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L I N E A R
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T E C H N I C A L
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MARch/APRIL 2011 • vOL 12, nO. 2 • www.LMTinfo.com
contents
AchIevInG effIcIencIeS ThROUGh PRAcTIceS & PRODUcTS
FeAtures PROfeSSIOnAL DeveLOPMenT SeRIeS 8
certification Matters, Part I: The fundamentals Of Lubrication The foundation on which those who seek certification must begin building their lube bona fides starts here: with the basics of the craft.
Ray Thibault, Contributing Editor
DeLIveRInG The GOODS 16
The Anatomy Of A centralized Lubrication System: Single Line Resistance (SLR) Systems
Which centralized, automated lube-delivery system is best for an application? This month, we examine the grandfather of them all. Ken Bannister, Contributing Editor
dePArtMeNts
LAB SPOTLIGhT 18
Particle counting: Importance & Application
A key component in developing and maintaining an oil-cleanliness program is the ability to accurately measure that cleanliness. The most common method involves optical particle counters.
Ray Thibault, Contributing Editor
UTILITIeS MAnAGeR 20
Making energy Savings happen Through People, Part II You’ve set up a steering team to help drive your organization’s energy-management efforts. Now it’s time to look at the roadmap. Henry Molise, P.E., HCM Energy Consulting, LLC
4 6 26 28 29 29 30
My Take from Our Perspective Problem Solvers Info highway Classified Supplier Index Lube Starz
PRODUcT ShOWcASe
24
Grease Spots Here, in the words of several leading suppliers, is a sampling of the grease solutions available for your applications.
The Capacity Assurance Conference! MAiNteNANce and reliAbility techNOlOGy suMMit
APril 26-29, 2011
Hyatt Regency O’Hare, Rosemont (Chicago), IL
MARCH/APRIL 2011
The Time To Decide Is
NOW!!!
www.MARTSconference.com www.lmtinfo.com | 3
MY TAKE
Jane Alexander, Editor-In-Chief
Going All In On Innovation
T
hat’s right: Applied Technology Publications (ATP), the parent of Lubrication Management & Technology and its sister publication, Maintenance Technology, is going all in on innovation with the “2011 Maintenance & Reliability Innovator of the Year Award.” While we’ll roll out this program with a big bang at our upcoming MARTS event (www.MARTSconference.com) the last week of April, here’s a preview of how you can participate and what’s in it for you if you do: Starting in May, you can submit your innovations (one entry per person) for judging through a special Website set up solely for this purpose. (Full details on this and what to include in your submission will be published in the May/June 2011 issue of this magazine and on www.LMTinfo.com.) Your innovation must be original—not plagiarized from other sources. You’ll also need to sign a publication release that will allow us to share your idea with the public at large. If your innovation is in use at your facility and/or if you have an employment condition requiring you to disclose all ideas to your company, you’ll also need to provide a publication release from your employer. Ideally, your submitted innovation should be capable of being used by others. The judges will expect you to explain why you came up with your idea; what it does; and what impact it has in terms of reliability, uptime, availability, throughput, safety, environment, efficiency, etc. Innovations will be categorized into one of three groups: (1) devices, gizmos and gadgets; (2) processes and procedures; and (3) innovative use of outside resources (i.e., third-party tools, including software). We’ll accept entries from May 1 to December 31, 2011, and score them based on practicality, simplicity and impact. Don’t wait until the last minute: There’s too much on the line. For one thing, starting this summer and running through December, we’ll be picking six monthly “Innovator” winners from all entries that have been received. Why bother to enter? In early 2012, you might be named as a category winner (see above), or even find yourself honored as the grand-prize “2011 Maintenance & Reliability Innovator of the Year”—and enjoying the bragging rights and other things that come with it. (Award ceremonies and prize presentations will be at MARTS 2012.) As for WHAT prizes, you’ll have to wait until the official award program rollout at this year’s MARTS to learn more. Let’s just say that ATP and several very innovative sponsors (including Inpro/Seal) have some great things up our sleeves! LMT
Achieving EffiCIencies THROUGH PRACTICES & PRODUCTS
March/April 2011 • Volume 12, No. 2 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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lubrication management & technology
MARCH/APRIL 2011
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DesigneD to Meet cHallenges™ The term “Shell Lubricants” refers to the various Shell Group companies engaged in the lubricants business. © 2011 SOPUS Products. All rights reserved.
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FROM OUR PERSPECTIVE
Ken Bannister, Contributing Editor
‘Survival Is Not Mandatory!’
T
he global economic recession and more recent geopolitical turmoil in parts of the world have forced us in North America to adjust to a new lifestyle—corporately and personally. The new reality is that managers must be willing and able to rapidly adjust their thought processes, methods and strategies to align with the ever-changing daily realities facing industries everywhere. W. Edwards Deming, the legendary consultant responsible for Japan’s post-war industrial success, argued that management has a choice: “It is not necessary to change,” he asserted. “Survival is not mandatory!” Published in 1993, his last work, The New Economics for Industry, Government, Education, reflected his system of knowledge and 14 principles for management (credited by Ford for helping it reverse $3 billion in losses between 1979 and 1982 and become America’s most profitable carmaker by 1986). Deming’s teachings are based on work quality from the onset—and that quality is everyone’s responsibility. This translates not only to the work we perform, but also to the goods and services we procure and use on a daily basis. Buying solely on cost is not an option. Japanese corporations have long known this and award their highest industrial honor, the Deming Prize, to organizations with sustained OEE (Overall Equipment Effectiveness) of 85% or higher. Many of you will recognize OEE as part of a Total Productive Maintenance (TPM) approach in which the maintenance department is both directly and indirectly responsible for asset availability, rate of product quality and rate of product throughput. Working as part of a combined team effort with Operations, Engineering and our suppliers, it’s incumbent upon the maintenance department to provide a solid foundation on which a product, process or management-style change can be accomplished quickly and successfully. This type of foundation is built on a qualitybased preventive maintenance program whose success isn’t measured by compliance, but rather by its
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LUBRICATION MANAGEMENT & TECHNOLOGY
effectiveness in preventing failure and the ability to deliver asset availability at the design level.
