011 | www.machinerylubrication.com
hi
l bi i
CONTROL CHART
I knew all was not well when the inspecting mechanic invited me
out into the workshop. When we got underneath the vehicle, the
first thing he pointed to was a broken front differential mount.
While I’m thinking to myself, “Wow, that’s not very cool,” he shows
me a lower front ball joint that’s shot. Strike two. Now I’m thinking,
“Enough already.” Thankfully, there was no strike three.
Of course, the ideal outcome from any maintenance inspection
or predictive maintenance task is to find nothing wrong. On the
other hand, the discovery of a fault, defect or other cause for alarm
vindicates performance of the task. It essentially turns what could
otherwise be classified as an expense into an investment. It’s kind
of bittersweet.
The dictionary defines expense as a loss for the sake of something
gained. Investment is defined as property or other possession
acquired for future financial return or benefit.
Since the above issues are not the sort of problems you can fix on
the side of the road with only a fistful of ring spanners, ignorance is
not bliss. Based on the proverbial truth that a stitch in time saves
nine, the $185 it cost to have my SUV inspected means that it was,
by definition, an investment. Early detection undoubtedly saved
me many hundreds, perhaps even thousands of dollars, and that’s
without considering the likely stress and inconvenience a breakdown
in the middle of nowhere would have caused.
This leads to another point, which is what you do by way of
preventative and predictive maintenance is largely determined by the
cost and consequences of failure. Being about to embark on a transcontinental road trip raised the stakes. Had I not been, I wouldn’t
have bothered having my SUV inspected. Yet it still would have been
a sound investment.
Notwithstanding the premise that a dollar spent on PM/PdM
should always come back with friends attached, the bottom line is
the more you know about the operational condition of your
machines the better, especially when this intelligence can be
acquired cheaply.
In the case of hydraulic machines, a lot of useful predictive data
can be gathered with minimal outlay. Pressure, temperature and
speed (flow) are three revealing vital signs of every hydraulic machine
that are easy and cheap to monitor.
95%
of Lube-Tips subscribers view proactive
maintenance as an investment.
From a reliability perspective, operating
pressure is load (and load influences wear) on
the system’s components. Pressure, of course,
is easy to monitor with the appropriate installation of pressure gauges or transducers.
Output speed is diminished by internal
leakage, a variable influenced by oil temperature
(viscosity) and wear. Speed, or early detection of
the loss of it, is easily achieved using a stopwatch to record machine cycle times.
The operating oil temperature and thus
viscosity influence component lubrication, and
when temperature is monitored from an established baseline, it can provide early warning of
loss of efficiency resulting from an increase in
component wear or damage. The operating oil
temperature of a hydraulic machine is easily
monitored using an infrared thermometer
(heat gun) or by the installation of appropriate
instrumentation.
In terms of tracking and compiling this data,
it’s a good idea to take readings on the hottest
and coldest days of the year as well as on a couple
of average temperature days in between. This
provides a baseline of information. In addition,
taking readings at regular intervals — each day or
shift, for example — can provide early warning of
impending problems. If the system starts to have
trouble, taking a set of readings will reveal if it’s
operating outside its normal parameters.
Beyond this, your mission is to determine
what you should be doing by way of proactive
maintenance for the hydraulic equipment you
own or are responsible for and to make sure it’s
all up to date.
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.
www.machinerylubrication.com
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November - December 2011
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ML
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COVER STORY
November - December 2011 | www.machinerylubrication.com
2011 Salary Survey:
Lubrication
Earn
Professionals
What
BY JASON SOWARDS, NORIA CORPORATION
Machinery Lubrication recently conducted an online survey
of lubrication professionals in the United States to discover
what they earn based on their experience, education level, geographic
location, age and other relevant factors. In addition to earning
power, the survey included questions regarding company size, job
security, job satisfaction and future potential.
Responses poured in from nearly every state, with Texas, California and Pennsylvania registering the most results, while
Vermont, Rhode Island and Delaware were the only states not
represented.
Employees from some of the industry’s largest and most wellknown companies participated in the survey, including Alcoa,
Cargill, Caterpillar, Dow Chemical, Holcim, Kimberly-Clark, TempleInland, Fluor and Entergy. We wish to extend our thanks to everyone
who contributed.
The Results
According to the results, machinery lubrication generally
remains a male-dominated industry, as more than 96 percent of
those responding to the survey were men. The small number of
women who completed the survey reported an average salary that
was 13 percent less than their male counterparts. Men were also
more likely to have received a raise in the past year, while women
were more likely to work fewer hours and be more satisfied with
their jobs.
The average age of the respondents was 49, with the youngest
being 25 and the eldest 71 years old. However, age did not seem to
play much of a role in compensation, as those 40 years of age and
younger earned just $2,000 less per year on average than their older
colleagues but were more likely to have received a raise and a bonus
in the past year.
www.machinerylubrication.com
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November - December 2011
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COVER STORY
Geographically, workers in the Western states reported the
highest salaries, followed by those in the South. Salaries in the
Northeast and Midwest lagged behind their contemporaries by
almost 15 percent.
Income
So what do lubrication workers earn? Salaries ranged from
$200,000 to $12,000 per year, with the average almost $77,000
annually. Education was a determining factor, as those who had
earned a bachelor’s degree averaged more than $20,000 more per
year than those who had completed some college work but had not
received a degree. Meanwhile, respondents with a graduate degree
made an average of almost $10,000 more per year than those with
only a bachelor’s degree. Predictably, workers with only a highschool education earned the least at almost 10 percent less than
those who had taken some college courses.
Professional certification also seems to have a big impact on
compensation, with those respondents holding some type of professional certification from the International Council for Machinery
Lubrication (ICML) or another organization reporting 10 percent
higher salaries than their non-certified peers.
“There are bonuses for any type of continuing education relative
to our business,” said one respondent.
“It depends on the site and the qualifications they set in place, but
for the most part they need to complete level I for oil analysis and
lubrication (to be paid more),” wrote another survey participant.
Certifications were most common among respondents in the
food processing, mining, rubber/plastic, paper, chemicals, power
generation and petroleum product industries. In addition, men were
almost twice as likely to hold a professional certification as their
female counterparts.
Somewhat surprising was the fact that experience did not seem
to affect the salary range as much as might be expected. Respondents with at least 10 years of experience in lubrication-related
work made only 5 percent more than those with less experience,
while those with 20 or more years of work experience garnered less
than $5,000 more per year on average than their less experienced
counterparts.
In comparison to 2010, income among lubrication professionals
rose in 2011 according to our survey. Seventy percent of workers
8|
November - December 2011 | www.machinerylubrication.com
COVER STORY
reported receiving a raise in the past year, although most saw an
increase of just 5 percent or less. Only 6 percent of respondents
received pay increases exceeding 10 percent. That was better than the
3 percent who watched their salaries decrease over the last 12 months.
Respondents with a bachelor’s degree or a professional certification and workers in power-generation facilities were among the
most likely to have received a raise in 2011, while professionals in
sales and petroleum products claimed the fewest raises over the past
year. The largest salary increases were reported by those in maintenance management and those workers living in Texas.
Bonuses were also prevalent in 2011, as more than 60 percent of
survey participants said that they received a bonus in the past 12
months. Those respondents working more than 40 hours each week
were the most likely to have received a bonus, while workers who did
not supervise any employees were among the least likely to have
received a bonus in the past year.
In addition to their annual salaries, more than 90 percent of respondents receive other benefits, including health insurance and 401(k)
contributions. However, only 35 percent collect any profit sharing.
Job Satisfaction
Rising income may have contributed to the high job satisfaction
and overall contentment among survey participants, as 68 percent
of respondents believe they are compensated fairly. Reliability
professionals were the respondents most likely to believe their
compensation was fair.
Job satisfaction was quite high for most of the lubrication professionals who completed our survey, with more than 70 percent rating
themselves as either satisfied or very satisfied with their jobs, compared
with only 5 percent who were dissatisfied. Maintenance workers ranked
as the most satisfied with their jobs among their peers.
The factors that were regarded as the most important to job
satisfaction were the challenge and stimulation of the position,
10 |
November - December 2011 | www.machinerylubrication.com
COVER STORY
followed by work environment and salary and benefits. Fellow
colleagues and making products that help people were at the
bottom of the list.
As for what respondents dislike about their jobs, most cited a
lack of recognition or the hours and workload of their position.
“With so much equipment to cover, there just isn’t enough time
to look at or even check oil levels on some equipment,” complained
one respondent.
“As our plant grows, I have limited resources to manage the
many competing priorities,” wrote another survey participant.
“The workload combined with my school load gets to be a bit
much sometimes, and it is somewhat hard to keep up with,” added
another respondent.
Work environment was another common item survey participants listed as something they disliked about their jobs.
“Too many here are retirement age and not willing to make
changes,” commented one respondent. “There is apathy, and
management is cutting costs, looking for short-term profits.”
“We have much opportunity for growth and profitability, but
there is a lack of commitment,” said another worker.
“Our inept management is unable to weed out the 2 percent
deadwood of the workforce that creates a toxic work environment,”
noted another respondent.
Work Hours
Long hours and hard work appear to be the norm for most in
machinery lubrication, as the majority of respondents work more
than 40 hours per week, and one-fourth claim to work 10 or more
hours each day. The extra hours seemed to pay off with an average
of almost $9,000 more per year for those working more than 40
hours weekly.
However, respondents holding a professional certification
tended to work fewer hours on average than those without certification, while those who supervise at least one employee reported
working more hours on average than those who do not serve as a
supervisor.
Employee loyalty was one trait most respondents shared, with
the majority having worked for their current employer at least 10
years and the average almost 15 years of service. Several even
reported working more than 40 years for the same employer.
Job Title and Function
Most survey takers described their primary job function as reliability, maintenance or maintenance management. Those listing
engineering in their job title or function earned the most, at $20,000
more per year on average than those in other fields.
While “petroleum products” was predictably listed as the
primary business activity for most respondents’ facilities, power
generation, food processing, chemicals and mining were among the
other top responses.
More than half of those responding to the survey supervise at
least one employee, yet those who did not oversee any employees
earned only 4 percent less than those in supervisory roles. The big
difference in salary appeared among supervisors when comparing
the number of employees managed, as those supervising fewer than
12 |
November - December 2011 | www.machinerylubrication.com
25 employees earned almost $12,000 less per year on average than
supervisors of more than 25 employees.
Survey participants with professional certifications were more
likely to serve as a supervisor than those without a certification, and
men were more likely to be supervisors than women.
When it comes to company size, it seems to pay to work for a
larger employer. While most survey participants work at facilities
with 100 or more employees, these workers at the larger plants
also reported 11 percent higher salaries than those employed at
smaller plants.
Job Security
Although 80 percent of respondents believe their jobs are secure and
73 percent do not anticipate their company losing any lubricationrelated jobs next year, most do not expect their company to add any
lubrication-related jobs, new product lines or shifts in the coming year.
“There can be no job security if the economy does not improve
and sales volumes do not increase,” wrote one respondent.
“If there is no manufacturing, there are no machines requiring
service,” warned another survey participant.
2012 Outlook
According to our survey results, optimism for 2012 is high, with
nearly two-thirds of respondents expecting their salary to increase in
the coming year, and only 2 percent anticipating a decrease in
compensation. Workers in Texas and California tended to be the
most optimistic with regards to salary increases for the coming year,
while survey participants in Ohio and Massachusetts were less
hopeful in their compensation expectations for 2012.
Most respondents listed the economy and worries of a doubledip recession as their greatest concerns heading into next year.
“The economic instability of our nation makes me afraid that we
will go back into recession,” said one respondent. “Manufacturing is
not strong yet.”
“I work in a construction-material supply organization, and
overall volumes keep dropping,” wrote another survey participant.
“The total number of available jobs to bid on is falling.”
“If the economy stays flat, the drop in revenue will cancel or defer
additional projects,” worried another respondent.
Others cited environmental regulations and overseas competition as threats to their companies.
“Environmental restrictions on manufacturers are making it
impossible to manufacture in the USA,” noted one respondent.
“There are too many choices on the market today,” wrote another
survey participant. “If you don’t deliver the right product at the right
price at the right time, there are plenty of manufacturers who can.”
“Competitors undervalue our business by offering our services at
prices below fair market value,” added another respondent.
The lack of knowledgeable personnel entering the job market and
the aging workforce were other common worries.
“The labor force to hire from isn’t willing to work,” complained
one respondent.
“We are growing so fast that we cannot get enough quality
people hired to do the jobs,” said another survey participant.
