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JAnUARY/feBRUARY 2011 • vOL 12, nO. 1 • www.LMTinfo.com
contents
AchIevInG effIcIencIeS ThROUGh PRAcTIceS & PRODUcTS
Features PROfeSSIOnAL DeveLOPmenT SeRIeS Lubrication Certification: Types, Requirements, Benefits
© OneO2-FOTOLIA.COM; © Aamon-FOTOLIA.COM
10
This article is the first in a year-long series on how lube pros can achieve certification and what’s in it for them when they do.
Ray Thibault, Contributing Editor
DeLIveRInG The GOODS 16
The Anatomy Of A centralized Lubrication System: Series Progressive (Or Single Line Progressive) Systems
Which centralized, automated lube-delivery system is best for an application? This month, we examine the most highly engineered of them all. Ken Bannister, Contributing Editor
UTILITIeS mAnAGeR 18
n Big money Talks William C. Livoti
n Part I: making energy Savings happen Through People Henry Molise, P.E., HCM Energy Consulting, LLC
LAB SPOTLIGhT 24
Introduction To common Oil-Analysis Tests (And how To Take A Successful Sample)
This regular feature will be looking at the most common oil-analysis tests and some of the labs that conduct them.
dePartMeNts 4 6 8 26
Publisher’s Statement
28 30 30
Problem Solvers
my Take from Our Perspective Contamination Solutions Showcase classified Supplier Index
Ray Thibault, Contributing Editor
Achieving efficiencies Through Practices & Products Apply for a free, one-year subscription at
www.LMTinfo.com JANUARY/FEBRUARY 2011
www.lmtinfo.com | 3
PUBLISHER’s Statement
Bill Kiesel, Publisher
Alive & Kicking. . . And Growing Strong
Y
ou may have read about the recent release of Mark Twain’s autobiography—100 years after his death. News of this muchanticipated event reminded me of one of my favorite Twain quotes: “The reports of my death are greatly exaggerated.” He, of course, was referring to some confusion around the illness of a cousin. Somehow, an obituary had been written, erroneously listing the famous author as the dearly departed. Today, more than a century later, I think this quote could easily apply to some of us in the B2B arena who are still delivering print publications and ancillary products to specific markets. To paraphrase Mr. Twain: “The reports of our demise have been greatly exaggerated.” At Applied Technology Publications there’s still plenty of life left— and lots of growing going on! We spent much of the economic downturn expanding our print, online, digital and other products and are excited about the future, especially since lubrication professionals are so crucial to the global economic recovery. We’re ready and eager to help you get this show on the road! Here are just a few of the great new things we’ve begun rolling out in Lubrication Management & Technology this month: n “Maintenance & Reliability Innovator Of The Year Award” in conjunction with Ken Bannister’s new Maintenance Technology column entitled “Don’t Procrastinate. . . Innovate! (Pg. 6) n “The Anatomy of A Centralized Automatic Lubrication System” to help you select the correct system for your application. (Pg. 16) n “Green Gadgets,” “Efficient Gadgets” and “Reliable Gadgets” to help you do your jobs better, faster, safer. (Pg. 22) n “Lab Spotlight,” exploring oil-analysis tests and labs. (Pg. 24) n “Lube Starz©,” profiles of some of our hard-working readers. (Pg. 17)
This list reflects just some of the new growth you’ll find amid our already strong lineup of offerings—including a bigger and better MARTS (Maintenance & Reliability Technology Summit) that kicks off April 26 with the 2nd Annual “Reliability Gives Voice to Autism” charity gala. Our goal is to give you everything you need. Moreover, we want to serve you better than ever. Happy New Year! LMT
Achieving EffiCIencies THROUGH PRACTICES & PRODUCTS
January/February 2011 • Volume 12, No. 1 arthur l. rice President/CEO arice@atpnetwork.com
bill kiesel Executive Vice President/Publisher bkiesel@atpnetwork.com
Jane alexander Editor-In-Chief jalexander@atpnetwork.com
RICK CARTER Executive Editor rcarter@atpnetwork.com
Kenneth E. Bannister ray thibault, CLS, OMA I & II RAYMOND L. ATKINS Contributing Editors
RANDY BUTTSTADT
Director of Creative Services rbuttstadt@atpnetwork.com
GREG PIETRAS
Editorial/Production Assistant gpietras@atpnetwork.com
ellen sandkam
Direct Mail esandkam@atplists.com
edward kane
Reprint Manager 800-382-0808, ext. 131 ekane@fostereprints.com
Editorial Office 1300 South Grove Ave., Suite 105 Barrington, IL 60010 847-382-8100 / FAX 847-304-8603 www.Lmtinfo.com
Subscriptions For inquiries or changes contact Jeffrey Heine, 630-739-0900 ext. 204 / Fax 630-739-7967 Lubrication Management & Technology (ISSN 19414447) is published bi-monthly by Applied Technology Publications, Inc., 1300 S. Grove Avenue, Suite 105, Barrington, IL 60010. Periodical postage paid at Barrington, IL and additional offices. Arthur L. Rice, III, President/CEO. Circulation records are maintained at Lubrication Management & Technology, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Lubrication Management & Technology copyright 2011. No part of this publication may be reproduced or transmitted without written permission from the publisher. Annual subscription rates for nonqualified people: North America, $140; all others, $280 (air). No subscription agency is authorized by us to solicit or take orders for subscriptions. Postmaster: Please send address changes to Lubrication Management & Technology, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Please indicate position, title, company name, company address. For other circulation information call (630) 739-0900. Canadian Publications Agreement No. 40886011. Canada Post returns: IMEX, Station A, P.O. Box 54, Windsor, ON N9A 6J5, or email: cpcreturns@wdsmail. com. Submissions Policy: Lubrication Management & Technology gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Printed in U.S.A.
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JANUARY/FEBRUARY 2011
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MY TAKE
Jane Alexander, Editor-In-Chief
It’s About Time!
H
appy New Year! I have some real good news for you. But first, the bad…The perfect storm that’s been brewing with regard to the dwindling labor pool and the loss of so many skilled, knowledgeable, experienced craftspeople from the workforce is about to blow. This isn’t just me talking. Let me quote one of my favorite industry experts (and yours):
“Statistics on the issue abound, including this: The Employment Policy Foundation (EPF) projects that we’ll suffer an 80% skill loss over the next 10 years as the Baby Boomer generation officially becomes eligible for retirement. We must recognize that a large percentage of those skilled jobs will be lost forever—and that the remaining workforce will be expected to absorb and cope with the devastating results. The clock is ticking faster and faster…” These chilling words come directly from the first installment of contributing editor Ken Bannister’s new column running every other month under the banner of “Don’t Procrastinate…Innovate!” in Maintenance Technology (MT) magazine. According to Ken, we shouldn’t look to government to legislate us out of the danger we’re in. Who knows what that might entail? He says it’s going to take some real innovation on the part of our industries—and the individuals now working in them—for us to survive the killer storm that is bearing down on us. We at Applied Technology Publications (ATP), parent of both MT and Lubrication Management & Technology (LMT), and the Maintenance & Reliability Technology Summit (MARTS) have heard the message loud and clear. Moreover, we’re going to put some real money where our editorial “mouth” is. Along with Ken’s new MT column, we’re launching the “Maintenance & Reliability Innovator of the Year Award” program—and the good news for you is that it’s open to those in the lubrication community! The competition will allow you to “pass on” and share your successful innovative gizmos, gadgets, procedures, methods and ideas with others in the maintenance and reliability arena. Additional details will come in future issues of both MT and LMT. In the meantime, though, you can learn more about the topic by going online* and reading “Tick-Tock: Time To Innovate!” Please note that Ken is issuing a challenge to all maintenance and reliability professionals—including you on the lube side of the house—to put on your innovative-thinking caps. There’s no time to waste, he says: “Begin writing down whatever improvement ideas you have and prepare yourself for a wave of innovation as we explore ideas to help us make it through our perfect storm.” I agree. It’s time to get going! By the way, on behalf of all of us at Applied Technology Publications, let me take this space to thank you for your past support. We look forward to serving your lubrication-information needs for many years to come! LMT jalexander@atpnetwork.com
* http://www.mt-online.com/component/content/article/282-january2011/1661-dont-procrastinateinnovatetick-tock-time-to-innovate.html?directory=90
6 | LUBRICATION MANAGEMENT & technology
JANUARY/FEBRUARY 2011
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FROM OUR PERSPECTIVE
Ken Bannister, Contributing Editor
Chasing An Optimal State?