If a business wants to survive, managers must be willing and able to adjust and adapt quickly. Best-practice organizations adapt quickly. They understand the need for flexible management capabilities based on the previously referenced solid foundation, including: n A PM program built on a backbone of effective lubrication, cleanliness, alignment and torqued fastenings. n A planning-and-scheduling approach that allows maintainers to complete work correctly the first time and be able to take pride in their workmanship. n A PM strategy based on an asset’s current condition, how it is used and how the immediate environment impacts its reliability. n A PM approach that first assesses if failure is preventable and, if it is not, defers to a planned run-to-fail strategy. Survival is borne of change (and our being able to rapidly adjust to changing conditions). As you study the bulleted list above, you’ll see why instituting a basic lubrication program can help you accomplish most of the requirements for a best-practice approach to a solid maintenance foundation. Good luck! LMT kbannister@engtechindustries.com
MARCH/APRIL 2011
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PROFESSIONAL DEVELOPMENT SERIES
Certification Matters:
The foundation on which those who seek certification must begin building their lube bona fides starts here, with the basics of the craft. Ray Thibault CLS, OMA I, OMA II, MLT, MLT II, MLA II, MLA III Contributing Editor
I
n LMT’s January/February 2011 issue, we focused on the importance of certification for lubrication professionals, as well as the programs that offer it. In this issue, we launch a series on the major knowledge that’s required in the pursuit of certification. While these articles are based on the content of STLE- and ICML-suggested training modules, they’re intended only as an informational framework for individuals who wish to become certified. Candidates should plan to engage in substantial additional study to develop the degree of in-depth lubrication knowledge that’s necessary to pass a certification exam. Here, we look at the most important topic: lubrication fundamentals. Centered around tribology, these fundamentals serve as the foundation on which other elements build. Tribology is the science of interacting surfaces in relative motion. The term comes from the Greek word “tribo” meaning “to rub.” The three major fields of study in this science are friction, wear and lubrication. Friction… Friction is defined as the force resisting the relative motion of two contacting bodies or fluid layers. The surface of a solid body is classified by its roughness—which is called root mean square and expressed as the centerline average of the peaks and valleys, called asperities, in microinches. Fluid friction consists of molecular plates sliding over one another. The resistance to the sliding, which is related to the fluid type and thickness, is called fluid friction. Solid friction is caused by contact of the asperities resulting in heat generation, welding and wear. This is minimized if a lubricant film prevents asperity contact. Fluid friction that’s not as severe—and which doesn’t cause wear—results from using a fluid that is too thick for the application. This situation means more energy is required to circulate the fluid (a condition related directly to viscosity). When choosing between a viscosity that is too high or too low for an application, always go with the higher one, which will prevent solid-surface contact at the expense of higher fluid friction.
8 | LUBRICATION MANAGEMENT & TECHNOLOGY
MARCH/APRIL 2011
PROFESSIONAL DEVELOPMENT SERIES
Wear… Wear is the rubbing away of metal surfaces due to mechanical action. As Table I shows, there are several wear modes.
■ To avert rust by keeping air/moisture from contacting metal ■ To remove contaminants by circulating fluid to filters or allowing settling in reservoir ■ To seal out contaminants (a major function of grease)
Table I. The Most Common Wear Modes
Lubrication regimes As shown in Fig. 1, sliding surfaces—such as plain bearings— go through three lubrication regimes: boundary, mixed and hydrodynamic. The following are the major variables relating to coefficient of friction and film (f) thickness:
Wear Mode Abrasive
Description Three-body abrasive wear is the most common mode. It is caused by clearancesize particles embedded between metal surfaces.
Adhesive
Asperity contact resulting from an insufficient lubricant film causes heat, welding and tearing away of metal surfaces. Scuffing, scoring and galling (the most severe form) describe this wear mode.
Fatigue
Fatigue is caused by particles bridging a clearance, which leads to stress risers resulting in the generation of micro-cracks that come together and spread, releasing material. Also, in non-conforming surfaces such as roller bearings, high loads can result in surface deformation producing surface cracks that spread and release material. “Spalling” is another name for fatigue wear.
Erosive
This wear mode is caused by small highspeed particles in a fluid stream that erode a metering edge or critical surface.
Corrosive
In the corrosive mode, an unprotected surface is attacked by either water or an acid fluid to produce rust.
Cavitation
A reduction in pressure in a pump fluid results in the production of vapor or dissolved air bubbles that collapse at the high-pressure part of the pump, causing severe surface damage. A closely related effect is air entrainment that enters the system through a leaky fitting under normal pressure. Collapse of these bubbles at high pressure also causes surface damage.
µ = (f) ZN/P
µ= Coefficient of friction Z= Viscosity N = Speed P= Load
The film thickness of a lubricant is directly related to viscosity and speed and indirectly related to load. This is known as the duty parameter ZN/P. At low speeds, such as startup of a rotating shaft, the speed is low; therefore the film thickness is thin, which results in metal-to-metal contact. This is a high-wear regime called “boundary lubrication” that usually requires anti-wear additives for protection. The highest wear in an engine occurs during startup because the lubricant film is not thick enough to prevent contact between the piston rings and cylinder. Engine oils have anti-wear agents—as speed increases, the increasing film thickness offers greater protection. There still will be some metal-to-metal contact, however. At this point, we have entered the “mixed lubrication” regime. When operating speed is finally reached, and if the correct viscosity has been selected for the load and speed, we enter the “hydrodynamic” regime, where there is no metal-to-metal contact. If load or speed changes, the viscosity needs to be adjusted to the new conditions. If the operating speed of a bearing increases, viscosity needs to be lowered to minimize fluid friction. Fig. 1. The three lubrication regimes
Lubrication… The final—and largest—component of tribology is lubrication, which is defined as the principle of supporting a sliding load on a friction-reducing film. The film substance, or lubricant, has the following functions: ■ To reduce friction and wear ■ To reduce heat through circulation and cooling MARCH/APRIL 2011
Boundary
Mixed
Hydrodynamic www.LMTinfo.com | 9
PROFESSIONAL DEVELOPMENT SERIES
There are instances during equipment startup—such as with large turbine rotors in a power plant—when no metal-tometal contact can be tolerated. In these cases, the only lubrication regime is hydrodynamic (by virtue of the use of lift pumps supplying high-pressure oil that totally separates the shaft and bearing). When running speed has been achieved, the pumps are shut off, and the shaft is supported by the natural hydrodynamic pressure exerted by the oil. “Elastohydrodynamic” is another lubrication regime— one that occurs between non-conforming surfaces such as ball bearings. Point contact occurs between the ball and raceway, resulting in very high pressures due to the small surface area carrying the load. An extremely thin film of oil (less than one micron in size) is trapped between the two surfaces. The high pressure that’s exerted turns the oil film into a solid and causes the raceway to stretch, thus allowing greater surface area to carry the load. After the ball passes, the raceway returns to its original shape. The deformation of the raceway will eventually fatigue the bearing (if no other failure mode causes the bearing to fail). Few rolling-element bearings make it to the fatigue stage. Lubricant composition A finished lubricant consists of a base stock and additives. (Table II reflects the API base stock classification system.) The right balance of high-quality base stocks blended with the right additives leads to high-quality finished lubricants. Most base stocks are mineral oils derived from crude oil. Lubricant base stocks are produced in oil refineries. A 42-gal. barrel of crude typically produces about 20 gallons of gasoline and about 0.5 gallons of base stock. Table II. The API Base Stock Classification System
Base Oil Category
Sulfur
Group I
>0.03%
Group II
≤0.03%
Group III
≤0.03%
Group IV
Polyalphaolefin (PAO) All stocks not included in Groups I to IV (Naphthenic oil and Non-PAO Synthetics)
Group V
Saturates
Viscosity Index
and/or
<90%
80 to 119
and
≥90%
80 to 119
and
≥90%
≥120
Groups I-III are paraffinic base stocks. Group I, made by solvent extraction, is being replaced in both engine and industrial oils by Group II, which reflects hydrocracked base stocks of a higher quality. Group III, the highest-quality base stocks, are used primarily to produce engine oils. Additives impart special properties to finished lubricants. Table III illustrates some of the most common ones. A correct balancing of additives is critical. 10 | LUBRICATION MANAGEMENT & TECHNOLOGY
Table III. The Most Common Additives Additive
Function
Application
Oxidation Inhibitor
Retards formation of sludge and varnish.