“When they cut the next cost, many will retire, taking a lot of
experience and leaving many scratching their heads,” wrote
another worker.
For more survey results or to participate in the next Machinery
Lubrication poll, go to www.machinerylubrication.com.
www.machinerylubrication.com
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November - December 2011
| 13
INDUSTRY FOCUS
PRODUCT NEWS
GREASE GUN LIGHT
The Grease Gun Light illuminates tough-to-reach areas where many grease zerks are
located, enabling technicians to service vehicles much more quickly. The light also
allows a technician to monitor the process to ensure that the grease fitting is
not overfilled. To use the Grease Gun Light, simply attach the female end of the
fitting to the end of the grease gun extension hose and then connect a grease
coupler to the male end of the fitting.
Thexton
www.thexton.com
800-328-6277
DRUM SCALE
Designed for weighing drums, barrels, containers, skids and pallets, the new
portable platform scale from Alliance Scale Inc. features an anti-slip platform
and a 1,000-pound capacity. The Alliance/CAS R-Series drum scale includes
a digital weigh indicator with easy-access ramps on two sides, side rails to
keep items onboard and two built-in handles and two rubber wheels for portability. The low-profile scale is available with a six-digit LED digital indicator
and provides 1/2,000 external resolution. The digital weigh indicator comes
with an 18-foot shielded cable and can be mounted virtually anywhere.
Alliance Scale
www.alliancescale.com
800-343-6802
GREASE TEST KIT
The SKF Grease Test Kit offers a portable and userfriendly way to perform bearing grease condition assessments in the field. The kit enables users to easily take
samples and evaluate grease consistency, oil bleeding
characteristics and contamination without special training or the use of harmful chemicals. The kit is equipped
with instructions, methodology, relevant tools for sampling and testing, and guidelines to interpret test results.
Only a small sample size (0.5 grams of grease) is required
to perform all
three tests, and
the process can
be conducted
as frequently as
necessary.
SKF USA Inc.
www.skfusa.com
800-440-4SKF
AUTOMATIC LUBRICATOR
The new WRDP series automatic lubricator
from TechValve is a wireless, programmable
unit that incorporates a rod displacement
pump system with power ratios up to 40-to-1
to guarantee reliable and accurate dispensing
of liquid lubricants and grease. Each unit has
an onboard human machine interface (HMI)
but can also be remotely programmed from
a computer anywhere in the facility. Programmable functions include number of cycles per
shot, material totalization and a test button to
manually run or test the program.
TechValve Lubrication
www.techvalveind.com
574-440-4961
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November - December 2011 | www.machinerylubrication.com
KINEMATIC VISCOMETER
The new Q3000 kinematic viscometer from Spectro Inc. is portable, solventfree and temperature-controlled. It uses a split-cell capillary technique that
allows the user to measure kinematic viscosity from only a few drops of oil.
The entire sampling and testing process takes only a few minutes and can
easily be conducted in the field or any portable environment. The Q3000
has an intuitive software user interface, weighs just less than 1.8 kg and
is powered by a lithium-ion battery that provides more than six hours of
continuous operation.
Spectro Inc.
www.spectroinc.com
978-486-0123
MULTI-METAL PROTECTANT
Sprayon Products’ new LU 787 Eco-Grade
Multi-Metal Protectant is a heavy-duty,
biodegradable, dry-film corrosion preventative that penetrates into cracks and
crevices of metal surfaces. Formulated
with 100-percent vegetable oils, the light
amber-colored protectant offers an environmentally friendly alternative to mineral
oil-based products. It provides 24 months
of outdoor protection and can be washed
off with standard soap and water but does
not come off in the rain. Sprayon LU 787
Eco-Grade Multi-Metal Protectant is
designed for use on mild steel, aluminum,
stainless steel, galvanized steel, chrome
parts and more.
Sprayon Products
www.sprayon.com
800-SPRAYON
LATCHING DRUM LID
SYNTHETIC MOTOR OIL
The new Z-Rod synthetic motor oil from
Amsoil is engineered specifically for classic
cars, muscle cars and other high-performance
applications. Available in 10W-30 and 20W-50
viscosities, the motor oil features high-quality
synthetic base stocks and a proprietary
additive package tailored to prevent wear
and provide maximum protection during
storage. The oil is formulated with high
levels of zinc and a unique blend of rust and
corrosion inhibitors.
New Pig’s new latching drum lid has fusible plugs for
converting a 55-gallon steel drum into a safe storage
container for oil or solvent-soaked materials. The drum
lid easily attaches to new or reconditioned drums, and its
FM-approved plugs make it ideal for use with flammable
or combustible solids. A nitrile gasket and locking mechanism completely seal the drum lid to help reduce vapor
emissions, while a removable hinge lets workers remove
the lid without loosening the band around the drum.
New Pig Corporation
www.newpig.com
800-468-4647
Amsoil
www.amsoil.com
800-777-8491
www.machinerylubrication.com
|
November - December 2011
15
ML
LUBE TIPS
PRE-FLUSH for
Better Oil SAMPLES
It is important to recognize that the amount of tubing, the
size of the sample port and the volume of static oil in relation
to the location of the sample port can all disturb the overall quality
of the sample. For an effective, data-rich sample, appropriate presample flushing volumes should be included in sampling procedures
and should be specific for each individual sample port. The industry
rule of thumb is to pre-flush six to 10 times the total volume of static
oil in a sample tube, port, port adapter and any dead legs of pipe in
the systems upstream of the sample port location.
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 editor@noria.com. To sign up for the LubeTips newsletter, visit www.machinerylubrication.com and click on
the “Newsletters” link at the top.
Protect Metals with Corrosion Inhibitors
Corrosion inhibitors are additives that suppress oxidation and
prevent formation of acids. These inhibitors form a protective film
on metal surfaces and are used primarily in internal combustion
engines to protect alloy bearings and other metals from corrosion.
Reasons for Increased Viscosity
Assuming that no water is emulsified in the system, some reasons
for an increase in viscosity of a circulating oil might include:
• The oil may have oxidized
• Pressure could have increased
• Temperature might have decreased
• Possible contamination with a higher viscosity fluid
• Evaporative losses of light oil fractions from
high temperatures
• Glycol contamination
• Soot contamination
Upgrade to a High-efficiency Filter
One of the biggest culprits for letting dirt into hydraulic and oil
reservoirs is the air breather. Many systems come with a standard
paper media breather with a nominal rating of about 40 microns.
This allows the smaller, more destructive particles to get into the
system very easily. Upgrading a standard breather to a high-efficiency filter is easily done using commercial bayonet adapters and
quality synthetic hydraulic filters.
Handle Containers with Care
Avoid damage to drums and other large containers
during handling. Negligent handling can cause leakage
or ingression of dirt. Each container for in-plant lubricants should be used for only one oil, clearly marked
for it and not substituted for another container. It also
should be kept clean and sealed to keep out dirt. Never
mix lubricants.
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November - December 2011 | www.machinerylubrication.com
Lab Reports Require Quick Action
Unless you have special arrangements,
most laboratories retain your oil sample
for only a short period of time. Seven
to 14 days is typical. When you get
back your reports and have a
questionable result or want
to have additional testing
performed, call the lab
immediately to avoid the risk
of your sample being discarded.
Getting More from Your Reservoir
A properly constructed reservoir is more than just a tank to hold
the oil until the pump demands fluid. Whenever practical, it should
also be capable of dissipating heat from the oil, separating air from
the oil and settling out contamination in the oil.
INDUSTRY FOCUS
BY STEFFEN D. NYMAN, C.C. JENSEN INC.
Removing
Dissolved
Contaminants from
Oil
0
Oil degradation products such as oxidation and varnish are known
to cause problems in many industries but especially within power
generation. The results are often costly turbine trip-outs, revenue
losses and even penalties for not producing electricity or steam.
Varnish-related issues seem to have escalated in the last few
years, and many have found that the so-called dissolved soft
contaminants are a major part of the problem. This article will
describe the creation of soft contaminants, their consequences and
how to detect them, as well as a new and improved method of
removing them utilizing cooling and cellulose depth filter media.
Warm vs. Cold Oil
One of the most recent findings regarding oil degradation
relates to how much oil temperature influences varnish precipitation, and thus how difficult it is to remove degradation products.
Basically, oil degradation can be described as:
Soft
As the oxidation process continues, polymerization causes the
formation of soft contaminants that alter the oil color and acidity
level. These soft contaminants are precursors to varnish but are
soluble in warm oil. However, changes in temperature will affect
the equilibrium. A decrease in oil temperature will lead to higher
concentrations of insolubles, which will precipitate out and
agglomerate into varnish formation, whereas an increase in
temperature will make the agglomerated contaminants go back
into solution. Thus, warm oil will dissolve soft contaminants,
while cold oil will let them fall out as varnish.
Most oils will allow soft contaminants to precipitate out
between 10 to 35 degrees C (50 to 95 degrees F). A comparison
can be drawn to sugar in coffee. Hot coffee can dissolve a lot of
sugar, but letting the coffee cool down will drop the saturation
point so the sugar falls out in the bottom of the mug. Reheating
the coffee will make the sugar go into solution again.
Consequences of Soft Contaminants
The last three steps are reversible.
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November - December 2011 | www.machinerylubrication.com
When soft contaminants are dissolved, typically in turbine oil
at temperatures above 40 degrees C (100 degrees F), they
cannot be removed through standard mechanical filters or electrostatic filters. Soft contaminants are polar in nature and
adsorb onto dipolar (colder) metallic surfaces in “cold spots” or
during outages when the turbine is stopped and the oil temperature drops. Soft contaminants also have lower thermal stability
than oil, so they are more likely to bake onto hot surfaces, e.g.,
journal bearings.
Varnish hardens into a lacquer-like coating on valve spools and
sleeves, bearings, gears and other internal surfaces of the lube
and hydraulic system. Even a thin layer of varnish is capable of
shutting down an entire power plant.
Varnish often forms in “cold spots” within the hydraulic
system where sticking and malfunction of servo valves create
problems in turbine regulation or during start-up.
The sticky nature of varnish captures hard contaminants as
they flow within the system, forming an abrasive, sandpaper-like
finish on the metal surface, which accelerates component wear.
INDUSTRY FOCUS
A valve spool covered in varnish.
Furthermore, varnish can obstruct oil flow and be an efficient
insulator that causes bearing surfaces with varnish coatings to
run hotter and heat exchangers coated with varnish to have
lower efficiencies.
Many gas turbines operate with an oil temperature of nearly
60 degrees C (140 degrees F) in the reservoir, while the oil leaving
the bearings is hotter than 80 degrees C (175 degrees F). At these
temperatures, the soft contaminants are dissolved completely in
the lube oil.
Detecting Soft Contaminants
While different laboratories offer different varnish potential
tests, the Ultra Centrifuge (UC) test and Membrane Patch Colorimetric (MPC) test offer good repeatability and easily
understandable results.
81%
of lubrication professionals have
experienced problems caused by oil
degradation products such as varnish
and oxidation, according to a recent
poll at machinerylubrication.com
sediment-rating scale with a number of one
to eight (with eight being the worst).
The UC test indicates the actual varnish
and insoluble contaminants in the oil.
Soft contaminants seen in this test will
result in varnish falling out as deposits on
system components. The test is not
recommended for oil that is highly
contaminated with particles, because it masks the result, or for
ester or glycol-based fluids, since specific gravity plays a role.
However, UC and MPC tests are very useful tools to trigger an
action, e.g., a filter or oil change.
Removing Dissolved Soft Contaminants
Most oil maintenance equipment available on the market is
not capable of removing dissolved soft contaminants, but a new
and improved method that combines cooling and cellulose depth
media has proven to be highly effective.
Utilizing air to cool oil prior to filtration with cellulose has
been tried before, but in most environments the ambient temperature isn’t low enough to cool the oil below the needed 40 degrees
C (100 degrees F). Field-test results clearly show how effective
extensive cooling combined with a large mass of cellulose can be
in removing oil degradation products from oil — dissolved and in
suspension — even from turbines operating at high temperatures.
The varnish level in turbine oil typically goes from alarm values to
safe values within a few weeks (MPC 60 to below MPC 20).
The MPC test shows soft contaminants (sludge and varnish)
present in the oil by discoloration of the white cellulose patch.
This quantifies oil degradation products, including those
dissolved in the oil. The darker the color and the higher the MPC
value, the more the oil is prone to form varnish deposits (typically
up to MPC 100, with MPC 20 being a safe value).