V
irtually every continuous-improvement and change-management program is geared toward taking a current state and evolving it into an optimal state. This is also true of a lubrication-management improvement program. In the case of a lubrication program, optimal state begins with adherence to the 4R principles: Deliver the RIGHT lubricant, in the RIGHT place, in the RIGHT amount, at the RIGHT time. Simple! If a bearing could talk, it would say its optimal state is best achieved by delivering a small amount of the correct lubricant on a continual basis so that it never runs dry and falls into a boundary/ dry running state (dry friction), or that its cavity is never over-filled, forcing it into a fluid-friction (wet-friction) state. Both of these states are less than optimal—and will result in premature bearing failure, as well as a marked increase in energy use to overcome the frictional retardation force. While vacationing in the Caribbean several years ago, I went for what was expected to be a relaxing barefoot stroll along the beach— albeit on a very hot day. Finding it difficult to negotiate the scorching sand without blistering my feet, I was forced to dash into about 18 inches of ocean water to cool off. Trying to continue my forward momentum there was not easy, as I needed to exert increasing amounts of energy to overcome the resistance of the water. Through a little trial and error, I eventually found my optimal state: walking in about a half-inch of water. There was almost no resistance and it was nice and cool and easy to move through with good traction. It didn’t take long for me to realize that this is how a bearing must feel in its optimal and not-so-optimal states. Running a successful lubrication program based on a manual-system approach requires a vigilant lubrication person who must always ensure that: (1) the right lubricant is in the grease gun; (2) the same grease gun is always used, in order to guarantee the same “shot size” delivery
8|
LUBRICATION MANAGEMENT & TECHNOLOGY
every time; and (3) he/she lubricates to a strict timetable and consistently/rigorously maintains absolute cleanliness of both gun and nipple. You probably know that this reality is difficult to achieve—and that a most likely result is a nonoptimal, feast-or-famine lubrication state.
To combat a non-optimal lubrication state, we must convert to the use of centralized and automated lubrication systems. To combat a non-optimal state, we must convert to the use of centralized and automated lubrication systems that are set up to deliver a small amount of lubricant on an almost continual basis. Automated systems deliver generous benefits over manual lubrication techniques that include up to three times extended bearing life and elimination of all of the associated downtime costs, reduction in lubricant use and significant energy savings (with an associated carbon-footprint reduction)—and all at little capital cost, which, in turn, generates fast and easy return on investment. To assist you in choosing the correct automated delivery systems for your particular application(s), Lubrication Management & Technology is launching a continuing series on “The Anatomy of a Centralized Lubrication System.” Over the course of the year, we’ll review the pros and cons of different system types and explain how they work. Please turn to page 16, where our first installment in this series focuses on “Series Progressive Delivery Systems.” LMT kbannister@engtechindustries.com
JANUARY/FEBRUARY 2011
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PROFESSIONAL DEVELOPMENT SERIES
Thumbs up on this…
Lubrication Certification: This article kicks off a year-long discussion on certification of lube pros, the means by which you can achieve it and what’s in it for you when you do. Ray Thibault CLS, OMA I, OMA II, MLT, MLT II, MLA II, MLA III Contributing Editor
A
lmost every professional group has certification programs to recognize achievement above and beyond what’s normally required just to do a job. Doctors and lawyers aspire to be Board Certified in their respective specialties. An engineer can obtain a Professional Engineer (P.E.) license that demonstrates a high level of expertise. In the accounting world, it’s desirable to be listed as a Certified Public Accountant (CPA). The manufacturing industry also has several certifications. For example:
■ The Vibration Institute has four levels of certification for analysts. There also are certification programs in Thermography and Ultrasonics. ■ The Certified Maintenance & Reliability Professional (CMRP) certification is offered by the Society for Maintenance & Reliability Professionals. Introduced in 2001, this certification program has become very popular among those in the maintenance and reliability field, including many in the lubrication community. Obtaining such certifications demonstrates a competence and a desire to exceed normal job requirements. This, of course, doesn’t mean that all certified individuals in a profession are more competent than those who are not certified. However, when it comes to selecting employees and/or service providers, the fact that a candidate holds certification from a credible, recognized body can make a big difference in the selection process.
10 | LUBRICATION MANAGEMENT & TECHNOLOGY
JANUARY/FEBRUARY 2011
PROFESSIONAL DEVELOPMENT SERIES
Table I. Certifications Offered by the International Council of Machinery Lubrication (ICML)
Certification Machinery Lubrication Technician Level I Machinery Lubrication Technician Level II Machinery Lubrication Analyst Level I Machinery Lubrication Analyst Level II Machinery Lubrication Analyst Level III Laboratory Lubrication Analyst Level I
# Certified
Year Introduced
3435 207 184 2194 161 58
2001 2007 2010 2001 2002 2002
What about lubrication specifically? Are there any certifications available? What are they? Who should have them? What are the benefits? What are the requirements for obtaining these certifications? Presently, there are two major certifying organizations for lubrication-related activities: the International Council of Machinery Lubrication (www.lubecouncil.org) and the Society of Tribologists and Lubrication Engineers (www.stle.org). International Council of Machinery Lubrication (ICML) ICML was formed in 2000 to promote competence in the field of lubrication through the development of certification standards. All of its certifications are in compliance with ISO 18436-4 or ISO 18436-5. Table I lists the certifications available through ICML. The two most popular certifications from ICML are the MLT I and the MLA II. The MLA II and III were originally named MLA I and MLA II. When ICML’s work was pioneered into the first international standard on qualification and assessment of oil-analysis personnel (ISO 18436-4), the then-MLA I was deemed too high a standard for an entry level of an international standard and became equivalent to the ISO category II. The then-MLA II became equivalent to the category III of the ISO. To denote such equivalence, ICML renamed its MLA I and II as “MLA II” and “MLA III,” respectively. The Category I of the standard was inspired by the ICML MLT I, with some very basic oil-analysis elements added— as it was being used for a standard targeting oil analysts. The new MLA I, with the subject areas of the MLT I plus the basic oil-analysis elements, was introduced by ICML in 2010. Therefore, if the formal training in the MLT I class includes basic oil analysis information in oil sampling, lubricant-health monitoring and very basic wear debris monitoring and analysis, both MLT I and MLA I certifications can be obtained from the same class by taking two separate exams. The MLT I is designed for individuals involved with dayto-day lubrication of machinery. Many of those certified are lubricant end-users, as evidenced by the large number of manufacturing companies that have associates with this certification. MLT II is directed at advanced understanding JANUARY/FEBRUARY 2011
of lubrication concepts. One lubricant company, Lubrication Engineers, is strongly encouraging its sales representatives to become certified as MLTs—and through a structured training program, the company now has 65 of them certified as such. This type of program benefits both the company and the personnel involved. In addition to the resulting certification, the knowledge gained in preparing for the exam helps generate better solutions for customer problems. The concepts in which proficiency is required to pass the MLT I exam are as follows: ■ Maintenance Strategy (5%) ■ Lubrication Theory (10%) ■ Lubricants (15%) ■ Lubricant Selection (15%) ■ Lubricant Applications (25%) ■ Preventive and Predictive Maintenance (10%) ■ Lube Condition Control (10%) ■ Lube Storage and Management (10%) MLA I-III involves demonstration of the skills that are necessary for performing lubricant analysis for machine condition monitoring. The most common certification in this category is the MLA II. The following are the concepts necessary to pass this exam: ■ Lubricant Roles and Functions (4%) ■ Oil-Analysis Maintenance Strategies (4%) ■ Oil Sampling (29%) ■ Lubricant Health Monitoring (21%) www.LMTinfo.com | 11
PROFESSIONAL DEVELOPMENT SERIES
Table II. Requirements & Pass Rate for Various ICML Certifications
Certification
Experience
Training Requirements
Exam
Pass Rate
Two years post-secondary education or on-the-job training in maintenance or lubrication.
16 hours of documented training in machinery lubrication.
Achieve a 70% score on 100question multiple-choice exam.
62%
MLT I MLT II
Three years post-secondary education or on-the-job training.
32 hours of documented formal training in machinery lubrication.
Achieve a 70% score on 100question multiple-choice exam.
49%
MLA I
12 months experience in lubrication-analysis-based machinery condition monitoring*.
24 hours of documented formal training as outlined in the Body of Knowledge of the MLA I.