Included in all industrial & engine oil formulations.
Rust Inhibitor
Absorbs on metal Included in most oil surface to prevent formulations. water and acid attack.
Corrosion Inhibitor
Protects nonferrous metals with a light chemical film.
Included in systems with yellow metals.
Anti-Wear Agent
Mild chemical reaction producing protective chemical film during boundary lubrication.
Primarily used in hydraulic and engine oils. Most common additive is ZDDP.
ExtremePressure Agent
Forms soap-like film due to heat activation resulting from metal-to-metal contact between gear teeth.
Provides protection in heavily loaded reduction gearboxes and greases. Usually a sulfur/phosphorous compound.
Viscosity Index Improver
Helps minimize viscosity decrease with increasing temperatures.
Used in multi-grade engine oils and hydraulic oils operating at low temperatures.
Pour Point Depressants
Allows better flowability of oils at low temperatures by changing crystal structure of wax particles.
Used in engine and other oils operating at low temperatures.
Demulsifiers
Promotes rapid separation of oil/water.
Used in turbine and gear oils primarily. NEVER used in engine oils.
Antifoam Agent
Reduces surface Used in many tension of air bubbles formulations where to break foam. air introduction is a problem.
Dispersant
Keeps finely divided Used in engine oils. particles from agglomerating, thereby reducing sludge.
Detergent
Keeps metal surfaces Used in engine and clean, prevents rust, paper-machine oils. and neutralizes acids.
Friction Modifiers
Changes friction characteristics of oil.
Used in engine oils and automatic transmission fluids. Common additive in engine oils is molybdenum disulfide(moly). MARCH/APRIL 2011
PROFESSIONAL DEVELOPMENT SERIES
Table IV lists typical additive treat rates. Table IV. Additive Treat Rates by Application
Lubricant Type
Additive Treat Rate, %
Engine Oil Automatic Transmission Fluid Automotive Gear Oil Industrial R&O Oil Hydraulic Oil Industrial Gear Oil
6-25 10-18 5-7 0.1-1.0 0.5-1.0 1.5-3.0
This topic of study for lube certification is not only the largest, it’s also the most important.
Key lubricant properties Viscosity, the most crucial lubricant property, is defined as resistance to flow—many people think of it as oil thickness. Kinematic viscosity is the most common viscosity system for industrial oils. Time to flow through a capillary tube is measured in seconds and converted to centistokes (cSt). Viscosities are measured at 40 C for industrial oils and 100 C for engine oils. The ISO VG is a simplified system for classifying viscosity grades. As shown in Table V, an ISO Viscosity Grade is the midpoint of a range that is +/- 10%. Table V. ISO Viscosity Grades Viscosity Grade ISO Standard 3448 ASTM D-2422
ISO VG 2 ISO VG 3 ISO VG 5 ISO VG 7 ISO VG 10 ISO VG 15 ISO VG 22 ISO VG 32 ISO VG 46 ISO VG 68 ISO VG 100 ISO VG 150 ISO VG 220 ISO VG 320 ISO VG 460 ISO VG 680 ISO VG 1000 ISO VG 1500 MARCH/APRIL 2011
Mid-Point Viscosity mm2/s (cSt), @ 40 C
2.2 3.2 4.6 6.8 10 15 22 32 46 68 100 150 220 320 460 680 1000 1500
Kinematic Viscosity Limits, mm2/s (cSt), @ 40 C
Min 1.98 2.88 4.14 6.12 9.00 13.5 19.8 28.8 41.4 61.2 90.0 135 198 288 414 612 900 1300
Max 2.42 3.52 5.06 7.48 11.0 16.5 24.2 35.2 50.6 74.8 110 165 242 352 506 748 1100 1650
Having a firm grasp and full understanding of these tribology-based fundamentals is one of the keys to success for anyone who is taking a lubrication certification exam. Viscosity Index (VI), another critical lubricant property, is defined as an arbitrary measure for the change of kinematic viscosity with temperature. Higher-quality paraffinic mineral oils have naturally high viscosity indexes before the addition of VI improvers. Group III has the highest viscosity index followed by Group II and Group I. This is especially important with multigrade engine oils that have to be light enough to flow at low temperatures and thick enough to protect at high engine temperatures. This is achieved by the use of VI improvers. The Viscosity Index can be determined by plotting a lubricant’s viscosity versus temperature (at 40 C and 100 C). A line with a lower slope would have a higher VI. Fig. 2. Plotting viscosity vs. temp to determine Viscosity Index Viscosity
Temperature Viscosity Curve
Temperature
40 C
100 C
High VI and multigrade oils have the advantage of flowing better at low temperatures and giving better protection with a higher viscosity at higher temperatures. www.LMTinfo.com | 11
PROFESSIONAL DEVELOPMENT SERIES
Synthetic lubricants Synthetics (as listed by major type and applications in Table VI) result from chemical reactions of pure components that produce materials of a larger molecular weight. Containing no wax or sulfur, as a composite group, they have the following advantages. (Note: Not all synthetics offer these advantages.) ■ Fire resistance ■ Oxidation stability ■ Thermal stability ■ High Viscosity Index ■ Enhanced lubricity ■ High flashpoints ■ Low pour points ■ Good demulsibility and anti-foaming characteristics ■ Natural detergency ■ Wide operating temperature range
Fig. 3. Components of a typical grease Oil - 80-95%
Thickener - 2-15% Lubricating Oils Soap, Thickener Additives Additives - 0-10%
Primarily soap-based, grease thickeners are produced through a saponification reaction between a fatty acid and a metallic hydroxide. The most common fatty acid is 12 hydroxy stearic acid and the most common base is lithium hydroxide. As shown in Fig. 4, there also are non-soap thickeners such as polyurea and clay. Fig. 4. Soap-based and non-soap grease thickeners Straight Li, Al, Ca, Na Soap
Table VI. Major Applications of Synthetic Lubricants Synthetic Type
Application
Polyalphaolefin (PAO)
Most versatile and most used synthetic. Used in gearboxes, screw compressors, oil mist, blowers, fans, motors and automotive.
Diesters
Primary use in high-temperature reciprocating compressors. Also used in oil-mist and non-hydrocarbon flooded screw compressors.