The UC test uses centrifugal force to extract insolubles and
varnish precursors, driving them to the bottom of the test tube.
The size of the concentrated material is then compared to a visual
A CJC varnish removal unit.
An example of UC and MPC results.
20
November - December 2011 | www.machinerylubrication.com
Cellulose-based filters reduce particle, varnish and water
contamination without the use of any chemicals or beads that
may be harmful to the integrity of an oil’s additive package. The
function can be compared to a sacrificial anode, except that
the active filter isn’t consumed but saturated with contaminants that fall out and are adsorbed in this new “cold spot” of
the lube/control oil system instead of in the bearings, valves
and inline filters.
This image reveals varnish
retained by cellulose.
How It Works
Soft contaminants can be removed by
adsorption to the cellulose material by
so-called polar attraction. This polar attraction is referred to as physisorption, which is
described as a physical attraction between the
cellulose and the fluid phase of soft contaminants/varnish. It occurs naturally with no
additional power needed.
Part of this polar attraction is due to
so-called van der Waals forces, which are
molecule-to-molecule forces that cause small
particles to adhere to a surface, e.g., how dust
sticks to glass. The other part of the attraction
is characterized as electrostatic forces incorporating hydrogen bonding between the soft
contaminant/varnish molecule and the strings
of cellulose.
Many offline cellulose filters utilize the principle of polar attraction for retaining varnish,
but some varnish removal units take it one step
further. As previously described, the efficiency of
varnish removal vastly depends on the oil
temperature, which is why certain varnish
removal units use extensive cooling to optimize
the process — retaining dissolved and suspended
soft contaminants from oil.
The CJC varnish removal unit (VRU) incorporates cooling as well as a “multi-pass”
arrangement known as “offline to offline” to
make the specially designed inserts remove all
soft contaminants from the oil. The cold oil is
An inline filter from a hydraulic system
covered in varnish.
circulated over the filter inserts and the chiller
five times before being reheated through a
cross-flow heat exchanger and sent back to the
system tank as varnish-free oil.
The additives in the now varnish-free oil will
start cleaning all the system components in
contact with the oil, resulting in a complete
varnish-free system after some weeks or months,
depending on the amount of varnish built up.
The following case study shows the results
of removing dissolved soft contaminants from
turbine oil.
Case Study
Energyworks Cartagena-Iberdrola is a
combined cycle power plant in Spain that
supplies steam and energy to SABIC (formerly
GE Plastics). Its setup installed in 2002 consisted
of two natural-gas-fired GE gas turbines of 42
megawatts (MW) each and one Alstom steam
turbine of 11 MW.
On each gas turbine, 6,500 liters (1,700
gallons) of turbine oil had been in operation
since March 2007, and the oil’s operating
temperature was between 66 to 85 degrees C
(150 to 185 degrees F). The inline pressure filters
were of a 5-micron filtration rate.
These MPC membranes — varnish
removal unit inlet (I) vs. outlet (0) — were
taken in four successive samples from
May 2011.
www.machinerylubrication.com
|
November - December 2011
21
INDUSTRY FOCUS
Benefits and Savings
These oil sample bottles show oil before
and after a single pass through a varnish
removal unit.
The Problem
The plant had experienced turbine trips
due to the malfunction of the hydraulic inlet
guide vane valves and clogged inline filters.
Dangerously high MPC values above MPC 60
also indicated soft contaminants and varnish
deposits as a result of turbine oil degradation. Therefore, the plant was ready to replace
the oil when another possibility came up.
The solution was a varnish removal unit,
which the plant agreed to try out. After 10
days with the unit in operation, the MPC
value in the main reservoir dropped from
MPC 64 to MPC 24, while oil samples from
the outlet of the varnish removal unit showed
MPC 12.
By removing dissolved soft contaminants
with a varnish removal unit, the plant not only
prevented an oil change but also avoided
future turbine trips. Replacing the 6,500 liters
of turbine oil alone would have cost approximately $25,000 per gas turbine. When adding
flushing and oil disposal costs, the total would
have been nearly $35,000 for an oil change.
The gas turbines in this combined cycle
plant are part of a complex energy production chain, so any downtime immediately
results in very high costs. If a turbine stops,
the plant loses energy worth $4,600 per hour,
plus the loss of steam production, which
results in penalties, since the neighboring
refinery needs the steam for its production.
This adds up to approximately $166,000 for a
turbine trip.
From an environmental point of view, the
benefits are quite clear. Without varnish
removal, the plant would have changed the
oil after only four years in use, which is a relatively short time considering the cost of
extracting the crude oil, refining, blending,
shipping, etc.
In a sustainable solution, the oil should be
able to last 10 to 20 years in operation
without compromising its properties and
without the need for flushing and cleaning
tanks or components.
While soft contaminants and varnish can
result in costly downtime in the power
industry, a combination of cooling and cellulose-based filters are capable of removing
even dissolved soft contaminants from oil so
turbine trips can be avoided and the reliability
and availability of the plant can be ensured.
About the Author
Varnish-covered VRU inserts after 10 days in operation.
22
November - December 2011 | www.machinerylubrication.com
Steffen D. Nyman is a certified
machine lubricant analyst and
4MAT trainer in adult teaching
skills. He has worked as a corporate trainer for C.C. Jensen since
2004, conducting more than
100 customized seminars in
understanding oil management,
including oil filtration systems
for the marine, mining, power,
offshore and wind industries.
E-mail Steffen at steffen@ccjensen.
com or visit www.ccjensen.com.
Oil Analysis
PRACTICING
OIL ANALYSIS
MATT SPURLOCK NORIA CORPORATION
HOW to DEVELOP
an EFFECTIVE OIL
ANALYSIS STRATEGY
Joining my sister at the emergency room for an issue with her
son was an enlightening moment. The ER doctor walked in,
reviewed some historical records on my nephew and began asking
questions. As any mother would do, my sister gave the doctor a
wealth of information, both relevant and not so relevant, to the
current situation. It was the doctor’s job to filter the information
and determine what was truly important and helpful. He kept
pressing for more information and grilling my sister for clarification
on even the smallest comment, which to her may have seemed
inconsequential, but to him was significant.
Example of an Oil Analysis
Program Strategy
A survey of 3,000 rotating assets showed that there were 1,500 oilfilled components (including pumps, gearboxes, hydraulic and lube
oil reservoirs). In theory, there could be 1,500 oil samples
collected at some interval. Studies showed
that this was not financially feasible, and
therefore the following criticality-based
strategy was implemented:
In the case of evaluating oil sample data, it is important to
realize that few problems can be resolved based on a single data
set or a single test. Like the doctor in the ER, an oil analyst
needs to have some historical data on the component being
checked. This means the analyst must know the right questions
to ask and have the ability to hear what is being said, not just
listening to the words.
One of the first questions to ask when reviewing oil analysis
data is, “What is the objective of the plant for this specific component?” It is fully possible and often quite warranted to have a
different oil analysis strategy for different components assigned to
the oil analysis program. The appropriate oil analysis strategy
should be assigned based on component criticality. During the
development of component criticality, a whole new set of issues
arises, including:
• Health, safety and environmental effects if failure occurs
• Production loss impact due to failure
• Potential costs of repair due to failure
• Historical mean time between failures (MTBF)
• Effectiveness of early warning systems
Understanding component criticality is absolutely vital in establishing an appropriate oil analysis strategy. I was recently in a mill
where components were added to the oil analysis program on an
ad-hoc basis. In short, if a component failed, it was then added to
oil analysis. At another mill, the maintenance manager wanted all
oil-filled components to go through oil analysis. Obviously, neither
of these strategies will end with the desired result, which should be
early identification of potential failure using a proven method to
cost effectively monitor equipment condition.
Test Slate and Test Interval
ld ’ hhelp
l bbut realize
li that
h this
hi scenario
i is
I couldn’t
repeated quite often in our world of oil analysis, with a few changes
in characters. In oil analysis, the patient is a machine. More specifically, it is a component of something larger. The end user has the
vested interest in the health of the component, and the person
evaluating the oil sample data is the doctor.
24 |
November - December 2011 | www.machinerylubrication.com
The next question to be asked should be, “Is the current test slate
and test interval capable of supplying the information we need to
meet the plant objectives for this component?”
When developing an oil analysis strategy, we must consider two
primary components: test slate and test interval. Both of these
components may change depending on the strategy taken.
Some of the best oil analysis programs utilize a hybrid approach
of on-site and off-site testing. In future columns, we will explore
Understanding component
criticality is absolutely vital in
establishing an appropriate oil
analysis strategy.
how to develop oil analysis strategies and form a cost benefits analysis
for both approaches.
In summary, there is no blanket strategy for oil analysis. The goal is to
exercise a method by which a well-developed oil analysis program can be
implemented and maintained. In doing so, the right questions need to be
asked with relevant information being supplied to the analyst of the data,
whether that analyst is on-site or remote. Once this takes place, we can
ensure the program will be in a better position to achieve the desired
results at an affordable cost.
By the way, my nephew ended up doing well after his ER visit. If we get
it right, our machines can survive simply through the routine visits.
About the Author
Matt Spurlock is the director of oil analysis services and technologies for Noria
Corporation. For the past 20 years, Matt has helped companies develop world-class
lubrication and oil analysis programs. Contact Matt at mspurlock@noria.com and
ask how Noria can help improve your lubrication program.
www.machinerylubrication.com
|
November - December 2011
| 25
Bearing Lubrication
FROM THE
FIELD
JOSH PICKLE NORIA CORPORATION
The DANGERS of
OVERGREASING
When it comes to regreasing bearings, more is not always the
Seal damage is another negative side effect of overgreasing.
better option and actually can be a costly mistake. Instead, Grease guns can produce up to 15,000 psi, and when you overgrease
greasing should be set on a frequency with proper calculations used a bearing housing, the lip seals can rupture, allowing contaminants
to determine the amount of grease needed at each relubrication. such as water and dirt to gain access into the bearing housing. Keep
The determining factor for the amount required
in mind that lip seals usually fail around 500 psi.
is based on the dimensions of the bearing or the
This excessive pressure can also damage single
bearing housing.
and double-shielded bearings, causing the
Overgreasing can lead to high operating
shields facing the grease supply to collapse into
temperatures, collapsed seals and in the case of
the bearing race and leading to wear and evengreased electric motors, energy loss and failtually failure. When too much pressure is
of lubrication professionals
believe overgreasing is
ures. The best ways to avoid these problems are
generated from a grease gun due to overa problem at their plant,
to establish a maintenance program, use calcugreasing, it is easy for the hard, crusty grease
according to a recent survey at
lations to determine the correct lubricant
formed from heat (high operating temperamachinerylubrication.com
amount and frequency of relubrication, and
tures) to be broken apart and sent directly into
utilize feedback instruments.
the bearing track.
Too much grease volume (overgreasing) in a bearing cavity will
Overgreasing electric motor cavities has the same effect as with
cause the rotating bearing elements to begin churning the grease, any bearing application except that grease can reach the motor
pushing it out of the way, resulting in energy loss and rising tempera- windings. When filled completely with grease, an electric motor
tures. This leads to rapid oxidation (chemical degradation) of the bearing will generate excessive heat due to churning. This results in
grease as well as an accelerated rate of oil bleed, which is a separa- energy loss as well as an accelerated rate of oil bleed and hardening
tion of the oil from the thickener. The heat that has been generated of the grease thickener. Again, the high pressure applied from a
over time along with the oil bleed eventually will cook the grease grease gun can result in grease finding its way between the shaft and
thickener into a hard, crusty build-up that can impair proper lubri- inner bearing cap and pressing into the inside of the motor. The
cation and even block new grease from reaching the core of the result over time is the coating of the electric motor windings with
bearing. This can result in accelerated wear of the rolling elements grease, which leads to both winding insulation and bearing failures.
and then component failure.
Setting up a maintenance program is key to solving the problem
of overgreasing. Each lube point, whether it be a bearing housing or
electric motor, should be tracked as an asset, and records kept for
scheduling planned maintenance or inspections of the asset. While
the initial setup of a maintenance system may take some time and
hard work, the end results will have a major impact.
Once you have planned the scheduling of the assets, you will need
to determine the timing and amount of grease (volume) that should
be applied at each point. The volume can be calculated with a simple
equation (ref. SKF):
G = 0.114 x D x B
Where G = the amount of grease in ounces
D = the bore diameter in inches
B = the bearing width in inches
Next, calibrate all grease guns in use and train the technicians on
70%
26 |
November - December 2011 | www.machinerylubrication.com
FROM THE FIELD
Tips to Control Overgreasing
 Discontinue greasing when you feel abnormal back pressure.