Achieve a 70% score on 100question multiple-choice exam.
64%
24 hours of documented formal training in lubrication analysis as outlined in the Body of Knowledge of the MLA II.
Achieve a 70% score on 100question multiple-choice exam.
61%
MLA II
24 months experience in lubricationanalysis-based machinery condition monitoring*, plus have the MLA I certification or 960 hours experience in oil analysis.
32 hours of documented formal training in lubrication analysis as outlined in the Body of Knowledge of the MLA III.
Achieve a 70% score on 100question multiple-choice exam.
48%
MLA III
36 months experience in lubricationanalysis-based machinery condition monitoring* and have MLA II certification.
16 hours of documented formal training in oil analysis for machine condition monitoring.
Achieve a 70% score on 100question multiple-choice exam.
68%
LLA I
Two years post-secondary education or on-the-job training in lubrication, lubricant analysis, chemistry, maintenance or reliability.
* Months of experience are based on 16 hours minimum per month of sampling and analysis experience.
■ Lubricant Contamination Measurement and Control (25%) ■ Wear Debris Monitoring and Analysis (17%) It’s worth mentioning that the large number of MLA II-certified individuals come primarily from oil-analysis end-user companies and international laboratories—not from domestic oil-analysis labs. Over its short history, ICML has done an outstanding job promoting lubrication certification. Today, there are nearly 1250 companies that have at least one ICML-certified person on staff. A total of over 6200 certifications are now in the ICML system. Table II lists the requirements for various ICML certifications, along with the pass rate. Table III. Certifications By The Society of Tribologists and Lubrication Engineers (STLE)
Certification
# Certified Year Introduced
Language(s), cost, renewal and recertification particulars. . . ICML exams are offered in English, Spanish, Portuguese, Italian, French, Korean, Japanese and Mandarin (and, upon request, can be offered in other languages). The exam cost in most countries is $200USD. Recertification is required every three years, at a cost of $100, along with achieving 15 points related to lubrication activities or retaking a 50-question, multiple-choice exam. Society of Tribologists and Lubrication Engineers (STLE) Founded in 1944, STLE was originally known as the American Society of Lubrication Engineers. It offers the certifications listed in Table III. Originally designed for lubrication engineers, the CLS is the oldest—and considered the highest-level—lubrication certification. The very rigorous CLS exam (which had a 60% pass rate in 2010) covers the following 16 areas of lubrication:
Certified Lubrication Specialist (CLS)
913
1993
■ Lubrication Fundamentals
Oil Monitoring Analyst Level I (OMA I)
315
1999
■ Fluid Conditioning
Oil Monitoring Analyst Level II (OMA II)
17
2001
Certified Metalworking Fluids Specialist (CMFS)
61
2005
12 | LUBRICATION MANAGEMENT & TECHNOLOGY
■ Storage, Handling and Application of Lubricants ■ Monitoring and Reducing Consumption of Lubricants JANUARY/FEBRUARY 2011
PROFESSIONAL DEVELOPMENT SERIES
■ Gears ■ Bearings ■ Seals ■ Fluid Power ■ Lubricant Manufacturing ■ Pneumatics ■ Metalworking ■ Solvents and Cleaners ■ Problem Solving ■ Lubricant Analysis ■ Lubrication Programs Many lubricant companies have stressed the importance of achieving the CLS to demonstrate the competence of their sales representatives and technical personnel. Increasing numbers of lubricant end-users are working to achieve the CLS, and major North American oil-analysis labs have focused on having their analysts obtain both the CLS and OMA certifications to demonstrate their competence. (INTERESTING NOTE: The four oilanalysis laboratories having the most CLS-certified analysts are ALS, Analysts, Inc., Polaris and Herguth. They account for most of the individuals that are CLS-certified oil analysts.) Some of the major lubricant companies are promoting/ encouraging their distributor/marketer representatives to obtain the CLS certification. Chevron is the leader in this area, with the largest number of CLS-certified personnel, as well as the largest network of CLS-certified marketers. Developed nearly 10 years ago, Chevron’s program stressing the importance of CLS certification has been very successful. Still, you don’t have to be a major lubricant company to promote certification.
Schaeffer Manufacturing, for example, initiated a formal training program in 2004 to help its representatives achieve CLS certification. This has led to over 50 people becoming CLS-certified— ed—that’s more than many of the large lubricant companies. Schaeffer’s management believes the certification not only has helped build a sales force that is highly competent in solving lubrication problems, it has opened doors with many new accounts. (INTERESTING NOTE: As a demonstration of Schaeffer’s commitment to the certification of its sales/technical personnel, even the company president has obtained his CLS.) The latest certification introduced by the STLE is the CMFS (Certified Metalworking Fluids Specialist). This is the most specialized certification that the organization offers— and has the most stringent requirements. In 2010, this exam had only a 50% pass rate. Another certification, Oil Monitoring Analyst Level II (OMA II), is also rather specialized. Only 17 individuals have achieved this certification. This select group has 50% of its members from Canada. (INTERESTING NOTE: The company Analysts, Inc., has four OMA II-certified associates, the most for any oil-analysis lab.) Table IV lists requirement for various STLE certifications. All STLE exams are based on multiple choices, with OMA I having 160 questions and the CLS having 155. The pass rates listed in Table IV are for 2010. Only two individuals took the OMA II exam in 2010, thus the pass rate is not listed. STLE exam language(s), cost, renewal and recertification details… STLE exams are currently offered only in English. To promote these certifications internationally, the exams will be offered in other languages in the future. The exam cost is $440 for non-STLE members, and $330 for members. The certification must be renewed every three years. The renewal fee is $250 for non-STLE members and $130 for members. Four requirements out of a list of 11 must be met for recertification or the exam must be retaken. The renewal requirements are not difficult to obtain, and demonstrate learning and continued involvement in the lubrication field.
Table IV. Requirements for Various STLE Certifications
Certification
Experience
Training Requirements
Exam
CLS
Three years minimum experience in the field of lubrication.
None
Achieve 70% score in 155-question multiple-choice exam.
OMA I
One year active employment utilizing oil analysis in the field of lubrication.
16 hours in oil-analysis-related courses, including company classes.
Achieve a 70% score on 160-question multiple-choice exam.
OMA II
One year active employment utilizing oil analysis in the field of lubrication.
16 hours in oil-analysis-related courses, including company classes.
Achieve a 70% score on 150-question multiple-choice exam.
CMFS
Minimum of a two-year degree in science None or engineering. Three years minimum experience working in a manufacturing environment as a fluid specialist or five years in a laboratory environment as a chemist.
JANUARY/FEBRUARY 2011
Achieve a 70% score on 150-question multiple-choice exam.
www.LMTinfo.com | 13
PROFESSIONAL DEVELOPMENT SERIES
Certification Benefits A common question from lubricant sales and technical representatives, along with plant personnel, is “What does a certification do for me, and which ones should I get?” The answer to the first part is “greater compensation and possibly greater opportunity.” Consider the following: The November 2006 issue of Lubes’n’Greases documented the monetary value of a CLS through a survey of salaries of lubricant sales reps. The survey revealed that those with a CLS were better-compensated than their peers without the CLS. This was quite evident in the area of distributor sales, where CLS-certified reps earned $30,000 p/yr more on average. Having the CLS shows you have passed a difficult, allencompassing exam in the lubrication field. (INTERESTING NOTE: Some lube companies put such value on certain certifications that they make them prerequisites to future promotions. Companies even have been known to pay a bonus for passing a certification exam—from $500-$5000, in some cases.)