Polyalkylene Glycol (PAG)
Primary use of this versatile synthetic is in worm gears, compressor cylinder lubrication, flooded hydrocarbon gas screw compressors, rotary screw air compressors and food grade applications.
Polyol Esters
Used in land-based aviation gas turbines, air and refrigeration gas compressors and fire-resistant and biodegradable hydraulic fluids.
Alkylated Aromatics Used in refrigeration compressors. Phosphate Esters
Used as fire-resistant hydraulic fluid for steam turbines.
Grease lubricants Grease is a solid to semisolid product resulting from dispersion of a thickening agent in a liquid lubricant—some people use the analogy of a sponge. It consists of a network of thickener pores filled with oil that’s released through heat motion, mechanical agitation and other forces. The oil is reabsorbed into the thickener when the forces are removed. Figure 3 shows grease components. 12 | LUBRICATION MANAGEMENT & TECHNOLOGY
Mixed Li, Al, Ca, Na Complex Li, Al, Ca, Na
Grease Thickeners
Clay Non-Soap
Polyurea Other
A straight soap thickener results from the reaction of one high-molecular fatty acid and a base. A mixed soap (not very common) is formed by reacting one fatty acid with two bases. A complex soap consists of one fatty acid and a short chain Di-acid reacting with a base—this grease type is becoming the most popular due to its high-temperature properties. The most common thickener base is lithium: In 2008, it accounted for 66% of thickeners in North America. (Lithium complex, at 36%, was the most used.) As shown in Table VII, greases are classified by the NLGI (National Lubricating Grease Institute) according to consistency. Table VII. NLGI Grease Classification Based on Consistency NLGI Grade
Worked Penetration Range @77 F, mm/10
000 00 0 1 2 3 4 5 6
445 to 475 400 to 430 355 to 385 310 to 340 265 to 295 220 to 250 175 to 205 130 to 160 85 to 115 MARCH/APRIL 2011
PROFESSIONAL DEVELOPMENT SERIES
The consistency of grease is determined by placing a funnel called a penetrometer on a smooth cup of grease at 77 F and, after five seconds, measuring its penetration in tenths of a millimeter. The greater the penetration, the softer the grease and the lower the NLGI Grade number. Most greases used today are NLGI 1, 2 or 3— the most common being NLGI 2. High-penetration greases (such as 00 and 0) are used in centralized lubrication systems in cold temperatures. As a general rule, try to use oil— wherever possible—because it can be cooled and cleaned. There are many applications, though, where oil cannot be used. The following list reflects situations where grease should be used:
The oil in the grease does the lubricating, thus using a high-quality base stock with the right additives is crucial for good performance. Most greases are formulated with paraffinic base stocks; some high-performance products use
synthetics like PAOs, diesters and PAGs. Since viscosity is the most important property, manufacturers select the right viscosity for the application (i.e., highspeed motor greases have a viscosity around 100 cSt).
■ In applications where leakage and drippage are present ■ In hard-to-reach places where lubricant circulation is impractical ■ When sealing in a high-contaminant environment (i.e., water and particle contamination) ■ When protecting metal surfaces from rust and corrosion ■ In the lubrication of intermittently operated machines ■ Where solid additives (such as moly) are suspended during slow-speed, high-load sliding conditions ■ In the lubrication of sealed-for-life equipment like electric motors ■ When lubricating under extreme or special operating conditions ■ In the lubrication of badly worn machines
We all want to be able to count on our industrial equipment to perform as designed, yet contamination often remains an overlooked factor behind premature machinery failure and diminished lubricant life. p Des-Case provides a wide array of highly-customizable, quality filtration units quickly delivered to you for use in your contamination control program. With over a million custom combinations, your ideal customized solution is just a few clicks away. descase.com/fl Visit descase.com/flowguard to learn more.
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www.LMTinfo.com | 13
PROFESSIONAL DEVELOPMENT SERIES
Shaft Alignment
& Geometric Measurement Greases must have a number of properties to be effective—properties that are required based on the application. Table VIII describes some of them. Table VIII. Key Grease Properties Based on Application
Rotalign® ULTRA
Vibration Analysis
& Balancing
h WatcOS E D I V ine Onl
Consistency
NLGI grade, which is based on amount of thickener, describes the stiffness of the grease. NLGI 2 is the most common grade.
Dropping
This is the temperature of grease where the first drop of liquid separates
Water Resist
Water washout test measures ability of a thickener to remain intact in a bearing when submerged in water. Water spray-off measures ability of a thickener to remain in a bearing in the presence of water spray. Both of these tests measure the percent of grease removed.
Base Oil Viscosity
Since oil does the lubricating in a grease, and viscosity is the most important property of the lubricant, the viscosity of the base oil needs to be designed correctly for the application.
Load Carrying Ability
Under high-load conditions, high-viscosity base stock is required and usually with EP additive or solid additive like molybdenum disulfide.
Shear Stability
Grease needs to maintain its consistency under high shear conditions. This test measures the softening of grease when sheared for 10,000 or 100,000 double strokes with a grease worker. Loss of less than one NLGI grease grade signifies a stable thickener under high shear conditions.
Compatibility
Compatibility is one of the most important grease properties. When two incompatible thickeners are mixed, grease usually becomes soft and runs out of the bearing. When mixing different thickener types, consult the supplier regarding compatibility. Some incompatible thickeners are aluminum and barium soaps, clay and some polyureas.
Pumpability
Pumpability is important when pumping grease in centralized systems at low temperatures. The most common test is Lincoln Ventmeter.
Oil Separation
For a grease to be effective, a small amount of oil must separate from the thickener (usually less than 3%).
VIBXPERT® II
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from the thickener in a perforated cup (or the point when the thickener breaks down and melts). Grease should be operated at temperatures no higher than 100-150 F below the dropping point. Complex soaps and polyureas have dropping points around 500 F.
Ray’s advice to you Having a firm grasp (and a full understanding) of these fundamentals is one of the keys to success on lubrications certification exams. This section is not only the largest—it’s the most important. For more information on the topics covered in this overview, please refer to previous articles I’ve authored over the years for LMT (http://www.mt-online.com/lmt-articles.html). You can also obtain study materials from the certifying organization(s) of your choice at www.stle.org and www.lubecouncil.org. Coming in the May/June issue The next article in this ongoing certification series will focus on bearings and their 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.
14 | LUBRICATION MANAGEMENT & TECHNOLOGY
MARCH/APRIL 2011
Reliability Is Gold Meet The Experts At
MAINTENANCE and RELIABILITY TECHNOLOGY SUMMIT
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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
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DELIVERING THE GOODS
The Anatomy Of A Centralized Lubrication System
Single Line Resistance (SLR) Systems Ken Bannister Contributing Editor While these Single Line Resistance (SLR) meter and control units may look identical from the outside, they differ in how they are constructed and how they operate. (Photo courtesy of Engtech Industries Inc.)