 Always make sure exhaust ports are cleaned out from any
debris or old, hard crust that could be blocking the passageway.
 Consider installing grease guns with pressure gauges, shut-off
grease fittings or relief-type vent plugs.
 Slowly pump grease into bearings every few seconds. Using a
quick-lever action could cause seal damage and not allow the
grease to distribute throughout the bearing correctly.
the proper procedures of usage. Calibrating a grease gun is very
simple. All you need are the grease gun and a postal scale. Determining the weight in ounces per full stroke (shot) of the grease gun
will allow you to identify the number of shots it takes to equal 1
ounce of grease. This will help you establish the right volume needed
to ensure you are delivering the precise amount at each use.
After you have determined the correct volume, it’s time to establish the proper frequency. There are several methods for estimating a
regreasing frequency, including multiple calculators, tables and
charts. The major factors in determining frequency are load, operation time, type of bearing, speed, temperature and environment.
28 |
November - December 2011 | www.machinerylubrication.com
Feedback tools can also be beneficial for fine-tuning your
frequency. For example, ultrasonic instrumentation is one of the
best ways to optimize the correct frequency and help you set up your
maintenance program.
Establishing appropriate procedures and inspections during relubrication is another important part of a maintenance program.
Some basic steps include:
• Cleaning areas around the fill and relief fittings.
• Ensuring the grease relief valve moves freely or the drain plug
is removed.
• Checking to be sure the relief passage is clean from any hardened grease that may be blocking grease from exiting.
• Greasing the bearing cavity with the correct calculated volume
of grease while slowly adding each shot to minimize excessive
pressure build-up.
• Allowing the motor to run during and after greasing to expel any
excess grease. This should be done before re-installing the purge
port or bottom grease relief valve and cleaning the area of any
excess grease.
About the Author
Josh Pickle is a technical consultant with Noria Corporation, focusing on
machinery lubrication and maintenance in support of Noria’s Lubrication
Process Design (LPD). He is a mechanical engineer who holds a Machine Lubrication Technician (MLT) Level I certification through the International Council
for Machinery Lubrication (ICML). Contact Josh at jpickle@noria.com.
ML
GET TO KNOW
DuPont’s
Nesselroad Paves the
Way at Washington
Works Plant
John Nesselroad got his start in machinery lubrication in 1989, serving as a production operator, training coordinator and lubrication technician for DuPont’s
Washington Works plant in Washington, W.Va. He has also worked as an equipment operator for Universal Glass, as an operator for Shell Chemical and as a production machinist for
Gould. Since 2008, he has served as a lubrication technician, helping his team improve the
company lubrication program and develop a proactive approach to lubrication practices.
Name: John Nesselroad
Age: 61
Title: Lubrication Technician
Company: DuPont
Location: Washington, W.Va.
Years of Service: 24 years
Q What types of training have you had to get to your
current position?
A I have received Noria MLT I training and ICML certification,
along with on-the-job training. I have also attended several Reliable
Plant conferences.
Q Are you planning to obtain additional training or
achieve higher certifications?
A At this point, I do not plan on additional training unless something is offered this year. I plan on retiring next year after 24 years of
service. However, other folks in our crew are looking at obtaining
(ICML) MLT II and MLA II certification training from Noria.
Q What’s a normal work day like for you?
A We have a morning meeting and then check any extra work via
work orders, work requests or e-mails. Next, we load the day’s lubrication routes on the PDA, gather up all lubrication materials at the
central lubrication shop and proceed to the work area. After lunch,
we attend an afternoon meeting to confirm our progress or issues.
We then return to the work area and verify that the area has adequate
amounts of oil in the satellite shops. At the end of the day, we clean
up and unload routes from the PDA.
Q What is the amount and range of equipment that you
help service through lubrication/oil analysis tasks?
A Site-wide we service 4,000 to 5,000 pieces of equipment, ranging
from small gearboxes or bearings containing 6 ounces of oil up to
large equipment reservoirs with 1,500 gallons of oil. We take many
samples on equipment that are typically 10 gallons or larger and/or
30 |
November - December 2011 | www.machinerylubrication.com
have high criticality. Our site currently has 12,000 lubrication tasks,
and we average about 200 to 300 oil samples a month.
Q What lubrication-related projects are you currently
working on?
A Currently, we are expanding to pick up the last production area
on our site. We also are modifying our sample files to ensure more
accurate streamline oil sampling and adding an additional lubrication bulk-storage system.
Q What have been some of the biggest project
successes in which you’ve played a part?
A I assisted with the revamping of our lubrication program, set up
filtration for all new oils that we use and helped with the expansion
of our lubrication program into all of our production areas.
Q How does your company view machinery lubrication
in terms of importance and overall business strategy?
A Our company is committed to machinery lubrication. Our site
works proactively in dealing with lubrication. We understand the
relationship between lubrication and equipment reliability, as well
as all of the advantages associated with a solid lubrication program.
Our site is getting a good return on its investment with longer equipment life and less money spent on oil and downtime.
Q What made DuPont decide to put more emphasis on
machinery lubrication?
A Cost and reliability. It is more cost efficient to maintain equipment than to run until failure. It’s the best practice. Our site wanted
to consolidate resources and put a centralized emphasis on lubrication. Operators are assigned these jobs, and it is their only job.
There is more attention and detail paid to lubrication tasks with the
lubrication group taking the ownership.
Lubrication is an essential element of any reliability engineering program.
The Washington Works site has had a lubrication program for decades. The
program had been administered through our maintenance organization with
the actual lubrication activities being completed by trained mechanics. In
many instances, the mechanics performing lubrication would be pulled from
their lubrication activities in order to perform other tasks.
We ran a trial in our power division using dedicated operators and found
that this worked out great. The operators were dedicated to the lubrication
tasks and weren’t continually being pulled to do other work. This set the
stage for us to pursue a dedicated lubrication team at Washington Works
using operators. The criticality of the lubrication function drove us to pursue
this dedicated work team, and the size of Washington Works made it cost
justifiable to have a dedicated group that is leveraged across the site.
Q What do you see as some of the more important trends
taking place in the lubrication and oil analysis field?
A We see oil cleanliness — all oil filtered before it ever reaches the equipment — as an important trend, as well as better storage of oils (containers,
bulk storage, etc.) and changing oil on condition instead of on time
because of increased and improved sampling.
Get to Know … You?
Want to be featured in the next “Get to Know” section or know
someone who should be profiled in an upcoming issue of Machinery Lubrication magazine? Nominate yourself or fellow lubrication professionals by
e-mailing a photo and contact information to editor@noria.com.
www.machinerylubrication.com
|
November - December 2011
| 31
ML
NOW ON
MachineryLubrication.com
Find more great articles and content from
Machinery Lubrication magazine online.
From Web exclusives and industry news to videos,
white papers, buyer’s guides and more, everything
that relates to machinery lubrication is available
now on www.machinerylubrication.com.
Lubrication Strategies
for Electric Motor Bearings
There is some disagreement among electric
motor manufacturers as to the best bearing
arrangement for horizontal-type, grease-lubricated, ball-bearing motors. There is also
disagreement on the best technique for replenishing the grease supply in the bearing cartridge.
This can result in industrial users employing
less-than-ideal lubrication strategies or vulnerable
bearing housing configurations. Read this article
on the ML site to discover the best greaselubrication methods for electric motor bearings.
Systematic Oil Analysis Interpretation
Even if every task is performed correctly, the
success of an oil analysis program hinges on
accurate interpretation of test data. The objective is to provide a method of translating data
into useful information through a disciplined,
systematic approach. This will allow you to get
the most from your program while preventing
you from jumping to conclusions too early in the
process, thereby reducing errors in interpretation. Find this article in the Oil Analysis section
on the ML site.
How Lubricants Work in Engines
Getting to the Root of Poor Lubrication
— Root Cause Analysis Techniques
for the Lubrication Professional
Lubrication professionals should be wellgrounded in the root cause analysis (RCA) process
and its supplementary tools and methods to recognize the fundamental reason for a problem so they
can implement a
root cause solution. Learn these
skills and integrate them with
your knowledge
of lubricants and
lubrication
systems by reading
this article on the
ML site.
32 |
November - December 2011 | www.machinerylubrication.com
This video describes how lubricants perform
their role in engines. Access this 4-minute, 43-second
video at www.machinerylubrication.com.
Detecting Wear Metals Using LaserInduced Breakdown Spectroscopy
By integrating a probe laser and a spectrometer, it is possible to achieve on-site, real-time
oil analysis while maintaining a relatively low
cost. Access this 3-minute, 2-second video at
www.machinerylubrication.com.
By the Numbers
50%
39%
or more of lubrication
procedures are outdated,
based on survey responses at
machinerylubrication.com
of machinerylubrication.com
visitors store lubricants outdoors.
ML
CROSSWORD PUZZLER
Get a Printable Version
of This Puzzle Online at:
MachineryLubrication.com/puzzle
1
4
2
3
5
6
7
8
9
10
11
12
13
14
15
16
17
ACROSS
2 A synergistic phenomenon of both particle silting and
polar adhesion.
6 A deposit resulting from the oxidation and polymerization of
fuels and lubricants when exposed to high temperatures.
7 A method by which a specified volume of fluid is filtered through
a membrane filter of known pore structure.
10 A crystalline form of carbon having a laminar structure.
DOWN
1 Formation of an air or vapor pocket due to lowering of pressure
in a liquid.
3 Lubricants containing asphaltic materials that are used for open
gears and steel cables.
4 A filter assembly containing multiple ports and integral relating
components that services more than one fluid circuit.
5 The change of direction or speed of light as it passes from one
medium to another.
11 A general wearing away of a surface by constant scratching.
8 The science and technology of interacting surfaces in
13 The fluid entering a component.
15 A fluid circulation process designed to remove contamination
from the wetted surfaces of a fluid system.
relative motion.
9 A separator that removes air from the system fluid through the
application of bubble dynamics.
16 Possessing viscosity.
12 The cuttings or filings that result from metal-working operations.
17 Compounds with an affinity for water.
14 Intimate mixture of oil and water.
Get the solution on page 38
www.machinerylubrication.com
|
November - December 2011
| 33
ML
CERTIFICATION NEWS
Clopay’s
LIPPERT REAPS the
BENEFITS of ICML
CERTIFICATION
BY SUZY JAMIESON, ICML
Scotty Lippert is often referred to as “ICML’s poster boy.”
For 26 years, Lippert has been with his current employer,
Clopay Plastics of Augusta, Ky. He was originally hired as an extrusion operator, promoted to team leader and then to supervisor
before finally landing in his current position as planned maintenance specialist/lubrication systems leader, which he has occupied
for the past 14 years.
Lippert truly personifies the spirit of ICML for a number of
reasons, including his mentoring, his giving nature and his passion
Recognizing Excellence
ICML’s John R. Battle and Augustus H. Gill awards were developed to benchmark industry by recognizing companies for their use
of world-class best practices in lubrication and oil analysis programs
for improved machine reliability. The organization hopes its awards’
criteria will serve as a road map and its award recipients will act
as mentors for companies seeking excellence in lubrication and oil
analysis programs.
ICML awards are open to companies worldwide at no
cost to the applicants and are independent of any involvement by the applicant companies in
any area of ICML activity. To
remain unbiased, it is ICML’s
policy
that
nominations
come directly from industry
confirmed via plant personnel.
For more information on
ICML’s certification programs,
visit www.lubecouncil.org. To
submit a nomination for one of
ICML’s recognition of excellence awards, e-mail your
plant information to
info@lubecouncil.org.
34 |
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November
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hi
l bi i
In 2004, Scotty Lippert and Clopay received ICML’s John R.
Battle Award for excellence in machinery lubrication.
for volunteering, which are demonstrated by his involvement in his
community, where he sits on several boards and committees and
serves as county magistrate and county deputy judge executive.
The respect that Clopay management pays to Lippert and his role
within the company is what ICML hopes each certified lubrication
technician and oil analyst will achieve.
“Since attending my first Noria training course in 2002 and earning
MLT I certification, not only did our company reap the benefits, but it
also has been a professional career boost for me,” Lippert says.