The more time and effort you put into self-study, the greater your chances of passing an exam. There are lubricant- and oil-analysis-bid situations where having a certain number of Certified Lubrication Specialists is part of the requirements to submit a bid. The MLT certification is very popular with plant-equipment lubricators and supervisors. For too many years, oilers were not recognized as vital to plant operation. This has changed, and the requirement for more knowledgeable lubricators is emerging. Certification programs have helped in this process. A very important benefit of obtaining a certification is the knowledge gained in preparing for the exam through structured training classes and self-study. A certified person who is purchasing a lubricant or service is more prone to deal with someone who has demonstrated his/her own competence by also obtaining a certification— I know of actual situations where lubricant sales reps were unable to arrange appointments with potential customers until they achieved a particular certification. This has become even more prevalent in our current economic environment. End-users must cut into already precious time to see sales reps. An unknown, uncertified rep will have more difficulty arranging a face-to-face meeting with purchasers than an unknown, yet certified individual. A certified rep, at least on the surface, appears to signal greater competency. Thus, he/she stands a better chance of 14 | LUBRICATION MANAGEMENT & TECHNOLOGY
getting an appointment with someone who IS familiar with lubricant certification programs. One of the requirements for both STLE and ICML certifications is that lubricant-related activities, such as attending conferences and training classes, need to be documented every three years for purposes of recertification. This requirement, in turn, results in certified individuals having more of a tendency to continue learning than uncertified personnel. (INTERESTING NOTE: Certified individuals often exude more confidence in the work environment than those who are uncertified.) Conclusion For those who attain lubrication certification, there are many benefits—both monetary and personal. The avenues to certification are available through two major certifying bodies: the International Council of Machinery Lubrication (ICML) and the Society of Tribologists and Lubrication Engineers (STLE). To date, ICML has granted 6000 certifications through six programs. STLE has granted over 1200 certifications involving four different programs. What certification is best for you? Presently, the MLT I and MLA II are the most popular (with a large number of manufacturing-plant personnel holding these certifications). The CLS is especially popular with lubricant companies and their sales representatives and lubricant personnel—it’s still considered the premier certification for the total field of lubrication, as it involves demonstrating knowledge in 16 separate areas. Interest in the CLS, though, is also increasing in manufacturing plants, primarily with individuals heavily involved in lubrication decisions. As noted previously, the major oil-analysis laboratories consider the CLS important for their analysts. Other certifications, such as the MLT II, MLA III, CMWFS and the OMA II, are more specialized, as evidenced by the small number certified. How do you achieve a certification? First, having experience in the lubrication field is very important. Next, you will need to do some self-study. (The more time and effort you put into self-study, the greater your chances of passing an exam.) Finally, attending a certification preparation class is very helpful—and is mandatory for any ISO-compliant certification. Your chances for success improve by taking certification exams soon after taking the associated training program. For more information on certification classes and to see who is certified, go to www. lubecouncil.org and www.stle.org. What’s next? This series continues through 2011 with discussions of topics found on the MLT, MLA, OMA and CLS exams. In the next issue, we’ll cover “Basic Principles of Lubrication.” LMT Contributing Editor Ray Thibault is based in Cypress (Houston), TX. An STLE-Certified Lubrication Specialist and Oil Monitoring Analyst, he conducts extensive training in a number of industries. Telephone: (281) 257-1526; e-mail: rlthibault@msn.com. For more info, enter 01 at www.LMTfreeinfo.com JANUARY/FEBRUARY 2011
BOOSTING YOUR BOTTOM LINE
Is It Time For An Energy Assessment?
H
ow long has it been since your operations had an energy assessment by an actual energy professional: one year… two years…never? Taking a step back, just what is an energy assessment— and is it really worth the trouble? An energy assessment (sometimes called an “energy audit”) provides a better understanding of how energy is used throughout your facility and identifies opportunities for energy savings. It may take the form of a walk-through of your operations to identify specific opportunities, or it may involve detailed measurement and analysis of specific processes and systems. There are often many energy-saving opportunities at a facility, from “quick wins,” repairs and tuneups that involve minimal disruptions to equipment and processes, to more significant upgrades and process improvements. In the case of motor-driven systems, an energy audit may reveal inefficient or improperly sized motors, variable frequency drive (VFD) retrofit opportunities, process changes that reduce motor speed or duty and other repair and optimization opportunities. Is an energy assessment worth the time and money? If improving plant efficiency and reducing operating costs is a core strategy at your facility, then investing in an energy audit is well worth the effort. A skilled professional can help identify numerous and, sometimes, hard-to-spot opportunities, as well as help quantify potential energy savings and payback period for identified changes. Energy audits may also lead to intangible benefits—such as increasing your team’s awareness of how energy impacts the bottom line. Getting started To get started, collect your most recent motor inventory data, system schematic, motor test results and (if applicable) previous audit results. If these resources are not readily available, begin by taking a basic motor inventory, including motor nameplate data, estimated operating hours and the electric costs to operate your facility.
JANUARY/FEBRUARY 2011
Next, contact a qualified energy assessor. Your local utility may offer an assessment program or provide a list of licensed energy service providers in your area. The U.S. Department of Energy Industrial Technologies Program (ITP) offers audit assistance to qualified plants.[1] The MDM Website [2] has links to system optimization, resources from local utilities and plant energy-management resources. Before committing to an audit, know up front what the approximate time and cost will be and the typical improvements and evaluation criteria that are recommended for your type of facility. Review case studies and references. Be prepared to put together an implementation plan and take action based on the assessment results. Regularly monitoring motor energy consumption, making motor-system efficiency improvements and tracking improvement over time are key components to sound motor management. Performing an energy assessment is a big step toward identifying savings opportunities, establishing savings goals and—very important— achieving results! LMT References 1. ITP Best Practices Plant Assessments, www. eere.energy.gov/industry/bestpractices/plant_ assessments.html 2. www.motorsmatter.org/resources/index.asp
The Motor Decisions Matter (MDM) campaign is managed by the Consortium for Energy Efficiency (CEE), a North American nonprofit organization that promotes energysaving products, equipment and technologies. For further information, contact MDM staff at mdminfo@cee1.org or (617) 589-3949.
www.LMTinfo.com | 15
DELIVERING THE GOODS
The Anatomy Of A Centralized Lubrication System
Series Progressive (Or Single Line Progressive) Systems Ken Bannister Contributing Editor
With some basic TLC, the Series Progressive (or Single Line Progressive) type of centralized lubrication system will deliver many years of trouble-free service, thanks to its engineering and tamper-proof design. (Photo courtesy of Engtech Industries Inc.)
A
rguably the best engineered of all lubrication systems, the Series Progressive (or Single Line Progressive) system pumps oil or grease in either a cyclical (total loss) or continuous (recirculative) manner. Engineered to positively deliver an exact displaced amount of lubricant to every single bearing point, the divider block design is capable of operating in severe environments and accommodating upwards of 200 delivery points in a single pump system.
Today, most lubrication OEMs offer a version of this popular system type. The original model—designed and developed in the U.S. by the Lubriquip organization in the early part of the 20th century and marketed under the Trabon name—continues to be sold today. ■ How This System Works A lubricant pump is connected to an engineered network of series progressive divider blocks, and via a controller is allowed to pump lubricant in a continuous or controlled cyclical systematic manner to each divider block. 16 | LUBRICATION MANAGEMENT & TECHNOLOGY
Divider blocks, which are built in a modular style, contain a series of lapped, hydraulically actuated spool valves sized for varying displacements. The ability to “cross-port” a valve results in “doubling” the delivery of lubricant on one side of the valve only. The valves are progressively linked together in series, causing them to “shuttle” over to one side of the block in a progressive pattern, then to “shuttle” back to their original positions as the lubricant continues to be pumped through the block. Because of its hydraulic nature, as a valve is shuttled back and forth, it displaces a lubricant charge on one end JANUARY/FEBRUARY 2011
It’s Time To Shine!
e b u z r LSta
of the valve to the bearing point, while simultaneously filling the void on the other side of the valve in preparation for displacement once the valve “shuttles” back.
■ The Pros & Cons With some basic TLC, the Series Progressive system type will deliver trouble-free service for many years, thanks to its engineering and tamper-proof design. With the blocks’ modularity, replacement parts are relatively inexpensive to purchase, stock and replace. As the accompanying dividervalve photo shows, the system can even be used with a manual grease gun to deliver an engineered amount of lubricant to each bearing point, and be automated later. (NOTE: The photo on page 16 clearly shows the block cycle pin and four overpressure indicators in “run” position.) The downside of the Series Progressive system is the difficulty in adding points once the initial system is installed—although this can still be achieved. Moreover, in comparison to other single line systems, the Series Progressive type demands more system engineering. The plus side to this, however, is that every system is engineered by the vendor specifically for your application, and provided with schematics and a Bill of Material to include in your CMMS and/or maintenance files. Coming Up In the next issue, we’ll discuss Single Line Resistance (SLR) centralized lubrication delivery systems. LMT For more details on centralized lubrication systems, see Ken Bannister’s book, Lubrication For Industry, published by Industrial Press, or contact him directly. Telephone: (519) 469-9173; e-mail: kbannister@engtechindustries.com. For more info, enter 02 at www.LMTfreeinfo.com
JANUARY/FEBRUARY 2011
©
We’re Looking For Lube Starz ! ©
© LASSE KRISTENSEN - FOTOLIA.COM
■ Monitoring The System To ensure every point has delivered a charge of lubricant, the first valve in the divider block can be attached to a cycle pin indicator that visually indicates the block has completed one full cycle by moving in and out one time. Attaching a counter/timer control to the cycle pin will indicate if no delivery has taken place within a given time period and signify a broken main delivery line. Blocked and crimped lines can be visually detected via simple mechanical overpressure indicators connected at the secondary delivery-line block outlet. Whenever a “restriction”-caused hydraulic backpressure is sensed, a visual indicator pin “pops” up to indicate the exact line/ bearing point requiring maintenance. If no electronic alarm sensors are used, operations and/or maintenance must perform regular visual checks for alarm indications.