T
he grandfather of all centralized lubrication systems, the Single Line Resistance (SLR) type is a fully engineered system designed to pump oil manually in a single-shot (total loss) method, in an automated cyclical (total loss) manner or in a continuous (recirculative) manner. This lowpressure design delivers an apportioned amount of lubricant to every bearing point when the pump is operated, and can be engineered to accommodate up to 200 delivery points in a single pump system. Today, the SLR is one of the most widely available lube systems in the marketplace. Originally developed for automotive applications, it was adapted for small to medium machine tools and manufacturing equipment. Introduced to industry in 1923, the system was a U.S. design from Joseph Bijur of the Bijur Lubricating Corp. (now Bijur-Delimon). 16 | LUBRICATION MANAGEMENT & TECHNOLOGY
■ How This System Works In a total-loss single-shot or cyclic SLR system, a piston pump delivers lubricant through a 5/32” or 3/16” diameter line at a pressure of approximately 60 psi. Each lube point is proportion-controlled by individual metering devices connected in series. Pressured lubricant is forced through the metering unit’s check valve and flows into the bearing point. As the system pressure subsides, the check valve closes and the pump resets itself ready for the next operation, the dormant system retaining a residual system line pressure of between 2-5 psi. In a recirculative SLR system, a gear pump delivers continuous oil flow through a flow-proportioning device known as a control unit. Meter and control units look identical from the outside, but differ considerably in how they are constructed. MARCH/APRIL 2011
SLRs provide excellent bearing lifecycle management at a minimal cost. A meter unit contains a metering pin of a controlled diameter that floats in an accurately reamed cylindrical passage producing an annular orifice of known flow rate. The clearance between the pin and the cylinder wall determines the meter-unit flow-rate designation. A control unit used in continuous systems has no check valve and uses a helical screw to meter the flow. The Pros & Cons On one hand, the SLR system is a simple, inexpensive, engineered lubrication solution designed for small- to medium-sized machinery. On the other hand, these types of systems are only good for use with oil—and they do not produce control signals. Because the SLR system’s metering units are piped in series (hence the single-line designation), care must be taken to ensure all fittings are leakproof/don’t leak and that meter or control units are never allowed to be “drilled” out to increase the rate of flow, which would have the same effect as a broken line. In such a situation, oil takes the path of least resistance and effectively “starves” all bearings simultaneously. The pros and cons of a Single Line Resistance lubrication delivery system boil down to this: With basic care and understanding, your SLRs will provide excellent bearing lifecycle management at a minimal cost. Coming Up In the next issue, we’ll feature Positive Displacement Injector (PDI) 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.
Single Line Resistance (SLR) Systems: Originally developed by Bijur... also offered by Lube, Chiba, Dropsa, Tecalamit, Beka and Trico For more information on these suppliers, enter 01 at www.LMTfreeinfo.com or visit www.MT-online.com/clsinfo
MARCH/APRIL 2011
For more info, enter 67 at www.LMTfreeinfo.com www.LMTinfo.com | 17
LAB SPOTLIGHT
Particle Counting: Importance & Application Ray Thibault, Contributing Editor
©OLIVIER - FOTOLIA.COM
C
lean oil greatly extends equipment life. Studies have indicated that over 70% of the equipment failures in circulating systems were caused by particulate contamination. A key component in developing and maintaining an oil-cleanliness program is the ability to accurately measure that cleanliness. The most common method involves optical particle counters designed for use in the field or an oil-analysis laboratory. Any circulating oil system where cleanliness is important should routinely have particle counts run on it. The frequency is dependent on the criticality of the equipment—normally, though, it’s on a monthly basis. Figure 1 is a diagram of a typical optical particle counter with a fluid flowing through a laser light source. As the light encounters particles, a photosensor records the resulting shadows. This provides an electrical input. The particle counter is calibrated with a sized test dust, and the results are expressed as the number of particles in specified size ranges—typically in terms of particles per milliliter. (Some labs, however, report particles per 100 milliliters.) Interestingly, the light will also count water droplets and air as particles. 18 | LUBRICATION MANAGEMENT & TECHNOLOGY
Fig. 1. Diagram of a typical optical particle counter
Restrictions on the use of optical particle counters include: ■ Water contamination greater than 300 ppm ■ Opaque fluid ■ Contaminated with particles > 200 micron in size ■ Lube is too viscous > 460 cSt Adjustments can be made by diluting dark samples and dehydrating them to remove water, but these are costly and introduce error in the results. Other methods of counting can be used when the above restrictions are encountered. The results are usually expressed on an oil-analysis report as shown in Fig. 2. MARCH/APRIL 2011
LAB SPOTLIGHT
Particle Count : Number Of Particles Ranged By Size Per Milliliter Of Fluid
ISO Code Fig. 2. Typical lab report of a particle-count analysis
17/16/14
4µ 1042
6µ 462
14µ 152
23µ 48
2
50µ
100µ 0
As particle size increases, the number of particles decreases ©LTC 2010
Particle counts are quantitative. While they express the number of particles for a certain size range, they don’t indicate the type—meaning a particle could be of a dirt or wear nature. Additional testing needs to be done to identify the types. (This matter will be addressed in a later “Lab Spotlight” on ferrography.) A quick way to determine the cleanliness of a fluid is to use the ISO 4406 Cleanliness Code (which is a three-number code). The first number expresses particles ≥4µ; the second number denotes particles ≥6µ; the third number expresses particles ≥14µ. Table I is used to arrive at this code. Table I. ISO 4406 Cleanliness Code Chart
Range Number
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6
Number of particles per ml More Than Up to and including
80000 40000 20000 10000 5000 2500 1300 640 320 160 80 40 20 10 5 2.5 1.3 0.64 0.32
160000 80000 40000 20000 10000 5000 2500 1300 640 320 160 80 40 20 10 5 2.5 1.3 0.64
Notice that for each increase in range, the number of particles doubles. This method is a shorthand way of assessing fluid cleanliness without worrying about the actual number of particles. Refer back to Fig. 2. Notice there are 1042 particles/ ml ≥4µ. Referring to the chart, the range number is expressed as 17. The number of particles ≥6µ is 462/ml, which is expressed as a range number of 16. The number of particles ≥14µ is 152/ml, which is expressed as a range number of 14. Putting this three-number code together results in a fluid-cleanliness code of 17/16/14. Remember that the first number will be greater than the second, which will be greater than the third. As for the bottom line on particle counting: The cost is minimal—the benefits are large. How can you determine the cleanliness of your fluid without particle counting? You can’t.