To date, Lippert’s program at Clopay remains the only dual
recipient of ICML’s two major awards. After becoming the inaugural
winners of ICML’s John R. Battle Award for excellence in machinery
lubrication in 2004, Clopay won ICML’s Augustus H. Gill Award for
excellence in oil analysis in 2006. Besides these prestigious awards,
the company also claimed Machinery Lubrication’s Lube Room
Challenge, while Lippert was named the 2007 Kentucky Manufacturing Employee of the Year for his work in the field of lubrication.
Since receiving these awards, Lippert’s plant in Kentucky has
been visited by several companies, most of them Fortune 500
companies from 11 different countries, to see first-hand and hear
directly from Lippert how Clopay became world class in their lubrication and oil analysis programs.
Being the humble person that he is, Lippert is still taken by
surprise with all the recognition that he receives.
“Acceptance from outside our plant to what we have done here
has been more than I could have imagined,” Lippert notes.
Still, the attention is well deserved. Just like ICML’s founding
companies, Clopay was driven by a commitment to improvement
when it set Lippert on his journey years ago.
“We didn’t set out to be noticed but to improve reliability,”
he recalls.
Improvement is exactly what Lippert and Clopay achieved, both
for the company and for industry. As other previous ICML award
recipients, Lippert embraces his role as an ICML volunteer mentor to
companies beginning their journey toward lubrication excellence.
“We have been open to other companies in sharing what we have
done at our plant,” Lippert explains. “Many plants have copied our
program and told us that it is the most efficient maintenance
program they have ever put in place. Personally, I have had many
phone calls after presenting at conferences from people who
attended asking for guidance and information on lubrication for
their plant. I never hesitate to share the procedures and work practices we have developed for our plant. After all, it is one thing to have
the guidelines for world-class lubrication, but actually putting them
into effect is up to that organization or person.”
The pride that Lippert has in the work he and his team do is
quite evident.
“We have many customers, and most are Fortune 500 companies
that come into our plant and do extensive audits,” he adds.
“Everyone has written on final audit documentation that we are a
benchmark for lubrication.”
Lippert also knows that excellence and world-class status are not
achieved effortlessly or overnight.
“Our plant lubricated the same way for more than half a century,”
he says. “Changing the culture of personnel is challenging, but once
they see the results, it does become easier to convert (them).”
The results of receiving both of ICML’s top awards have gone far
beyond what Lippert thought was possible.
“The fame and recognition we have received from winning the
ICML awards have been as overwhelming for me as the results we see
from world-class lubrication in our plant,” he says. “Since winning
these awards, I have received a citation of excellence from the
Kentucky House of Representatives and also from the U.S. House of
Representatives in Washington D.C., and I even met with the
governor of Kentucky.”
Almost 10 years after achieving his MLT I certification and having
enjoyed a spotlight-filled journey since, Lippert remains the same
grounded, extremely driven and passionate lubrication practitioner,
except now, as ICML intended for each practitioner, he’s garnered
the industry recognition of his work in machinery lubrication as
being the dignified, technically valid field that it is.
www.machinerylubrication.com
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November - December 2011
| 35
CERTIFICATION NEWS
ICML THANKS SUPPORTERS FOR 10 YEARS OF SERVICE
The International Council for Machinery Lubrication (ICML) would like to thank the following advisory board and
certification committee members for their countless efforts in making ICML possible. The organization also would
like to acknowledge the companies listed below for providing volunteers, sponsoring exam venues, offering overall
support of the organization’s efforts worldwide and participating directly or via one of their employees as members
of ICML. The organization thanks you for 10 wonderful years of service and looks forward to many more to come.
ICML Advisory
Board Members
Lindon Collinsworth, TXU
AES
Confiabilidad Sac, Peru
Paul Dufresne, Georgia-Pacific
Aes Warrior Run LLC
Rick Baldridge, Cargill Inc.
Janet Barker, Southwest Research
Institute
Larry Cote, Canadian Institute for
NDE (CINDE)
Angel Espinoza, Minera Yanacocha
Aiken Technical College
Confialub Consultoria em
Lubrificação, Brazil
John Farrell, Republic Interactive
Consulting
AIS Bolivia
Coors Brewing Company
CP&L
Randy Hall, Temple-Inland
Alcoa
Alcoa, Iceland
Crane & Co. Inc.
Art Durnan, Rio Tinto
D.A. Stuart Co.
Dale Jones, Allegheny Technologies
Alcoa, Jamaica
Allegheny Technologies
D.E.I. Ltd., UK
Allied Reliability
Diavik Diamond Mines Inc., Canada
Allied Services Group
Dominion
Ameren UE
Dow Corning and Molykote
AMRRI
DuPont
Amsoil Inc.
Eli Lilly
Analysts Inc.
ELVIB International Maintenance
Anheuser Busch Inc.
Entergy Inc.
AP&P Consulting
EPCO Inc.
Arizona Public Service Company
Eventful Management, Australia
Ben Staats, Weldwood - International
Paper Company
Astriven, Ecuador
Evoilution LLC
Austin Energy Lab Services
Exodus Machines Inc.
Mark Sterling, Johnson Oil Company
Australian Paper
ExxonMobil
Robert Stitzel, Phillips Petroleum
Company
AV Technology Ltd., UK
Factor Humano, Dominican Republic
(Levels I & II)
Baltic Control, Greece
Flint Hills Resources
Jerry Barske, Nuclear Management
Company
Paul Whetstone, Refined Global
Solutions Inc.
Belray
Gateway Energy & Coke
Dave Williams, BP Castol Australia
BFB Oil Research
General Motors
Aaron Black, Allied Services Group
Georgia-Pacific
Chesley Brown, TXU
BHP Billiton Iron Ore
Laboratory Lubricant Analyst
Gerdau Ameristeel
Michael Bryson, Southern California
Edison
BP Castol, Australia
(Levels I & II)
Bruce Power
Goldcorp Canada Ltd.
Janet Barker, Southwest Research
Institute
Bucyrus International
Kurt Bittner, PSEG Nuclear
Canadian Institute for NDE (CINDE)
Lane Crandall, Oil Analysis Lab Inc.
Cargill Inc.
Holcim
Cheryl Huff, R&G Laboratories Inc.
Caribbean Analytical Services Ltd.,
Trinidad & Tobago
Hormel
I-Care Sprl, Belgium
Cashman Equipment Company
INCOI, Bolivia
Catalyst Paper
Industrial Oils Unlimited
C.C. Jensen
Ingelube SA, Chile
Center for Reliability Excellence,
Philippines
Inspectorate America
CEN-TEX Lube Partners
INVISTA
Chevron Texaco Global Lubricant
ISP Elastomers
Chrysler
Ivy Tech
Cia Vale do Rio Doce, Brazil
Johnson Oil Company
Organizations Involved
with ICML
City of Yuma
JR Simplot
Clarion Boards Inc.
Kennecott Utah Copper
ABBSOM, South Africa
Clarus Technologies LLC
KEW Engineering Ltd., UK
Aconcagua Timber Corp.
Cliffs Natural Resources Inc.
Laboratorio Dr. Lantos, Argentina
Technician (Levels I & II)
Ademinsa Venezolana
Clopay Corporation
Lauregan Properties, New Zealand
David Anderson, Catalyst Paper
ADEMINSAC, Peru
Compass21, Japan
Laurentide Controls, Canada
John Belsky, Unicco
AEP Nuclear
ConAgra Foods
Lion Oil
James Fitch, Noria Corporation
William Hillman, A&B Asset
Management Specialists
Leith Hitchcock, GP Allied-Australia
Doug McBride, Georgia-Pacific
Gerald Putt, Goodyear (Retired)
Kevan Slater, Maximum RPM
Donald Smolenski, General Motors
Mike Weiksner, Aiken Technical
College
ICML Certification
Committee Members
Machine Lubricant Analyst
Andrew Calcagno, General Motors
Dan Durbin, Anheuser Busch Inc.
Angel Espinoza, Minera Yanacocha
John Forsman, Nuclear Management
Company
John Gobert, The Hurt Company Inc.
Brian Groff, Bucyrus International
Jon Hershey, Pfizer Corporation
Don Howard Jr., Belray
Louis LaBella, Lion Oil
Doug McBride, Georgia-Pacific
Scott McCormack, Ameren UE
Jeffery S. Miller, DuPont
Stefan Minnaar, Rio Tinto
Robert Pearson, Catalyst Paper
Robert Perez, EPCO Inc.
Phillip Pinkston, Allied Services Group
Gene Shockey, Industrial Oils
Unlimited Inc.
Bryan Johnson, Arizona Public
Service Company
Shenghua Li, Chevron Global
Lubricants
Dave Lander, Clarion Boards Inc.
Bruce Morton, Cashman Equipment
Company
Doug McBride, Georgia-Pacific
John Sander, Lubrication Engineers Inc.
Steve Mitchell, AEP Nuclear
Mark Smith, Analysts Inc.
Cliff Smart, Xcel Energy
Matt Spurlock, Noria Corporation
Justin Stover, C.C. Jensen
Richard Wurzbach, MRG Corporation
Allan Thibodeaux, Valero Energy
Brian Thorp, Seminole Electric
Cooperative Inc.
Machine Lubrication
36 |
Jon Hershey, Pfizer Corporation
November - December 2011 | www.machinerylubrication.com
Burlinghton Resources
Goodyear Tire & Rubber Co.
GPAllied Asia Pacific, Australia
Graniterock
International Paper
Lube M.A.T.E. Oil Analysis &
Lubrication Specialists
Oil Analyzers
Rio Tinto
Oil-Dri Corp
Lubrication Engineers Inc.
RO-QUIP Asia Pacific Pte Ltd.
Packaging Corp of America
Lubrication Systems Co.
Salt River Project
Pall Corporation
Lubrication Technologies, Inc.
Saudi Aramco, Saudi Arabia
PBBPolisur SA
Lubrication Training & Consulting (LTC)
SCA Tissue North America
PDVSA Intevep, Venezuela
Lubrificar
Schroeder Industries LLC
Petro Canada
Lubrin, Brazil
Petrobras
Seminole Electric Cooperative Inc.
LubriSource
Lubrisupport
Lubrosoft, China
Mantenimiento Trading, Venezuela
Maximum RPM
Mecoil Diagnosi Meccaniche
Srl, Italy
Petrogal S.A., Portugal
Shanghai Lubrosoft Lubricating
Technology Co. Ltd.
Pfizer Corporation
Shawn Industries, Inc.
PG&E National Energy Group
Shell CIA. de Petróleos del Ecuador
Phillips Petroleum Company
Polk State College
Portola Packaging Inc. México,
S.A. De C.V.
Shell Services, Australia
SI Corporation
Sigma Reliability Solutions, LLC
PROACTIVE Conditioning &
Monitoring Sdn Bhd, Malaysia
Sil, Brazil
Michelin Tire Corporation
Minera San Cristobal, Bolivia
Proaxion Technologies Inc.
SKF Australia
Minera Yanacocha, Peru
Project AM, S.A., Panama
SKF India Ltd.
Mosaic Potash
PSEG Nuclear
SKF Latin America
MRG Corporation
MRG Labs
PT. Tiara Vibrasindo Pratama,
Indonesia
Sociedad Minera Cerro Verde, Peru
Newcrest Mining
R&G Laboratories, Inc.
Noria Corporation
Refined Global Solutions, Inc.
Noria Latin America
Reliable Contamination Control LLC
North Charleston Sewer District
Reliable Process Solutions
Nuclear Management Company
Repsol Comercial S.A.C.
Oil Analysis Lab Inc.
Republic Interactive Consulting
Metalux Molecular (Singapore) Pte Ltd.
Simplot Canada Ltd.
Solge Corporation, S. Korea
Somerset Community College
Southern California Edison
Southern Company
Southwest Research Institute
Sun Coast Resources Inc.
Teck Highland Valley Copper
Tecnicas Reunidas
Temple-Inland
Termogram, Costa Rica
The Hurt Company Inc.
The Hydraulic Shop
Thomas Petroleum
TXU
UE Systems
UNICCO
United Cement Company of
Nigeria Ltd. (UniCem)
Valero Energy
Vela Eirl
Ventura Foods
Vine Tribometric Consultants
Vision Industrial Sales
Votorantin Metais, Peru
VS Consultores S.A., Venezuela
Wartsila Automation Services
Washington County Career Center
WE Energies
Wearcheck, S. Africa
West Fraser
Westpower Equipment Ltd.
Wise Choice Synthetics Inc.
Xcel Energy
Zellstoff Celgar, Canada
www.machinerylubrication.com
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November - December 2011
| 37
ML
ASTM STANDARDS
ASTM DEVELOPS
NEW Standard
PRACTICE for GREASE
Sampling
The American Society for Testing and Materials (ASTM)
recently issued Method D7718-11, providing an approved
standard practice for sampling critical grease-lubricated equipment.