Where Are You? Our new Lube Starz Section is all about our readers, the hardest-working lube pros in the universe! Are you game? If so, please identify yourself. We want to learn who you are, where you work, how long you’ve been in your current position, what brought you to the lubrication field and what you like most about your job. If you’re chosen as the subject of a short, published profile, you’ll soon be reading about yourself in an upcoming Lube Starz Section in LUBRICATION MANAGEMENT & TECHNOLOGY and on our Website. On top of that, each person profiled in this section will receive a baseball cap designating him/her as one of our honest-to-goodness Lube Starz. Go to www.LMTinfo.com/LubeStarz and download the profile form. Fill it out and follow the instructions for submitting it with your photo. That’s all there is to it.
Start Shining! Let Us Hear From You Soon! www.LMTinfo.com/LubeStarz
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UM BIG MONEY TALKS William C. Livoti
What’s New in 2011: Pending Regulation
A
s we enter a new year, let’s first reflect on the past. What actions (changes) have we as a country undertaken to improve our environment, economy and overall quality of life? If that sounds like a trick question, it is. It’s also intended to be thought-provoking. Legislation to address environmental issues has the potential to significantly impact our economy and—consequently—the quality of our lives. Unfortunately, some proposed legislation could play a role in stalling what most of us would characterize as a painfully slow economic recovery. A number of power companies say new rules won’t stop them from expanding over the next few years. Others are replacing coal-fired plants with cleaner natural-gas plants to avoid pending legislation that could force coal plants to install Carbon Capture and Sequestration technology at significant cost. Let’s understand what’s on the table. As noted by Power-Gen Worldwide (www.power genworldwide.com), the North American Electric Reliability Corp. (NERC) has analyzed the potential impact of four rules under development by the EPA. They are the Clean Water Act — Section 316 (b), involving cooling-water intake structures; Title I of the Clean Air Act — National Emission Standards for Hazardous Air Pollutants (NESHAP) for the electric power industry, also known as the Maximum Achievable Control Technology Standard; the Clean Air Transport Rule; and Coal Combustion Residuals (CCR) Disposal Regulations. The proposed regs specifically involve: ■ Sulfur dioxide and nitrogen oxide caps ■ Reconsideration of the ambient ozone standard ■ Limitation of power-plant mercury emissions ■ A rule to tighten controls on power-plant coolingwater intakes ■ Another rule for managing coal ash
NERC’s analysis* points to a number of possible repercussions, should these new rules take effect: ■ We could lose up to 19% of our fossil-fired steam capacity by 2018. ■ Planning of reserve margins could be affected. ■ Reserves could fall below reserve margins in about half of NERC regions (U.S., Canada and part of Mexico) by 2015. ■ Plant retirements could exceed 50GW on a fleet capacity of 340GW (15%). ■ 100GW (existing plants) would require “large investment” to meet emission rules. ■ Retirements could cut demand for steam coal by 15-31%. ■ Natural-gas demand could grow 8-16% as some coal plants are replaced. ■ Coal plants could close due to “economics.” (Coal prices are a premium to natural gas by themselves. Now add the cost of environmental controls.) I believe in protecting our environment, cutting energy consumption and reducing greenhouse gases—who doesn’t? That said, we need to approach these issues with a great deal of common sense. Pending regulations could be tantamount to cutting off our collective noses to spite our faces. LMT *To read the referenced 2010 NERC analysis “Potential Resource Adequacy Impacts of U.S. Environmental Regulations,” go to http://www.nerc.com/files/EPA_ Scenario_Final.pdf
Bill Livoti is a fluid power and power industry engineer with Baldor Electric Company. Telephone: (864) 281-2118; e-mail: wclivoti@baldor.com. For more info, enter 260 at www.LMTfreeinfo.com
18 | UTILITIES MANAGER
VOLUME 6 / NO. 1
UM UTILITIES MANAGER Part I of II…
Making Energy Savings Happen Through People ©DMITRIY MEINIKOV - FOTOLIA.COM
Energy-efficiency isn’t just about technology. If your organization hasn’t adjusted its culture to help raise and sustain the energy consciousness of your human assets, now’s the time to do it. Henry Molise, P.E. HCM Energy Consulting, LLC
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requently, even successful world-class organizations have difficulty conserving energy and cutting the cost of utilities. This is despite the availability of more costeffective energy-management technologies than ever before. Some may be satisfied with implementing a few immediate, finite savings—proverbial “low-hanging fruit.” Such a strategy often captures only part of the potential savings for existing facilities, without ensuring that future operations will be energy-efficient. For those who wish to achieve energy savings over the long haul, modest adjustments in the culture of an organization can motivate people toward continuous improvement.
The most successful—sustained—energy-management system is developed as a business process within the organization. Most employees really want to help cut costs and reduce energy-related emissions; they’ll do just that if provided with the needed direction, training, resources, incentives, recognition and rewards. It may take a few years for energy-management to fully gain momentum in an organization, but it’s worth the effort for both the bottom line and the environment. In this first installment of a two-part series, the focus is on a framework of business principles for initiating and administering an organizational energy-management system. The second installment (coming in a special UTILITIES MANAGER follow-up in a later issue of LMT) will discuss actual energy-saving implementation strategies. Volume 6 / no. 1
utilities manager | 19
UM UTILITIES MANAGER
Understanding the energy perspective of the site manager To understand the challenge of achieving energy savings, consider the priorities of a site manager—which often can be summed up as follows: n Get the product or service out the door. n Have the work performed safely. n Comply with laws and regulations. n Keep facilities maintained for reliability and longevity. n Minimize costs. In the above list, energy-management would fall into the fifth priority. A further challenge is that energy costs are often a small percentage of the total expense budget. Yet most site managers and their bosses would welcome a reduction in energy costs and a reduction in environmental impact— as long as these reductions are consistent with financial and other organizational objectives. Energy policy: Support from the top The most successful approach to an energy-management culture is to begin from the top down—in the form of a commitment from the top. Thus, the first action to develop the needed organizational culture is development of an energy policy that is endorsed by senior management. The energy policy needs to be only a short, simple statement of what is to be achieved from a broad perspective, and it can be drafted at almost any level of the organization. A few paragraphs can be written to express that the organization, with respect to energy-efficiency, will have a policy to: n Reduce the life-cycle costs of energy and utilities. n Reduce energy-related emissions, on-site and off-site.
Senior management will also have a follow-up role in recognizing and praising energy-related achievements. Without the up-front commitment of senior management, progress in energy reduction and the associated cost savings is likely to be limited and slow. Steering the effort Once an energy policy is in place, the use of a steering team is the best way to develop a strategy for implementation of the policy. Ideally, the team should represent a cross-section of the organization in terms of: 1) function and/or division; 2) geography; 3) specialists in engineering, operations and maintenance; and 4) ad-hoc representatives of procurement, finance, environmental affairs and communications. The team can be led best by a person designated as the organization’s “energy champion” or energy manager. The steering team should make use of the ideas of others wherever possible, such as: n The U.S. Environmental Protection Agency (EPA)/Dept. of Energy (DOE) Energy Star and state energy programs n Trade organizations n Your local utility suppliers’ Websites n “Sister” facilities within the same organization n Competitors or comparable outside organizations n Consultants Even in businesses where competitors would never share production technology, research technology or other trade secrets, they often are very willing to share information on how to conserve energy and utilities. Goal development Measurable goals need to be developed by the steering team. The improvements can be expressed in terms of:
n Be a good citizen in conserving resources. n Enhance public image.
n Percentage reductions or absolute reductions—These include units of energy usage, costs and related emissions.
After internal reviews, endorsement and internal publication of the energy policy need to come from as high in the organization as possible (preferably from the chief executive officer).
n Public-relations image and community relations—These include favorable news coverage and public recognition by community leaders.