What’s Next? The May/June “Lab Spotlight” will explore Viscometry Testing. LMT For more info, enter 02 at www.LMTfreeinfo.com MARCH/APRIL 2011
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UM SPECIAL UTILITIES MANAGER FOLLOW-UP Part II of IIâ&#x20AC;Ś
ŠDMITRIY MEINIKOV - FOTOLIA.COM
Making Energy Savings Happen Through People
Implementation & Strategies For Success Henry Molise, P.E. HCM Energy Consulting, LLC
P
art I of this two-part article (pgs. 19-22, Utilities Manager supplement, LUBRICATION MANAGEMENT & TECHNOLOGY, January/February 2011) discussed development of an organizational energy policy, endorsed by senior management. Concepts and systems for an energy steering team to begin administering energy management as a culture within an organization were also highlighted. In this concluding installment, the focus is on implementation and follow-up by the steering team. This team develops priorities, provides needed tools and techniques and develops incentives that encourage employees to make energy savings happen.
Momentum for energy management can begin by identifying 80% of the potential results that may result from only 20% of the potential actions. Even if the ratio is closer to 70:30, these actions will tend to have low risk and a high probability of success. The results can then be publicized and used to justify the future actions that may have a somewhat higher degree of difficulty and risk. Energy conservation in existing facilities Energy is often wasted when people are resistant to change. Every employee must be viewed as an energy manager when it comes to reducing energy uses in existing facilities. Employees at all levels must be encouraged via staff meetings or mass communication to: n Suggest energy-saving measures n Turn things off when not in use n Operate equipment at the lowest possible power or thermal level n Enable the use of controls which reduce energy use during unoccupied periods n Report malfunctioning equipment 20 | LUBRICATION MANAGEMENT & TECHNOLOGY
Training needs must be identified so people will have the know-how to reduce energy and utilities usage. Often, employees will identify their own training need if asked. An Intranet Website is a valuable tool for providing information to employees on energy-conservation techniques, as well as for tracking the energy uses. Energy performance and ideas need to be periodically discussed at staff meetings, in conjunction with environmental issues such as recycling. Organized energy assessments should be made periodically for every facility. New findings are most likely to result over time if energy assessments are performed using various methods, some of which include: n Using an energy expert from outside the organization n Cross-assessments, whereby a team from one facility in the same organization performs an assessment for another facility, and vice-versa n Self-assessments, using a trained assessor from within the organization The energy assessment should be performed according to a predeveloped protocol. The protocol should be designed to minimize site personnel time and disruption of facility operations. MARCH/APRIL 2011
SPECIAL UTILITIES MANAGER FOLLOW-UP UM
Operation and maintenance Planned or predictive maintenance techniques will best ensure energy-efficient operation of equipment. Reactive maintenance is likely to result in increased energy usage, as bearings wear to failure, motors run too hot, electrical distribution losses increase, components wear excessively, etc. Standard, documented operation and maintenance (O&M) procedures should be developed to ensure energy efficiency and reliability for major energy-using equipment. O&M standard procedures should require various levels of approval from within the O&M organization, and should be updated on a regular basis. The ideas of O&M personnel must be actively sought for energy improvements in existing facilities—and during review of designs for new or modified facilities. On the contrary, consider what happens when O&M people who probably know that an installed system will not perform as intended are NOT consulted: They’ll no doubt make it operate as best they can, but often the end result will be unnecessarily high energy use. REMEMBER: Communication among O&M people across sites is helpful for energy-saving ideas, where an organization has more than one site. Energy-efficiency improvements frequently result in reduced maintenance requirements because things run cooler, rotating equipment spins more slowly and control is improved. These types of maintenance savings should be calculated and used to help justify energy-efficiency projects. Best practices specific to the organization Over time, the organization will identify best practices for energy savings in addition to aforementioned O&M procedures. Subjects for best practices include lighting systems, HVAC systems, compressed air systems, steam systems, process energy systems and any other energy-using systems. The energy champion or his/her delegate should document energy best practices, and the steering team should approve the documents. This documentation should be kept in as simple a format as possible, such as bullet points or checklists. The documents should be periodically updated and made readily available—such as on an Intranet Website. Energy best practices can be obtained within the organization, and selected from outside sources such as the U.S. EPA/DOE Energy Star Website and trade organizations. O&M personnel should be encouraged to participate in development and review. REMEMBER: Best-practices documents specific to the organization are a valuable checklist tool for energy assessments, as well as for the design of new or modified facilities.
MARCH/APRIL 2011
New and modified facilities There is nothing more frustrating to an energy manager or steering team as first witnessing the progress of an existing facility becoming energy efficient, only to then see the opening (or commissioning) of a new addition that doesn’t meet organizational energy objectives. The cost of energyefficiency measures in a new facility is almost always lower than for retrofitting existing facilities. As with the purchase of major energy-using equipment, energy decisions for a new facility design should be based on lifecycle cost (LCC). Basing decisions on LCC in the design process will take more time, effort and resources, but will pay dividends in the long run. So, energy efficiency needs to be made part of the capital project management process for new or modified facilities. This process will usually consist of a number of phases, including business planning, facility planning, front-end engineering, project execution and operation and evaluation. REMEMBER: The best opportunities in project development are in the facility-planning and front-end engineering phases. Far fewer opportunities exist in the project-execution phase wherein contracts are awarded, design details are finalized and equipment is purchased. Besides using best practices in the design (as noted above), there should be peer reviews of the design during the front-end engineering phase of projects. Peers ideally include technical experts who are not otherwise involved in the project design. The people who will be responsible for O&M should also review the design at this point. Typical performance measurements for facility project teams involve: 1. Completion on time 2. Spending within the capital budget, and 3. Facility economically performing per business needs Of these three performance measurements, the first two are by far the easiest to obtain, while energy efficiency falls into the third category. In reality, project team members are often rewarded for only items 1 and 2 above. Sometimes, energyefficiency measures are even eliminated late in the project to keep it within the capital budget. REMEMBER: Organizations wanting energy efficiency must reward project teams based on all three of the above objectives, even if more time and effort is needed to evaluate the third objective. Doing so will avoid the embarrassment of having to retrofit cost-saving energy improvements into a brand new facility, at much higher cost than if things were done correctly from the beginning.