The new standard uses the methodology of the Grease Thief, which
enables users to get a representative in-service grease sample from
motor bearings, gearboxes, motor-operated valves and other critical
machinery, then trend the analysis results for condition monitoring.
This analysis of in-service lubricating grease not only can aid in
predicting the life and condition of the grease-lubricated component, but it also can be combined with other technologies such as
infrared imaging, vibration analysis and ultrasonic vibration analysis
to predict when a machine may fail.
The information obtained through these analyses may allow for
more overall uptime by aiding in the prediction of grease-lubricated
component failures as part of a predictive maintenance schedule.
The prediction of a failing grease-lubricated component should also
improve the level of safety of all who work around the component.
“The new standard establishes methods for obtaining good
samples from many types of components,” says Richard Wurzbach of
MRG Labs. “Until now, there has not been reliable guidance for taking
grease samples, which has severely limited the use of grease analysis as
a diagnostic tool. With the advent of new technology and a standard
approach for sampling, the door has been opened for grease analysis
to take on the challenge of improving reliability of wind turbines,
robotics, power plants, mining operations and manufacturing.”
The use of the Grease Thief in the place of motor bearing drain
plugs allows for proper grease purging while also capturing any
purged grease for analysis.
Traditionally, vibration analysis would be used to monitor the
mechanical condition of a grease-lubricated electric motor.
However, with the Grease Thief sampling devices, you can extract a
reasonably representative sample of grease to detect mixing, grease
degradation and wear particles.
“This standard practice is the basis for companies to create
procedures and processes to ensure reliable monitoring of greases
38 |
November - December 2011 | www.machinerylubrication.com
and grease-lubricated component condition,” Wurzbach adds.
“Five methods are outlined, providing the proper precautions and
steps, tools and methods, to consistently obtain and submit grease
samples for analysis.”
The Grease Thief Analyzer utilizes a die-extrusion process to
measure changes in grease consistency and flow characteristics, and
prepares a thin-film substrate for subsequent lab analysis with
typical oil analysis instrumentation. Sampling kits provide the
opportunity to obtain results from as little as 1 gram of grease.
“In the same way that oil analysis has been enhanced by the use
of sampling fittings and prescribed sampling procedures, grease
analysis results can now stand on solid ground to encourage and
enable reliable and consistent results,” Wurzbach notes. “The
limited circulation of grease in machinery dictates that any samples
be carefully obtained by an established best practice and with the
right tools for the job. With the Grease Thief sampling technology
and procedural guidance based on ASTM D7718, users now have
the ability to confidently monitor and enhance the reliability of critical grease-lubricated components.”
For more information, visit www.astm.org or contact MRG Labs
at www.mrgcorp.com.
From page 33
M
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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. The reservoir should be cleaned/flushed when:
A)
B)
C)
D)
E)
Every time the oil is changed.
The plant is in a shutdown.
The system fluid viscosity changes by 7 percent or more.
Sludge and deposits are detected at the oil drain.
The breather is changed.
2. Which of the following represents
the highest NLGI consistency?
A)
B)
C)
D)
E)
Block grease
ISO 460
000
18/16/13
8
3. Which hardware is the best for sampling pressurized lines above 500 psi?
A)
B)
C)
D)
E)
A long dead-leg of piping with a plug at the end
A pressure-regulating valve or a helical coil connected to a mini-mess valve
A capped drain plug
A mini-mess valve located on an elbow
A mini-mess valve located on a straight length of pipe
4. A crackle test can only detect water above:
A) The saturation point, which
depends on oil type and temperature
B) 100 ppm
C) 1,000 ppm
D) 10,000 ppm
E) 1 percent
5. Anti-wear and extreme pressure additives function by:
Reacting within the bulk oil to form wear protecting chemicals.
Are used in the same oil formulations.
Reacting with the iron surface due to frictional heat to reduce surface damage.
Stopping the wear reaction pathway.
Altering the surface tension of the oil.
Answers: 1-D; 2-A; 3-B; 4-A; 5-C
A)
B)
C)
D)
E)
www.machinerylubrication.com
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November - December 2011
| 39
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Cornerstone Controls, Inc.
Harvard’s filter systems are designed and
built with quality materials and craftsmanship to provide years of trouble-free
service. Filter elements for viscosity ranges
from fuels to gear oils (ISO 1000). Customers report clean fluids to ISO 13/12/8
in operation. Contaminant capacity
per element is about four pounds. The
product has demonstrated the ability to
remove one gallon of water from oil.
Harvard Corporation
www.harvardcorp.com 800-523-1327
GARZO, Inc.
www.garzoproducts.com/108.html
713-466-8679
tmpafford@garzoproducts.com
Valve reduces sampling time by 80%
Plus - Unique 360° rotating spout
allows easy one hand sampling. Stainless steel chain and clip. NEW higher
flow for low pressure applications.
NEW rugged spout design with easy
to grip knurled cap.
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.
Checkfluid, Inc.
www.inolex.com
800-521-9891
lubeinfo@inolex.com
Inolex Chemical Company
407-688-7439
www.bellperformance.com/bell-ultra
www.checkfluid.com 866-652-8728
info@checkfluid.com
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.
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.
Hornche Corporation
One Eye Industries, Inc.
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
at TechHelp@Castrol.com
www.oneeyeindustries.com
877-888-8727
info@oneeyeindustries.com
877-641-1600
www.easylube.com
service@easylube.com
40
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.
November - December 2011 | www.machinerylubrication.com
Castrol Industrial
North America Inc.
PAID A DVERTISING SECTION
Summit RHT is a superior ammonia
compressor oil. The API Group II
hydro-processed formula is chemically stable with lower oil-carryover,
less wear, less foaming, extended
oil drain intervals and operational
efficiency gains.
The IFH Group has dozens of mobile
lubrication carts that hold 15, 30, 65
gallons or more. IFH offers 2- and
4-wheeled carts & custom-mobile
lubrication systems that can be put
on trailers, electric carts or trucks.
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.
The IFH Group, Inc.
UE Systems, Inc.
www.ifhgroup.com
800-435-7003
www.uesystems.com
info@uesystems.com 800-223-1325
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.
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.
Meltric Corporation
Cannon Instrument Company
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.
www.cannoninstrument.com
800-676-6232
sales@cannoninstrument.com
www.analystsinc.com 800-655-4473
orders@analystsinc.com
www.meltric.com 800-433-7642
mail@meltric.com
This DVD includes instructive videos
and animations to give viewers a
better understanding of electric
motor bearings and how to lubricate them properly.
Noria Corporation
store.noria.com
800-597-5460
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.
Royal Purple, Inc.
www.royal-purple-industrial.com
888-382-6300
mcrosby@royalpurple.com
Summit Industrial Products
www.klsummit.com/RHTSeries.pdf
JoeG@klsummit.com
800-749-5823
Analysts, Inc.
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
www.machinerylubrication.com
|
November - December 2011
41
Synthetic Lubricants
BACK PAGE
BASICS
JEREMY WRIGHT | NORIA CORPORATION
The BASICS
of SYNTHETIC OIL
TECHNOLOGY
In the 1930s, Dr. Hermann Zorn of Germany was searching
for a lubricant with the properties of natural oils derived
from crude oil but without the undesirable properties (high pour
points, tendency to gum or gel in combustion engines, low oxidation
resistance at higher temperatures, etc.). Germany was also in need
of a product that was not derived from crude oil, as the nation’s
access to crude oil was becoming increasingly scarce. By the mid1940s, the fruit of Dr. Zorn’s labor included more than 3,500
different blends of esters, including diesters and polyolesters.
of lubrication professionals use both
synthetic and mineral-based lubricants in
their plant, according to a recent survey at
machinerylubrication.com
Types and Terminology
There are two American Petroleum Institute (API) base oil categories that include synthetics. The first is API Group IV. The only
synthetic base oil included in this group is polyalphaolefin or PAO.
PAOs are made by polymerizing an alpha-olefin molecule like
ethylene. In an alpha-olefin molecule, there is a carbon-carbon
double bond with hydrogen branching off.
The second category is API
Group V. These are nonPAO synthetic bases. Examples
include diesters, polyolesters,
alkylated benzenes, phosphate
esters, etc. Basically, if it is a
synthetic and it is not a PAO, it
is a Group V.
Some confusion has arisen recently regarding the use of the word
“synthetic.” Several petrochemical companies have developed
42 |
November - December 2011 | www.machinerylubrication.com
POSSIBLE ADVANTAGES
The first real-world trial for these lubricants came during World
War II when both Germany and U.S. forces began using synthetic
base oil in aircraft engines. They noticed the synthetics made engine
starts much easier in colder climates (due to the high viscosity index)
and significantly decreased soot deposits that would build up in oil
radiators when using conventional (crude oil-derived) lubricants.
SYNTHETIC
PROPERTIES
POSSIBLE DISADVANTAGES
54%
processes involving catalytic conversion of crude oil base stock under
high pressures and temperatures in the presence of hydrogen to form
very high-quality mineral lubricants. These oils, which are known as
API Group III, are so highly refined that their properties almost match
that of the Group IV synthetics. They are so close in fact that the U.S.
court system sided with a manufacturer of these Group III “synthetics”
when a lawsuit was brought up for false advertising. Even though
these Group III base oils are derived from crude oil, they can now
legally, from a marketing standpoint, call them synthetic.
WHAT IT MEANS
Higher flash point
Improved fire resistance and thermal
stability
Lower pour point
Improved low-temperature
pumpability/lubrication
Fire resistance
Good for high-risk hydraulic applications
Oxidation stability
Extended oil drains, resists severe
conditions
Thermal stability
Oil doesn’t degrade or thicken at
high temperatures
High viscosity index
Functions like a multi-grade oil
Lower friction
Reduced energy consumption costs
Natural detergency
Helps keep surfaces clean of deposits
High shear strength
No viscosity thinning, unlike multi-grade
mineral oils
High cost
A synthetic can cost four to 15 times more
than mineral oil
Toxicity
Phosphate esters may be a toxicity risk
Hazardous disposal
Disposal of phosphate esters is more
expensive
Solubility
Some additives are difficult to maintain
in solution
Seal compatibility
Some seals may shrink or swell with
synthetics, some incompatibility with
coats (e.g., paints) and plastics
Hydrolytic stability
Ester-based synthetics may degrade in
the presence of water
Mixability
Some are unmixable in other fluids
(incompatible)
BACK PAGE BASICS
When to Choose a Synthetic
About the Author
When designing a lubrication program, I use a very simple set of
rules to know when to choose a synthetic for an application. They
are as follows:
• when equipment-performance demands exceed the capabilities
of mineral-based fluid,
• when synthetic properties can become problem-solvers,
• when life-cycle cost savings can be realized, or
• when safety and environmental issues can be enhanced.
Jeremy Wright is vice president of technical services for Noria Corporation. He serves as a senior technical consultant for Lubrication Process
Design projects and as a senior instructor for Noria’s Fundamentals of
Machinery Lubrication and Advanced Machinery Lubrication training. He
is a certified maintenance reliability professional through the Society for
Maintenance and Reliability Professionals, and holds Machine Lubricant
Analyst Level III and Machine Lubrication Technician Level II certifications
through the International Council for Machinery Lubrication. Contact
Jeremy at jwright@noria.com.