REMEMBER: The greatest chance of success will occur when the regular performance reviews of all levels of management include demonstrated progress toward the energy policy. 20 | utilities manager
n Local, regional or national awards In the setting of goals, the steering team needs to address this question: What counts besides energy? Other potential measurable savings from energy-management include: Volume 6 / no. 1
UTILITIES MANAGER UM
n Savings in utilities-system equipment procurement. Examples include: ◆ Potential capital-spending avoidance or postponement
for an additional air compressor, pump, chiller, boiler, electric substation, air handler, piping or duct system ◆ Capital savings from bulk-purchasing of energy-efficient equipment
n Total energy usage, all expressed in a single unit (e.g., BTUs, Joules, kilocalories). (Note that the energy represented by electricity can be expressed in two ways—as delivered [3413 BTU/kWhr], or as produced [often about 10,000 BTU/ kWhr]. The off-site impact is expressed as the latter of the two.)
n Water- and sewer-use savings
n On-site utilities production (e.g., steam, compressed air, chilled water)
n Energy-related maintenance and safety improvements
Demand-side information to keep includes:
n Increased equipment production capacity and reliability
n Sub-meter data
n Improved human productivity due to increased levels of comfort
n Energy usage per unit (e.g., BTU/square ft., BTU per unit of product, energy input per unit of output)
Counting these additional related savings will substantially increase peoples’ interest in managing energy.
n Results of energy and cost-saving actions taken (metered or calculated), to identify progress toward the goals (including savings per unit of time [e.g., monthly and annually] expressed as energy units, cost and emission reductions [tons of carbon dioxide])
Goal-related measurements The two basic types of energy-saving-initiative measurements are: 1) metered; and 2) calculated. In a perfect world, all energy savings would be metered. In reality, the cost of metering the exact savings is most often not justified by the accuracy gained. Therefore, engineering calculations must often be accepted to determine savings in lieu of metering. In calculating annual savings—or attempting to meter savings—there’s often difficulty in making adjustments for effects of year-to-year production activity, weather-related energy usage and/or other variables. The simplest goal is, perhaps, expressed as an annual percentage reduction, whereby the numerator is the metered or calculated savings for all initiatives implemented in the present year, and the denominator is the total energy usage or cost from the previous year. Reporting the results Whatever measurement system is developed, it must reflect the organization’s energy policy and goals. For operations with multiple sites or units, a uniform reporting system is necessary. Results need to be kept in a spreadsheet format that is capable of statistical analysis. Assistance of specialists may be needed—for example, in calculating emission reductions related to energy conservation. If at all possible, the results should be available for viewing by anyone in the organization, such as on an Intranet Website. Supply-side information that needs to be kept by time period includes: n Purchased utility usage and cost (e.g., electricity, natural gas, water, sewage-treatment services) Volume 6 / no. 1
Benchmarking performance Where possible, comparison of a site’s energy performance should be made against similar facilities. Seek indices that compare unit values, such as BTU/square foot, BTU per unit of production or input versus output. In addition, perform benchmarking of unit energy and utility costs if available. Weatherrelated adjustments may be made using local degree-day data. A site’s performance can be compared with other facilities within the same organization—or from outside the organization. The most confidence in the results of benchmarking comes when more than one benchmark measurement is used. Use the findings from benchmarking to prioritize future efforts. Financial criteria The financial specialist is a key ally in energy management: He/she must define the approved hurdle rate for capital investments in energy reductions. The hurdle rate may be expressed in terms of payback period or rate of return. Energy investments can typically use the organization’s normal process for capital and expense appropriations, for which the financial specialist is an advisor. REMEMBER: More energy-saving initiatives will be implemented where projects with returns not quite meeting the hurdle rate can be packaged with projects that surpass the hurdle rate. This results in the largest possible package of savings, while still meeting the required hurdle rate.
utilities manager | 21
UM UTILITIES MANAGER
Furthermore, an understanding is needed as to whether non-monetary factors can be used to help justify energyimprovement projects, such as associated improved reliability, safety or public image. Energy-improvement projects tend to have lower risk than most other investments, and therefore may justify a less stringent hurdle rate than some other projects. For example, compare the risk of return on an energy-savings project with the risk of investing in the research and development of a new product, building facilities to manufacture it and then hoping that customers will buy it. Too many times, systems that use large amounts of energy are specified and selected based on capital cost only. Design and selection decisions for such facilities need to be made based on life-cycle cost (LCC), rather than first cost. Consider the total cost of ownership (TCO) of a boiler, chiller, air compressor, pump or HVAC system—or, perhaps, even an entire building or production process. Frequently, less than 10 to 20% of the TCO is represented by the capital cost, while more than 80 to 90% of cost is for energy expenses. The lowest LCC alternative is not always the one with the lowest capital cost. The most common reason for making decisions
Green•Efficient•Reliable They’ll be showcased regularly in our pages over the course of the year. Watch for them. These sections are designed to put a big spotlight on all types of products to help you do your jobs better. Lots better.
Next Issue: ©S - FOTOLIA.COM
Efficient Gadgets NOTE TO ADVERTISERS:
Got a Gadget to Spotlight? Call Your Sales Rep Today, Or Contact Kathy Jaros 847.382.8100 x 117 kjaros@atpnetwork.com
Henry Molise is president of HCM Energy Consulting, LLC. A registered professional engineer in Michigan, he has 30 years of experience as a corporate energy manager and environmental engineer in the pharmaceutical industry. Molise is past chairman of the Energy Committee of the Michigan Manufacturers Association. E-mail: hcmolise@juno.com.
Green
High-Temperature Air Amplifier For Moving Hot Air
XAIR’s new High Temperature Air Amplifier offers a simple, low-cost way to move high volumes of hot air to surfaces requiring uniform heating while in a furnace or oven. Amplifying airflow up to 18:1 at outlet, it’s most efficient for pushing high volumes of hot air to points that typically remain cool. With no impellers or moving parts to wear out, it’s rated for environments (even corrosive ones) up to 700 F (374 C). The unit’s surface is protected by a mil-spec coating process (developed for the aircraft industry) that allows for easy disassembly or cleaning. Efficiency is high; the sound level is low (at only 72 dba). Applications include directing hot air to mold cavities for uniform wall thickness of plastic parts, exhausting smoke and fumes, distributing heat in ovens or molds and sampling flue gases. The High Temperature Air Amplifier is constructed of type 303 Stainless Steel and available in 1-1/4” (32mm) diameter only. Prices start at $359. EXAIR Corp. Cincinnati, OH www.EXAIR.com
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A framework for success In summary, the framework described here in Part I of this series, is for initiating and administering energy management as a good business practice. This can usually be accomplished consistent with the long-standing objectives of the organization, beginning with an energy policy. Look for the concluding installment, Part II, when we will discuss implementation and follow-up strategies for success. LMT
Gadgets
We’ve Got Gadgets Galore!
based only on capital cost(s) is that it takes more effort and understanding to calculate LCC than it does to identify capital costs. The financial specialist can assist engineers and managers with LCC calculation methods. The extra effort is well worth it—and can literally help pay dividends.
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22 | utilities manager
Volume 6 / no. 1
Easy On. Easy Off.
Baldor•Dodge® hydraulically-assisted ISAF bearings are so easy to install and remove you won’t believe it until you see it. Simply slip the bearing on the shaft, apply hydraulic pressure to position the bearing on the adapter sleeve and you’re ready to go. To remove, apply hydraulic pressure to the dismount piston and the bearing is pushed off the adapter sleeve. No feeler gauges or special tools needed. Plus, once it’s installed, the full shaft contact eliminates fretting corrosion. Each bearing arrives fully assembled, sealed and lubricated for even easier installation than ever before. No wonder a prestigious trade publication recognized Baldor•Dodge ISAF hydraulically-assisted bearings as a product of the year winner. Easy on and off bearings… only from Baldor. dodge-pt.com
baldor.com
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LAB SPOTLIGHT
Introduction To Common Oil-Analysis Tests (And How To Take A Successful Sample) Ray Thibault, Contributing Editor
O
il analysis is one of the most valuable condition-monitoring tools available to reliability-focused operations. Why? It can save countless dollars by preventing equipment failures and helping maximize the life of lubricants. Oil analysis tells us the condition of a lubricant, which, in turn, lets us be proactive about replacing it before equipment damage occurs. Wear debris analysis—a specific type of oil analysis—also can tell the condition of equipment, which allows us to respond to potential failures at an early stage. In short, the proper use of oil analysis can help: ■ Improve asset reliability
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■ Acid Number measures acid buildup, which denotes oxidation. ■ FTIR measures chemistry changes in a lubricant, which are good indicators of oxidation and nitration. ■ Base Number is for engine oils. It measures the depletion of the detergent, which neutralizes acids. ■ Flash Point is a measure of light components, which lower the viscosity of lubricants. ■ Particle Counts, by size and amount, are determined with the use of a laser counter.