www.LMTinfo.com | 21
UM SPECIAL UTILITIES MANAGER FOLLOW-UP
Procurement of energy-intensive equipment or systems The discussion of LCC leads to the procurement process. When it comes to major energy-using equipment and systems, simply seeking the lowest bid is inconsistent with energy-management objectives. After all, often more than 80 or 90% of the life-cycle cost of such equipment and systems is for energy input. The importance of the role of a procurement specialist is enhanced by incorporating LCC principles into the process. A general approach for procurement according to lowest life-cycle cost is described here. Specifications must be developed by the unit initiating the purchase of energy-intensive equipment—or its engineering service provider—taking LCC objectives into consideration. Then, requests for proposal (RFPs) must be developed to ensure that suppliers understand the customer goal of minimum life-cycle cost. From the RFP, suppliers must understand the process to be used by their customer in calculating LCC so they can propose equipment and any maintenance agreements accordingly. There are many ways to develop an RFP that ultimately awards the proposal to the supplier with the lowest life-cyclecost, depending on the scope of what is to be purchased. The LCC calculation method should be approved by a financial specialist. As an example, the calculation process used to select the successful proposal can be based on the following items: 1. The capital cost 2. Annual energy-input expense costs based on: a. A system output profile of hours of anticipated equipment or system operation per year at various part loads b. The energy input needed at each part load condition (data provided by the supplier), which will be verified by pre-acceptance performance testing c. The unit cost of energy input to the equipment or system 3. Annual maintenance costs and 4. Determination of life-cycle costs by either: a. A present-worth factor, which converts annual costs (#2 and 3 above) to equivalent capital cost. Then, life-cycle cost is the sum of capital cost plus the present worth of annual costs, or b. A discounted cash-flow model that calculates life-cycle cost as “net present value” In the procurement process, a penalty must be specified in the event that pre-acceptance testing (per 2.b. above) shows that energy efficiency is lower than stated in the supplier proposal. The penalty may be calculated based on the anticipated increased life-cycle energy cost due to the underperformance. Equipment bulk-purchasing commitments, where feasible, can lead to other LCC savings. These could include lower prices for equipment, standardization of spare parts, a reduc22 | LUBRICATION MANAGEMENT & TECHNOLOGY
tion in RFPs and, sometimes, even free engineering assistance from the supplier. A procurement specialist is also a valuable leader or team member for the purchasing of the supplies of energy and utilities. Other energy-supply team members would be facility specialists, engineers and financial specialists. Together, they can identify competitive utility-supply alternatives, perform analyses of various available tariffs and seek the best combination of reliability versus cost. Some competitive supply alternatives may include deregulated electricity, transportation gas or cogeneration of electricity and thermal energy. REMEMBER: Best-practices documents can be developed for procurement procedures for energy-intensive equipment, and for purchasing supplies of energy and utilities. Communication Internal communication specialists are quite useful in making all employees aware of energy management. For example, they can assist with Website development, employee newsletters and press releases regarding the topic. The development of an Intranet site will enable communication of: n The organization’s energy policy n Specific goals and progress n Measurements n Benchmarking n Results of statistical analysis n Energy-conservation techniques n Case histories n References (internal and external links) n Best practices n Awards and recognition REMEMBER: Success needs to be celebrated! Awards or rewards are often highly effective motivators, especially if they are presented from senior management, with publicity. These can be as simple as trophies, plaques, free dinners, entertainment tickets, time off, etc. Monetary rewards can also be used. Review and adjustment The energy steering team must periodically examine energysavings results, compare results with goals and make adjustments for future efforts. Lessons learned must be identified and leveraged. This will ensure longevity of the energy-savings culture. LMT 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. For more info, enter 03 at www.LMTfreeinfo.com MARCH/APRIL 2011
Get Ready!
Get Set!
Get Going!
Put MARTS 2011 On Your Calendar Now!
Education, Networking, Solutions To Your Problems!
APRIL 26-29, 2011
Know any good books? CALL FOR ENTRIES:
We thank all attendees, presenters and exhibitors for helping us make MARTS 2010 a rousing success. MARTS 2011 promises to be even bigger and better! Check regularly on www.MARTSconference.com for event news and scheduling updates.
Reliability Keeps Giving Voice To Autism As in 2010, MARTS 2011 will kick off with another “Reliability Gives Voice to Autism” (RGVA) charity event. This gala evening of fun, food and entertainment at MARTS 2010 was this year’s #1 industrial contributor to the Autism Society of Illinois. Stay tuned for details on how you and your company can be part of this great cause. “I am forever grateful for the efforts made by the organizers and volunteers of RGVA on behalf of the Autism Society - Illinois. With the success of the inaugural event, I am looking forward to the 2011 Reliability Gives Voice to Autism with exuberant anticipation.” … Michael Gallivan, President, Board of Directors, Autism Society - Illinois
We’re grateful, too… Applied Technology Publications is delighted that others across the reliability community have chosen to join us in the battle to raise awareness and funding for autism. To all of you, thank you for your contributions and good luck in your fight. For more information, contact Bill Kiesel at bkiesel@atpnetwork.com
MAINTENANCE and RELIABILITY TECHNOLOGY SUMMIT
Reliability Gives Voice to Autism
Book Awards
Calling all authors and publishers of reliability, maintenance and autism-related books! Submit your entries for the first Reliability Gives Voice to Autism (RGVA) Book Awards. Honoring the best titles in each category, these awards are co-sponsored by Applied Technology Publications and SUCCESS by DESIGN, with proceeds going to the Autism Society of Illinois.
The RGVA Book Awards competition is open to all writers and publishers who produce books written in English that are intended for the reliability, maintenance and autism genres. Independent spirit and expertise comes from publishers of all sizes and budgets, and books will be judged with that in mind. Awards will be presented during the Reliability Gives Voice To Autism dinner on April 26, 2011, at MARTS (Maintenance & Reliability Technology Summit),
The Capacity Assurance Conference!
at the Hyatt Regency O’Hare, Rosemont (Chicago, Illinois).
APRIL 26-29, 2011
For complete rules and guidelines on submitting reliability, maintenance or autism-related books for judging (including entry-fee info), visit:
Hyatt Regency O’Hare, Rosemont (Chicago), IL
www.MARTSconference.com
For more info, enter 69 at www.MT-freeinfo.com
www.MARTSconference.com
PRODUCT SHOWCASE
Grease Spots There’s plenty of detailed product literature on grease for you to wade through these days. Here, in the words of several leading suppliers, is just a sampling of the grease solutions available for your applications.
Thermax® Semi-Fluid Special-Purpose Synthetic Grease
R
oyal Purple’s Thermax Semi-Fluid Grease is an ultra-tough, aluminum complex, EP product that has the fluidity to be poured like an oil, yet maintain enough “body” at operating temperature to resist channeling or leaking past faulty seals that are often found in older gearboxes. It also has very good oxidation stability and provides excellent rust and corrosion protection to both ferrous and nonferrous metals. According to Royal Purple, its advanced Synslide® additive technology is what gives the company’s EP lubricants their performance advantages, including the ability to provide maximum protection under boundary lubrication conditions typically caused by heavily loaded, slow-speed and/or shock-load conditions.