SYNTHETIC FLUID
STRENGTHS
WEAKNESSES
APPLICATIONS
POLYALPHAOLEFINS
High VI, high thermal oxidative stability, low volatility,
good flow properties at low
temperatures, nontoxic
Limited biodegradability,
limited additive solubility,
seal shrinkage risk
Engine oils, gear oils, bearing oils,
compressor oils, high-temperature grease,
lube-for-life applications
DIESTERS AND
POLYOLESTERS
Nontoxic, biodegradable,
high VI, good low-temperature properties, miscible with
mineral oils
Low viscosities only, bad
hydrolytic stability, limited
seal and paint compatibility
Compressor oils, high-temperature grease,
co-base stock with PAOs, bearing oils,
gear oils, oil mist, jet engine oils
Fire resistant, biodegrades
quickly, excellent wear resistance, scuffing protection
Low VI, limited seal
compatibility, not miscible
with mineral oils, moderate
hydrolytic stability
Fire-resistant hydraulic fluids used in
power plants, factories, marine vessels,
mining, aircraft, mobile equipment
Excellent lubricity, nontoxic,
good thermal and oxidative
stability, high VI
Additives marginally
miscible, not miscible with
mineral oils, limited seal
and paint compatibility
Refrigeration compressors, brake fluids
(water soluble), fire-resistant fluids (water
soluble), gas compressors (low gas solubility), worm and high-temperature gears,
chain lube (clean burn off), metal-working
and quenchants, H1 food grade
Highest VI, high chemical
stability, excellent seal compatibility, very good thermal
and oxidative stability
Worst mixed and boundary
film lubrication properties,
not miscible with mineral
oils or additives
High-temperature fluids, specialty greases,
lubricant-contacting chemicals, some
brake fluids
PHOSPHATE ESTERS
POLYALKYLENE
GLYCOLS
SILICONES
Machinery Lubrication Statement of Ownership 2011
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Publication Title: Machinery Lubrication
Publication Number: 021-695
Filing Date: November 14, 2011
Issue Frequency: Bi-monthly
Number of Issues Published Annually: 6
Annual Subscription Price: Free to qualified subscribers
Complete Mailing Address of Known Office of Publication:
Noria Corporation, 1328 E. 43rd Ct., Tulsa, OK 74105
Complete Mailing Address of Headquarters or General Business Office of Publisher:
Noria Corporation, 1328 E. 43rd Ct., Tulsa, OK 74105
Full Names and Complete Mailing Addresses of Publisher, Editor, and Managing Editor:
Publisher: Mike Ramsey, Noria Corporation, 1328 E. 43rd Ct., Tulsa, OK 74105
Editor: Jim Fitch, Noria Corporation, 1328 E. 43rd Ct., Tulsa, OK 74105
Managing Editor: Jason Sowards, Noria Corporation, 1328 E. 43rd Ct., Tulsa, OK 74105
Owner (If the publication is owned by a corporation, give the name and address of the corporation immediately
followed by the names and addresses of all stockholders owning or holding 1 percent or more of the total amount of
stock) Owner: Noria Corporation, 1328 E. 43rd Ct., Tulsa, OK 74105
Known Bondholders, Mortgagees, and Other Security Holders Owning or Holding 1 Percent or More of Total Amount
of Bonds, Mortgages, or Other Securities: None
Tax Status (For completion by nonprofit organizations authorized to mail at nonprofit rates): Has not changed
During Preceding 12 Months
Publication Title: Machinery Lubrication
Issue Date for Circulation Data Below: SEP/OCT 2011
Extent and Nature of Circulation: to disseminate information to members Average No. Copies Each Issue During
Preceding 12 Months a. Total Number of Copies (Net press run): 28,104 b. Legitimate Paid and/or Requested Distribution (By Mail and Outside the Mail) (1) Outside County Paid/Requested Mail Subscriptions stated on PS Form
44 |
November - December 2011 | www.machinerylubrication.com
3541: 14,319 (2) In-County Paid/Requested Mail Subscriptions stated on PS Form 3541: 0 (3) Sales Through Dealers
and Carriers, Street Vendors, Counter Sales, and Other Paid or Requested Distribution Outside USPS®: 0 (4)
Requested Copies Distributed by Other Mail Classes Through the USPS (e.g. First-Class Mail®): 0 c. Total Paid and/
or Requested Circulation: 14,319 d. Nonrequested Distribution (By Mail and Outside the Mail) (1) Outside County
Nonrequested Copies Stated on PS Form 3541: 13,197 (2) In-County Nonrequested Copies Stated on PS Form 3541:
0 (3) Nonrequested Copies Distributed Through the USPS by Other Classes of Mail: 0 (4) Nonrequested Copies
Distributed Outside the Mail: 200 e. Total Nonrequested Distribution: 13,397 f. Total Distribution: 27,716 g. Copies
not Distributed: 388 h. Total: 28,104 i. Percent Paid and/or Requested Circulation 52%
No. Copies of Single Issue Published Nearest to Filing Date a. Total Number of Copies (Net press run): 28,500 b.
Legitimate Paid and/or Requested Distribution (By Mail and Outside the Mail) (1) Outside County Paid/Requested
Mail Subscriptions stated on PS Form 3541: 14,602 (2) In-County Paid/Requested Mail Subscriptions stated on PS
Form 3541: 0 (3) Sales Through Dealers and Carriers, Street Vendors, Counter Sales, and Other Paid or Requested
Distribution Outside USPS®: 0 (4) Requested Copies Distributed by Other Mail Classes Through the USPS (e.g.
First-Class Mail®): 0 c. Total Paid and/or Requested Circulation: 14,602 d. Nonrequested Distribution (By Mail and
Outside the Mail) (1) Outside County Nonrequested Copies Stated on PS Form 3541: 13,380 (2) In-County Nonrequested Copies Stated on PS Form 3541: 0 (3) Nonrequested Copies Distributed Through the USPS by Other Classes
of Mail: 0 (4) Nonrequested Copies Distributed Outside the Mail: 75 e. Total Nonrequested Distribution: 13,455 f.
Total Distribution: 28,057 g. Copies not Distributed: 443 h. Total: 28,500 i. Percent Paid and/or Requested Circulation 52%
16. Publication of Statement of Ownership for a Requester Publication is required and will be printed in the NOV/DEC
2011 issue of this publication.
17. Signature and Title of Editor, Publisher, Business Manager, or Owner: Mike Ramsey, November 14, 2011. I certify that
all information furnished on this form is true and complete. I understand that anyone who furnishes false or
misleading information on this form or who omits material or information requested on the form may be subject to
criminal sanctions (including fines and imprisonment) and/or civil sanctions (including civil penalties).
11
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feer
Noria’s 113th Annual Conference
& Exhibition
1
0
5 0
1 1
17
2
2
0
1
2
IINDIANAPOLIS,
NDIANAPOLIS IN
IN • MAY
MAY 1 - 3
In its 13th year, RELIABLE PLANT has lined up some major drivers for conference tracks and sessions. Attendees will gain useful
insight in multiple areas of lubrication, oil analysis and reliability. With superior conference content and intensely loyal spectators, no
other forum brings industry professionals together and provides comprehensive coverage of trends, technologies and issues.
Schedule at a Glance
Monday, April 30
7:00 a.m. – 6:00 p.m.
8:00 a.m. – 5:00 p.m.
8:00 a.m. – 4:30 p.m.
5:30 p.m. – 8:30 p.m.
5:30 p.m. – 8:30 p.m.
Tuesday, May 1
7:00 a.m. – 6:00 p.m.
7:30 a.m. – 8:00 a.m.
8:00 a.m. – 9:20 a.m.
9:30 a.m. – 10:50 a.m.
11:00 a.m. – 11:50 a.m.
12:00 p.m. – 1:20 p.m.
1:30 p.m. – 5:20 p.m.
5:30 p.m. – 6:30 p.m.
9:30 a.m. – 6:30 p.m.
Wednesday, May 2
7:00 a.m. – 6:00 p.m.
7:30 a.m. – 8:00 a.m.
8:00 a.m. – 9:50 a.m.
10:00 a.m. – 10:50 a.m.
11:00 a.m. – 11:50 a.m.
12:00 p.m. – 1:20 p.m.
1:30 p.m. – 5:20 p.m.
3:30 p.m. – 4:40 p.m.
5:30 p.m. – 6:30 p.m.
6:00 p.m. – 9:00 p.m.
Registration at the Indiana Convention Center
Exhibit Hall Set Up
Pre-Conference Workshops
Certification Testing –– International Council for
Machinery Lubrication (ICML)
Certification Testing –– Society for Maintenance
& Reliability Professionals (SMRP)
Registration at the Indiana Convention Center
Continental Breakfast
Opening Keynote Session
Exhibit Hall Grand Opening
Conference Sessions
Lunch in Exhibit Hall
Conference Sessions
Meet and Greet Reception in Exhibit Hall
Exhibition Hours
9:30 a.m. – 6:30 p.m.
Registration at the Indiana Convention Center
Continental Breakfast
Conference Sessions
Refreshments in Exhibit Hall
Conference Sessions
Lunch in Exhibit Hall
Conference Sessions
Refreshments in Exhibit Hall
Networking Reception in Exhibit Hall
Certification Testing –– International Council for
Machinery Lubrication (ICML)
Certification Testing –– Society for Maintenance
& Reliability Professionals (SMRP)
Exhibition Hours
Thursday, May 3
7:00 a.m. – 11:00 a.m.
7:30 a.m. – 8:00 a.m.
8:00 a.m. – 8:50 a.m.
9:20 a.m. – 11:10 a.m.
11:15 a.m.
8:50 a.m. – 12:00 p.m.
Registration at the Indiana Convention Center
Continental Breakfast
Conference Sessions
Conference Sessions
Giveaways in Exhibit Hall
Exhibition Hours
6:00 p.m. – 9:00 p.m.
TRACK TALK
FROM THE INSIDE LANE
“You’re always looking
for that edge to help you manufacture your product
with quality and low cost to stay ahead of your
competitors – that’s what this is all about.”
Brian Wommack, Power Partners
For complete details, visit conference.reliableplant.com
Learning Sessions
RELIABLE PLANT will feature five conference tracks – three focused on lubrication and two
fo
focused on reliability – and approximately 13 sessions per day over the course of three days.
W
With a packed agenda of tactics and solutions for substantial advances in plant performance
an
and profitability, attendees will have 60+ learning sessions to choose from.
• Lubrication Excellence – Devoted exclusively to using
effective lubrication and oil analysis practices to get the
most from a plant’s physical equipment assets. These unique
presentations, delivered by experts and successful lubrication
practitioners, demonstrate how to achieve the efficiencies and
financial benefits of a proper, proactive lubrication program.
• Reliability World – Spotlights the winning strategies and best
practices that drive reliability results to the bottom line. Industry
experts deliver compelling, practical learning sessions, with
particular focus on case studies where the use of effective
reliability strategies has led to measurable economic and
productivity benefits.
Be sure to visit conference.reliableplant.com for a complete schedule of pre-conference workshops, learning sessions and
keynote information.
General Session/Featured Keynote
IndyCar Series driver Davey Hamilton will launch us out of the pole position during the Opening General
Session with a keynote address that’s bound to deliver horsepower and start your engines!
Tuesday, May 1
8:00 a.m. – 9:20 a.m.
Open to all registered attendees
Hamilton, a second-generation racer whose career was inspired by his father Ken, is a versatile driver who won championships in Super
Modifieds and the famed Copper World Classic three times. He competed regularly in the IZOD IndyCar Series from 1996-2001 until
his life was changed forever after a crash at Texas Motor Speedway in which he nearly lost his feet and legs. After 21 operations and
two years of rehabilitation, Hamilton returned to IndyCar racing at the Indianapolis 500 in May 2007, and provides driver analysis for the
Indianapolis Motor Speedway Radio Network.
In February 2009, Hamilton formed a Firestone Indy Lights team with Kingdom Racing. Brandon Wagner serves as the team’s driver
and scored the team’s first win in 2010.
Win a High Performance Hideout!
Need a place of your own to escape, but can’t outfit your ideal hideaway? Let RELIABLE PLANT do it! Perhaps a turbo-charged TV room
complete with 70” screen, Blu-Ray and surround sound system, recliners and a game table? It’s all within your grasp.
How to Win: Check out the latest products and services from the sponsoring
exhibiting companies in the Exhibit Hall, get your entry form stamped and then
register to win! Visit conference.reliableplant.com for complete contest rules
and eligibility.
Diagram shown is for demo purposes only – winner will be awarded a check to outfit their own
High Performance Hideout!
Giveaway sponsored by:
Air Sentry, ALS Tribology, Analysts, Inc., Argo-Hytos, Inc., Azima DLI, CITGO Petroleum Corporation, Donaldson
Company, Inc., Emerson Process Management, Esco Products, Inc., Fluidall, LLC, Fluitec International,
Harvard Corporation, Herguth Laboratories, Inc., Hach Company, HYDAC Technology Corporation,
Hy-Pro Filtration, Indiana Bottle Company, Inpro/Seal Company, JAX, Inc., Kluber Lubrication N.A.,
Liquidynamics, Lubrication Engineers, Inc., Ludeca, Inc., MP Filtri U.S.A., PerkinElmer, Inc.,
POLARIS Laboratories, Pulsarlube U.S.A., Inc., SKF U.S.A., Inc., Specialty Manufacturing, Inc.,
Ultralube, Y2K Fluid Power, Shell Lubricants
Picture
Yourself
Here
Who Should Attend
Whether you’re entry-level or a seasoned
member of your plant’s management team,
you’ll benefit from the comprehensive
schedule of sessions, case studies and peer
interactions.