■ Identify and eliminate repetitive equipment problems ■ Voltammetry measures depletion of antioxidants in lubricants. ■ Reduce unscheduled maintenance ■ Maximize use of lubricants in service ■ Reduce maintenance and lubrication costs
Tests for equipment condition through the measurement of wear debris include: ■ Atomic Emission Spectroscopy measures metals in parts per million (limited to particles under 10 microns in size).
■ Extend equipment component life Tests for oil condition include: ■ Viscosity measures the resistance of a fluid to flow, is the most important property of a lubricant. ■ Karl Fischer measures all forms of water at low levels and is recommended for industrial equipment. (The Qualitative Crackle test is used for engine oils.) 24 | LUBRICATION MANAGEMENT & TECHNOLOGY
■ Ferrous Density, both direct-read ferrogram and particle quantifier, measures ferrous particles without the size limitation of emission spectroscopy. ■ Analytical Ferrography looks at size, shape and color (the three most important physical characteristics of a particle) to determine the wear mechanism and severity in machinery. This is the only common oil-analysis test that can justify equipment shutdown. JANUARY/FEBRUARY 2011
LAB SPOTLIGHT
Sampling Guidelines Any successful oil-analysis program begins with sampling. Remember, though, that bad data is worse than no data. Thus, if you’re collecting samples incorrectly, an oil-analysis program is a waste of time and money. Key guidelines include: ■ Take warmed-up machine samples while equipment is running. If that’s not possible, sample no later than 30 minutes after shutdown ■ Use clean, sealed bottles and flush the system properly (at least 5-10 times the sample-line volume). This is critical when running particle counts.
Integrity
■ Collect samples from the right location: ❖ Sample from live fluid zones. Fluid is moving through the system. The best spot is the return line back to the reservoir. ❖ Sample, if possible, from a turbulent region (such as an elbow) to get better particle distribution.
ice
Customer Serv
❖ Sample downstream from components such as bearings, gears, etc. Never sample after a filter, unless you’re trying to determine filter efficiency. ❖ Sample from the same location each time. This is difficult with static sampling, especially with the use of a plastic tube and vacuum gun. Use permanent pitot tubes, where possible, when conducting static sampling. Never do drain samples from the bottom of a reservoir.
Dedication
■ Properly document samples on the sample bottle. It’s not uncommon for incorrect information to end up on a sample bottle, which leads to erroneous results. ■ Send samples immediately to the laboratory. An unsent sample may contain information on potential problems that can’t be identified until the sample is analyzed.
Systems
■ Properly establish sample intervals based on the following criteria: ❖ Criticality is the most important factor. The typical interval for critical equipment is monthly. ❖ OEM recommendations are important. Some OEMs provide samplinginterval guidelines. ❖ Environmental conditions can dictate frequency. Severe environments necessitate more frequent sampling. ❖ Current PMs and lube- and filter-changing schedules can also dictate sampling frequency.
Technical A b
ility
Why would you need to use any other lab? Contact Herguth Laboratories, Inc. today to find out what sets us apart.
❖ Historical problems with the equipment (or similar equipment) may call for more frequent sampling. What’s Next? During 2011, this column will explore some of the most important oil-analysis tests. In the next issue, the focus will be on Particle Count Testing. LMT For more info, enter 03 at www.LMTfreeinfo.com JANUARY/FEBRUARY 2011
1-800-OIL-LABS • www.herguth.com
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CONTAMINATION SOLUTIONS SHOWCASE
Selecting The Right Breathers For Bath-Lubricated Systems A “one-size-fits-all” approach to contamination solutions won’t take your program where it needs to go. Jarrod Potteiger Product and Educational Services Manager Des-Case Corporation
T
o achieve a world-class lubrication program, standards must be developed for how to modify each common type of machine for lubrication, contamination control, inspections and oil sampling. While traditional desiccant breathers work quite well for most applications, they may not always be the best choice. Bath-lubricated systems don’t normally breathe very much—thus, they put only a moderate demand on the breather with respect to dehumidification. The problem with using a traditional disposable desiccant breather for such an application is that the breather is always exposed to the ambient environment and always stripping moisture, whether the system is breathing or not. As a result, the life of the breather is unnecessarily curtailed, potentially requiring frequent replacement. Many users choose to continue with the use of standard breathers in these circumstances as the value is still there, BUT there is a better way: Seal the breather when the system isn’t breathing. That’s the idea behind hybrid breather technology. The Better Way/The Best Fit Hybrid breathers combine the features of traditional desiccant breathers with expansion chambers and low-pressure check valves so that the system is effectively sealed until it needs to breathe as a result of expansion or contraction in the headspace. With the desiccant stage protected from the ambient environment, the breather only dehumidifies the incoming air, thereby increasing the life of the breather significantly. In humid environments, it is common for hybrid breathers to last five or more times longer than traditional desiccant breathers. 26 | LUBRICATION MANAGEMENT & TECHNOLOGY
Des-Case Hydroguard Breather
When volumetric changes are relatively small, the bladder system in a hybrid breather—such as Des-Case’s Hydroguard™— inflates or deflates. When this volume is exceeded, the low-pressure check valves on the bottom of the breather open to allow the exchange of air with the environment, wherein the air is filtered and dehumidified as with a typical desiccant breather. For any system that breathes intermittently and has an airflow rate requirement below 2.5 cfm, the hybrid breather is by far the best option. The use of these breathers, combined with good seals and good oil-handling practices, will often reduce the frequency of need for periodic offline filtration— allowing cleanliness targets to be met with minimum effort. For those applications that are exposed to very humid environments or washdown activities, but also require large air-flow capacity, there are breathers equipped with large check valves, like Des-Case’s Extreme Duty breather: It can accommodate flow rates of up to 16 cfm while still protecting the desiccant from unnecessary exposure to moisture. The Extreme Duty breather doesn’t have an expansion bladder, but does offer a rugged, automotive-grade housing for applications exposed to high vibration levels. When it comes to selecting breathers, the “one-size-fits-all” approach is not really ideal. Today, there are many different designs available and there is definitely a best fit for each particular application. Breather selection is an important part of the process of developing a world-class lubrication program and should not be oversimplified. LMT E-mail Jarrod Potteiger at jarrod.potteiger@descase.com. For more info, enter 04 at www.LMTfreeinfo.com SPONSORED INFORMATION
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PROBLEM SOLVERS
Cooling-Lubricant Supply System
R
exroth’s new Rapidstar Supply Unit (RSU) supply system for cooling lubricants offers the advantages of a modular system for low- and high-pressure supply. When paired with the company’s KST booster, high-pressure generation is moved into the hydraulic unit when internally cooled tools are used. This omits the motor-pump supply line on the cooling-lubricant side and reduces energy consumption up to 88%. Bosch Rexroth AG Hoffman Estates, IL
For more info, enter 30 at www.LMTfreeinfo.com
Chemical-Resistant Bearing
T
he iglide® C210 bearing from igus® delivers superior resistance to a range of acids, solvents and hydrogen peroxide, and can handle continuous temperatures of 212 F. As with all iglide products, the bearing’s tribo-polymer is lubricationfree and corrosion-resistant, making it resistant to the aggressive chemicals used in food and packaging industries.
igus, Inc. East Providence, RI
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Bio-Based Penetrating Lubricant
G
2 Fuel Technologies’ Bio-blast is a fast-acting, penetrating lubricant with patented additives and bio-solvents that won’t stain metals. It drives out moisture, providing a high dielectric insulating property in electrical equipment and removing rust and dirt. This recyclable product contains no VOCs, is USDA-certified as Bio-Preferred and meets ASTM D-5864 standards for ultimate biodegradability. G2 Fuel Technologies Tampa, FL
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7-Step Best Practice Lubrication Program Professional Self-Directed Implementation ToolKit
Tap into your Liquid Gold for less than $20 per day!* Whether you’re looking to increase asset utilization and maintainability, reduce contamination, downtime, energy consumption and/or your carbon footprint, or simply cut your maintenance and operating costs, you’re ready for a 7-Step Best Practice lubrication program! For more information on this “expert in a box” approach to successful lubrication programs, contact ENGTECH Industries at 519.469.9173 or email info@engtechindustries.com * Amortized over one year
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28 | LUBRICATION MANAGEMENT & TECHNOLOGY
JANUARY/FEBRUARY 2011
PROBLEM SOLVERS
Variable-Area Lubrication Flowmeters
Tough Food Grade Lube
U
J
niversal Flow Monitors has added compact, noncontact magnetically coupled transmitters to its line of variable-area lubrication flowmeters, replacing potentiometers that can easily wear out. Optional alarm switches protect machinery and minimize downtime in the event of flow failure. The entire line can be used when local flow indication and mechanical flow switching or 4-20 mA transmitters are desired. Universal Flow Monitors, Inc. Hazel Park, MI
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Dual-Gauge Filter Adapter
T
he LF-9904 dual-gauge adapter from Schroeder Industries fits in the existing pressure indicator port of any Schroeder filter, providing a fast and safe way to take oil samples or test pressures in hydraulic or pneumatic systems under operation. Its two ports can sample upstream and downstream fluid, which allows for the use of two test points not previously built into the filter. The adapter’s standard Viton seal is compatible with most hydraulic fluids and petroleum products. Schroeder Industries Leetsdale, PA
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&B Industries offers White Guard Supreme H-1 Food Grade lubricant (fortified with PTFE) for use in a number of applications, including food processing and packaging. According to the company, the product is highly resistant to heat, water washout, acid and alkaline cleaners such as those found in meatpacking plants, water and wastewater treatment facilities, bottling operations, bakeries and canneries. With its rust and corrosion inhibitors, White Guard Supreme is well suited for conveyors, rollers, slides, bearings, chains, sprockets and guide rails. It has a Timken load of 40 and a drop point of 510 F. J&B Industries Rio Hondo, TX
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Additions To Machine-Safety Line
Customized, Targeted Lists For Your Marketing Needs
E
ATP List Services
lobau’s machine-safety line now includes solenoid interlocks, emergency stop buttons and standstill monitors that complement the company’s safety sensors and control units for applications up to SIL 3 and PLe. Safety sensors in SS housings for food processing applications also are available. Elobau Sensor Technology, Inc. Gurnee, IL For more info, enter 35 at www.LMTfreeinfo.com JANUARY/FEBRUARY 2011
Ellen Sandkam
www.atplists.com 1300 S. Grove Ave., Suite 105, Barrington, IL 60010 847-382-8100 x110 / 800-223-3423 x110 info@atplists.com / esandkam@atplists.com For more info, enter 72 at www.LMTfreeinfo.com
www.LMTinfo.com | 29
CLASSIFIED
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
1300 South Grove Avenue, Suite 105 Barrington, IL 60010 PH 847-382-8100 FX 847-304-8603
Specializing In
Machinery Health Personnel PM & PdM Field Service • Mgt • Sales • Hrly
www.LMTinfo.com
SALES STAFF
Nationwide • Confidential • All Fees Company Paid
OH, KY, TN 135 N. Rocky River Road Berea, OH 44017 440-463-0907; Fax 440-891-1254 JOHN DAVIS jdavis@atpnetwork.com
www.lineal.com lisalineal@lineal.com
TOLL FREE 877-386-1091 For rate information on advertising in the Classified Section Contact your Sales Rep or JERRY PRESTON: Phone: (480) 396-9585 e-mail: jpreston@atpnetwork.com
Customized, Targeted Lists For Your Marketing Needs Ellen Sandkam www.atplists.com
ATP
List Services
847-382-8100 x110 / 800-223-3423 x110 info@atplists.com / esandkam@atplists.com
Index ADVERTISER
JANUARY/FEBRUARY 2011 Volume 12, No. 1 •
WEBSITE
CIRCLE #
PAGE #
A2 Technologies ................................ www.a2technologies.com ....................... 62..................... 5 ATP Lists ............................................ www.atplists.com .................................... 72................... 29
AL, SoCA,** DC, DE, FL, GA, MD, MS, NC, NJ, PA, SC, VA, WV 1750 Holmes Drive West Chester, PA 19382 610-793-3093; Fax 610-793-3094 JIM HANLEY jhanley@atpnetwork.com AR, AZ, CA,* CO, KS, NV, NM, OK, UT 3629 N.Sonoran Heights Mesa, AZ 85207 480-396-9585 JERRY PRESTON jpreston@atpnetwork.com CT, ME, MA, NH, NY, RI, VT, ON, QC P.O. Box 1059 Osterville, MA 02655 508-428-3331; Fax 508-428-2545 VINCENT LeGENDRE vlegendre@atpnetwork.com
Baldor Electric Company................. www.dodge-pt.com................................. 68................... 23 Bel-Ray Company ............................. www.belray.com ...................................... 61.................IFC Des-Case Corporation ..................... www.descase.com/flowguard ................. 70................... 27 Engtech Industries Inc...................... www.engtechindustries.com .................. 71................... 28 EXAIR Corporation ......................... www.exair.com ........................................ 67................... 22 Herguth Laboratories, Inc................ www.herguth.com................................... 69................... 25 Hy-Pro Filtration .............................. www.hyprofiltration.com....................... 63..................... 7 Lanxess Corporation ........................ www.mpp.us.lanxess.com ...................... 64..................... 9 Lube Starz .......................................... www.lmtinfo.com/lubestarz................... 66................... 17 MARTS .............................................. www.martsconference.com.................... 73................... 31 Royal Purple ...................................... www.royal-purple-industrial.com......... 74..................BC
Access LMTfreeinfo.com and enter the circle number of the product in which you are interested, or you can search even deeper and link directly to the advertiser’s Website. Submissions Policy: Lubrication Management &Technology gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish, and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. 30 |
LUBRICATION MANAGEMENT & TECHNOLOGY
IL, IN, KS, LA, MI, MN, MO, OR, TX, WA,WI, BC 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 847-382-8100 x108; Fax 847-304-8603 TOM MADDING tmadding@atpnetwork.com IA, MT, NE, ND, SD, WY, AB, MB, SK 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 847-382-8100 x106; Fax 847-304-8603 ARTHUR L. RICE arice@atpnetwork.com CLASSIFIED ADVERTISING 3629 N.Sonoran Heights Mesa, AZ 85207 480-396-9585 JERRY PRESTON jpreston@atpnetwork.com
* CA (from LA – North) **SoCA (from Orange County – South) JANUARY/FEBRUARY 2011
Reliability Is Gold Meet The Experts At
MAINTENANCE and RELIABILITY TECHNOLOGY SUMMIT
The Capacity Assurance Conference!
APRIL 26-29, 2011 MARTS 2011 Attendees Will Enjoy... • A four-day educational experience created exclusively for reliability professionals
• 30 hour-long Conferences over two days – Wednesday, April 27 and Thursday, April 28 – kicked off by international reliability expert and best-selling author James Reyes-Picknell • 7 full-day Workshops on Tuesday, April 26 • 6 full-day Workshops on Friday, April 29 • Two professional certification opportunities Now entering its eighth year, MARTS is an exciting learning event in a great location that helps reliability professionals at all levels improve their skills and excel on the job. Pricing and attendance options for every budget make it easy for individuals or groups to share the MARTS experience. Registration is open at www.martsconference.com
The Capacity Assurance Conference! MAINTENANCE and RELIABILITY TECHNOLOGY SUMMIT
APRIL 26-29, 2011
Hyatt Regency O’Hare, Rosemont (Chicago), IL
www.MARTSconference.com For more info, enter 73 at www.LMTfreeinfo.com
“...we extended drain intervals from every 15 days to every three months AND reduced engine repairs and replacements.” Luis Garza Kingfisher Marine Most efforts to improve operating efficiency and lower maintenance costs are labor intensive and involve painful cultural changes. Numerous progressive companies have experienced significant cost savings simply by upgrading lubricants. You can learn how by reading the special report ‘Lowest Total Cost of Ownership’. This special report includes extensive case studies that document real-world savings through lubricant upgrades. Get your FREE copy of the ‘Lowest Total Cost of Ownership’ today by calling 866-447-5173 . . .
For more information on Royal Purple, visit royal-purple-industrial.com today.
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