Asset Care Planners
CBM Coordinators and Specialists
Chief Engineers
Design Engineers
Engineering Managers
Engineers
Facility Managers
General Managers
Hydraulic Specialists
Industrial Maintenance Supervisors
Industrial Mechanics
Infrared/Vibration Technicians
Lab Managers
Lube Analysts
Lubrication Specialists
Lubrication Technologists and Technicians
Machinery Engineers
Maintenance Engineers
Maintenance Managers
Maintenance Planners
Maintenance Supervisors and Foremen
Managers of Maintenance and Reliability
Mechanical Engineers
Operations Managers
PdM Analysts and Specialists
Planners and Schedulers
Plant Engineers
Plant Managers
Project Leaders
Quality Managers
Reliability Coordinators
Reliability Engineers
Reliability Team Leaders
Reliability Technicians
Safety Managers and Directors
Senior Reliability Engineers
TPM Coordinators and Facilitators
….and more
How
H
o You’ll Benefit from Attending
• Secure answers and ideas to address specific issues and needs in your plant
• Acquire new skills you can immediately apply on the job
• Go home with the best tools and processes to implement and sustain a successful
plant reliability program
Company Ad
Company
Comp
Advantages
• More time operating – less downtime
• More output per hour – yield
• Higher first-pass quality – fewer rejects
• Help develop a new generation of leaders
• Teams leave with a common vision and understanding
• Low maintenance costs – organizations with the highest reliability have the
lowest maintenance costs
TRACK TALK
FROM THE INSIDE LANE
“It’s been a very
good conference – full of very practical hands-on
sessions and excellent take-home information that
can be readily applied.”
Jerry Sanders, Michelin
Cert
Level 1
Noria Skills
on
Preparati
ification
Training
Level
Lev
L
ev
evel
vel II MLA
vel
Certification
Preparation
Noria Skills Training
RY
MACHINAETION
LUBRIC
entals of
Pract
Pra
ctic
ica
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al
Fundam
Get a FREE Noria training coupon – valued at $1,195!
Full-conference registration includes a $1,195 training coupon that can be used toward
Noria’s lubrication or oil analysis training courses for up to one year. Use it yourself or give itt
to a co-worker. It’s like attending the conference and getting Noria training for free!
OIL ANALYSIS
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Terms and Conditions: Only one coupon issued per person. Coupon is transferrable within your organization and must be present
presented
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registering for the training. Coupon is valid for Noria public training courses in the United States taking place between May 4, 2012, and May 3,
2013, or online courses purchased prior to May 4, 2013. Coupons are given to full conference (Tuesday-Thursday) attendees who pay their
conference registration fee and attend the conference. Speakers and exhibitors are not eligible unless paying full conference registration fees.
Coupons may not be used for onsite training.
For complete details, visit conference.reliableplant.com
Lubrication Excellence – Manager’s Summit
Jim Fitch – Noria Corporation
Monday, April 30, 1:00 p.m. – 4:30 p.m.
There’s a revolution occurring. Managers who once desired equipment maintenance reliability now
demand it…it is a matter of corporate survival in the global economy, and effective machinery lubrication is
an essential enabler to success.
This movement has led companies in all industries to take control of reliability by reinventing their lubrication
programs. Those who are responding to the challenge are seeing amazing results….on the bottom line, where
it counts most.
The change goes beyond simply using better lubricants. The leaders are employing technologies, empowering employees and
building ultramodern new practices – creating new and energized reliability culture. The workshop will address the following topics:
• The 31 elements needed to attain lubrication excellence
• Benchmarking lubrication programs to the “Optimum Reference State”
• How to write an engineering specification for lubrication excellence
• Performance metrics for PM compliance, contamination control and lubricant quality targets
• How to rate lubrication and oil analysis skills
• The top 10 things organizations do wrong when trying to attain lubrication excellence
• The role of certification, education and continuous improvement
• How to leverage the “behavior factor” in lubrication excellence
• How to build a first-rate lubrication team with the specific collection of skills needed
• The critical role of well-aligned lubricant suppliers and machinery OEMs
• Why on site analysis is a “secret sauce” for world-class lubrication
TRACK TALK
FROM THE INSIDE LANE
• What kind of return-on-investment you can expect from your program
“We’re starting a new
lubrication program at our plant. The conference
• The importance of standardization and procedure-based lubrication
was a good way to get some foundational skills to
• The honest truth about synthetics and premium lubricants
get things kicked off.”
• Lubrication low-hanging fruit and quick kills
General Mills Employee
• The power of the daily one-minute inspection when done correctly
• Three crucial requests to make of component rebuild shops
• How to select a lubricant supplier and what needs to be put in a supply agreement
Certification
Set yourself apart as a leader among peers – break away from the pack!
The International Council for Machinery Lubrication (ICML) will offer certification exam opportunities during RELIABLE
PLANT 2012. Advance registration is required. All exams will be conducted at the Indiana Convention Center on Monday,
April 30, from 5:30 p.m. to 8:30 p.m. and on Wednesday, May 2, from 6:00 p.m. to 9:00 p.m. To learn more about the
certification types, registration fees and exam preparation, visit the ICML website at www.LubeCouncil.org or call 918-259-2950.
The Society for Maintenance & Reliability Professionals (SMRP) will also offer onsite certification exam opportunities on
Monday, April 30, from 5:30 p.m. to 8:30 p.m. and on Wednesday, May 2, from 6:00 p.m. to 9:00 p.m. at the Indiana
Convention Center. Advance registration is required. Please visit the SMRP website at www.smrp.org or call
1-800-950-7354 to select your certification and ensure your seat in one of the testing sessions.
Call for Speakers
We are actively seeking speakers with interesting case studies, personal expertise and innovative ideas to contribute to our
conference agenda this year. There is still time to GET IT IN GEAR and share your insight with industry colleagues and key decisionmakers. Be the pace car and make your mark at RELIABLE PLANT 2012 – submit online abstracts and program ideas at
conference.reliableplant.com.
Reliable Plant 2012 Sponsors
FLUI T E C
Supporting Partners
Media Sponsors
About Indy
Indianapolis, which will serve as host city to the 2012 Super Bowl, is known as America’s most walkable city and is the racing
capital of the world. Downtown Indy features the second largest inner-city park in the U.S., as well as a water canal system, outdoor
amphitheater, zoo and running trails. The Indianapolis Convention Center is nestled among a social hub of museums, shopping venues
and an abundance of area restaurants suitable for all palates.
With pleasant Indianapolis temperatures, a convenient geographic location that is close to a large base of manufacturers, and an inviting
downtown scene, RELIABLE PLANT will attract attendees from all over the globe. Make plans now to attend in 2012 – the race to
excellence awaits you!
For complete details, visit conference.reliableplant.com
Hotel and Venue
RELIABLE PLANT 2012 will be held at the Indiana Convention Center (Indianapolis, IN). Specially rated blocks of rooms are reserved
at the Westin Indianapolis, which is located directly across the street from the Indiana Convention Center. You can take advantage of
these discounted rates by booking your room(s) directly with the Westin using the group name “Reliable Plant Conference” at the time
of reservation. Availability is limited, and you
are encouraged to make reservations
early. Visit conference.reliableplant.com for
more information.
Westin Indianapolis
50 South Capitol Ave.
Indianapolis, IN 46204
1-800-937-8461
Room rates – book by April 9, 2012, and save!
Single or double occupancy: $139.
*All room rates exclusive of state and local taxes or
applicable service or hotel specific fees in effect at the
time of the conference. Hotel tax rates are subject to
change without notice.
Reserve your room today!
• Call the Westin at 1-800-937-8461
• Be sure to mention Noria Corporation or
RELIABLE PLANT 2012
• Make all hotel reservation changes or
cancellations directly with the Westin
Airlines and Car Rental
Air Travel
American Airlines is offering discounted fares for attendees of RELIABLE PLANT 2012. Some restrictions may apply for airline
tickets and discounts may not be available on all fares. For reservations and ticketing information, call American’s Meeting
Services Desk at 1-800-433-1790 anywhere in the U.S. or Canada and reference authorization number: 7142BU.
Discount fares are valid for round-trip travel on American Airlines and American Eagle and can be booked online at
www.aa.com/group without a ticketing charge. Valid group travel dates are April 28-May 7, 2012.
United Airlines is offering discounted fares for attendees of RELIABLE PLANT 2012. Some restrictions may apply for
airline tickets and discounts may not be available on all fares. For reservations and ticketing information, call United Meetings at
1-800-521-4041 and refer to group code: 587JR. Valid group travel dates are April 26-May 9, 2012.
Car Rental
Discounted group car rental rates are available from April 28-May 7, 2012. Reservations can be made by calling
1-800-331-1600 or online at www.avis.com and reference discount code: J906910.
Discounted group car rental rates are available from April 25-May 11, 2012. Reservations can be made by calling
1-800-654-2240 or online at www.hertz.com and reference discount code: CV#04NZ0002.
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Online: conference.reliableplant.com
By Phone: Call us at 800-597-5460 or 918-749-1400
Monday through Friday, 8:00 a.m. to 5:00 p.m. (CST)
On Site:
Monday, April 30
Tuesday, May 1
Wednesday, May 2
Thursday, May 3
7:00 a.m. – 6:00 p.m.
7:00 a.m. – 6:00 p.m.
7:00 a.m. – 6:00 p.m.
7:30 a.m. – 11:00 a.m.
Register Now!
Full Conference Registration
On or before January 20, 2012..............................................$695
On or before March 30, 2012................................................$795
After March 30, 2012 ............................................................$995
Full-Conference Registration Includes:
• Admission to all break-out conference sessions
(Tuesday-Thursday, May 1-3)
• Conference proceedings on CD ROM
• Opening general session and keynote speaker (May 1)
• Exhibition hall access (Tuesday-Thursday, May 1-3)
• Lunches in the exhibit hall (Tuesday-Wednesday, May 1-2)
• Daily refreshment breaks (Tuesday-Thursday, May 1-3)
• Daily continental breakfasts (Tuesday-Thursday, May 1-3)
• Networking receptions (Tuesday-Wednesday, May 1-2)
• FREE Noria training coupon, valued at $1,195
Group Discounts
3 to 9 attendees: Send three or more full-conference registrations
for only $550 each, plus a 30% discount on all pre-conference
workshop fees.
10 or more attendees: Send 10 or more full-conference
registrations for only $350 each, plus a 30% discount on all
pre-conference workshop fees.
TRACK TALK
FROM THE INSIDE LANE
“The vendors have
been excellent. We’ve been talking on the phone,
but having all the information right here and having
hands-on application for direct usage in the field
has been very beneficial for us.”
Invista Employees
One-Day Conference Registration............................................$395
• Admission to one day of break-out conference sessions (choose
from Tuesday, Wednesday
or Thursday)
• Opening general session
(Tuesday only, May 1)
• Exhibition hall access for
one day (choose from
Tuesday, Wednesday or
Thursday)
• Lunch in the exhibition hall forr one day
(Tuesday or Wednesday, May 1 or May 2)
• Day’s refreshment breaks
• Day’s continental breakfast
• Day’s reception (Tuesday and Wednesday, May 1 or May 2)
Exhibition-Only Registration
With exhibitor guest pass (all three days)...................................FREE
Without guest pass (all three days)............................................$50
Pre-Conference Workshops
Monday, April 30
Half day with full-conference registration....................................$225
Half day with workshop only.......................................................$295
Workshop registration includes:
• Course materials
• Refreshment breaks
• Opening general session (Tuesday, May 1)
• Exhibition hall access (Tuesday, May 1)
Spouse/Family Registration......................................................$135
• Opening general session (Tuesday, May 1)
• Exhibition hall access
• Daily lunches in the exhibition hall (Tuesday-Wednesday, May 1-2)
• Daily continental breakfasts (Tuesday-Thursday, May 1-3)
• Receptions in the exhibition hall (Tuesday-Wednesday, May 1-2)
Cancellations must be in writing and postmarked by March 30, 2012. All cancellations received
after this date are subject to a $75 administrative fee, but you will also receive a $75 coupon good
for use against the cost of a Noria training or conference. If you don’t cancel and you don’t attend,
you will be charged the full registration fee. However, a company may substitute one attendee for
another, without penalty. Written notice prior to the event is required for
substitute attendees.
1328 East 43rd Court | Tulsa, OK 74105 | 800-597-5460 | conference.reliableplant.com