Royal Purple, Inc. Porter, TX
For more info, enter 30 at www.LMTfreeinfo.com
A Wide Range Of Krytox Greases ®
D
uPont™ Krytox greases are created by thickening synthetic perfluoropolyether-(PFPE-)based oil with polytetrafluoroethylene (PTFE) powder, creating a white, nontoxic grease that provides excellent lubrication in demanding applications. The PTFE thickener forms a barrier that holds the base oil at friction contact points for long-term lubrication without requiring complicated oil recirculation systems. Krytox is available in a wide range of NLGI grades, both as soft/fluid greases for sealed gear drives and stiffer, channeling greases for highspeed component lubrication, such as bearings. Because these products cannot be washed out with water, are not affected by steam and are non-reactive to acids and industrial cleaning solutions, bearings are protected against oxidation and lubricant washout. DuPont Wilmington, DE
For more info, enter 31 at www.LMTfreeinfo.com
Premium-Quality, Multipurpose Alvania® Greases RL
S
hell notes that its Alvania Greases RL 2 and 3 are smooth-textured, amber-colored, non-EP, lithium-soap-thickened products inhibited with additives that promote long lubricant life while providing excellent lubrication and corrosion protection. The company also says both offerings are suited to general plant and electric-motor bearing applications and that Alvania Grease RL 2 is readily pumpable in pressure-grease-dispensing systems. Recognizing the trend toward the use of low-noise greases (and OEM requirements in regard to factory-fill, low-noise bearings), Shell has formulated this line with non-crystalline additives to reduce the hard particles that can lead to noise. Shell Houston, TX
24 | LUBRICATION MANAGEMENT & TECHNOLOGY
For more info, enter 32 at www.LMTfreeinfo.com MARCH/APRIL 2011
It’s Time To Shine!
Mobilith SHC Series Supreme-Performance Multipurpose Greases
e b u z r LSta
M
obilith SHC greases are high-performance products scientifically engineered to exceed the demanding requirements for severe applications at extreme temperatures. They combine the unique features of synthesized hydrocarbon-based fluids with those of an advanced lithium-complex thickener, which contribute to excellent adhesion, structural stability and resistance to water. According to ExxonMobil, a carefully selected proprietary additive system provides outstanding wear protection and rust and corrosion inhibition. The low internal friction and high natural Viscosity Index of the base fluids offer the potential for improved mechanical efficiency, low starting and running torque and excellent low-temperature pumpability. Benefits include enhanced bearing life, a wide temperature range of applications and longer grease life compared to conventional oils.
For more info, enter 33 at www.LMTfreeinfo.com
UltraLube® Professional-Grade Biodegradeable Lubricant Line
P
lews & Edelmann says its recently launched UltraLube professional-grade bio-based greases, oils, spray lubricants and penetrants offer four times more natural lubricity than petroleum-based products. This allows fast penetration into areas where lubrication is needed most and the creation of long-lasting bonds to metal and plastic surfaces. The manufacturer also notes that with their higher Viscosity Index, the greases in this new line are less likely to “thin down” at higher temperatures, leading to reduced friction, heat and wear. These eco-safe, nontoxic, non-flammable, extremely-high-flash-point products contain no VOCs and mix easily with petroleum-based greases. Registered by the USDA BioPreferred™ program, they’re suitable for applications in environmentally sensitive areas near waterways.
Plews & Edelmann A Tomkins Company Dixon, IL
We’re Looking For Lube Starz ! ©
© LASSE KRISTENSEN - FOTOLIA.COM
Mobil Industrial Lubricants Fairfax, VA
©
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
For more info, enter 34 at www.LMTfreeinfo.com For more info, enter 70 at www.LMTfreeinfo.com MARCH/APRIL 2011
www.LMTinfo.com | 25
PROBLEM SOLVERS
Dry Lube Spray Solution
High-Load Fastener System
B
T
’laster’s new Graphite Dry Lube spray forms a quick-drying film that offers long-wearing protection under extreme pressures and temps (from -100 F to 850 F). This high-performance product bonds to rubber, metal, wood and plastic, and can be used anywhere a dry lubricant is essential. It’s suitable as a general industrial-maintenance lubricant in, among other things, plant machinery and handling equipment, winches, sprockets, die-casting applications and the pre-assembly lubrication of moving parts. B’laster Corp. Valley View (Cleveland), OH
For more info, enter 35 at www.LMTfreeinfo.com
he Hytorc® Clamp-Nut™ connection device for high-load applications is available as an integrated system that includes a torque wrench, driver and the Clamp-Nut fastener. The Clamp-Nut is a three-piece fastener that prevents galling and has a load range up to 1.5 million pounds. The system creates a self-contained force system that eliminates damage because no torque is transmitted to the bolt.
Hytorc Mahwah, NJ For more info, enter 36 at www.LMTfreeinfo.com
Electronic Torque Wrenches
T
he three new Fixed Ratcheting Head electronic torque wrenches offered by Stanley Proto accept standard Proto sockets. They’re available in 1/4”, 3/8” and 1/2” drive versions, with torque ranges from 25 in-lb (2.8 Nm) to 250 ft-lb (339 Nm). All of these products feature easy-to-read LCD displays, fast sampling rates and visual and audible indicators to show when targets have been reached or overtorqued. Stanley Proto Industrial Tools New Britain, CT For more info, enter 37 at www.LMTfreeinfo.com
Customized, Targeted Lists For Your Marketing Needs
ATP List Services 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
Thermographic Organizer, Analyzer, Reporter
C
ompatible with most of today’s infrared cameras, IRT Cronista software organizes and analyzes thermographic data and generates Microsoft Word reports. Powerful temperature-measurement tools provide in-depth info with multi-points, multi-profile lines, area analyses, hot-spot detection, isotherms, trends and more. Easily link IR and visual images and voice and text notes, then access them through the software’s database. Simple, customizable report templates and detailed help files are included.
IRcameras, Inc. Walpole, MA
For more info, enter 71 at www.LMTfreeinfo.com For more info, enter 38 at www.LMTfreeinfo.com
26 | LUBRICATION MANAGEMENT & TECHNOLOGY
MARCH/APRIL 2011
PROBLEM SOLVERS
Efficient & Thorough Wire Rope Lubrication
On-Site Oil-Monitoring In The Palm Of Your Hand
F
S
Fluid Defense Systems Oswego, IL
Spectro, Inc. Littleton, MA
luid Defense Systems says that its GREASE SAFE® Wire Rope Lubricator offers fast and effective one-pass lubrication of wire ropes from 5/16” (8mm) to 2 5/8” (67mm) in diameter at speeds up to 3333 feet (1000 meters) per hour. It also provides more thorough results than manual methods by forcing lubricant under high pressure into the core of the rope. The result is a smooth, minimal film on the outer strands and lubricant pushed through to the inner strands, expelling water and other matter in the process.
For more info, enter 39 at www.LMTfreeinfo.com
pectro's Fluidscan Q1000 is a small, rugged handheld mid-infrared condition-based maintenance monitor that protects machinery by determining when a lubricant needs to be changed. The device provides alerts on contamination, degradation and cross-contamination at the point of use by measuring key oil-condition parameters in both synthetic and petroleumbased lubricants and fluids. These parameters include TAN, TBN, oxidation, nitration, sulfation, additive depletion, incorrect lubricant, water, glycol, soot and glycerine, and FAME in Biodiesels.
For more info, enter 40 at www.LMTfreeinfo.com
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
For more info, enter 72 at www.LMTfreeinfo.com MARCH/APRIL 2011
www.LMTinfo.com | 27
PROBLEM SOLVERS
Advanced, High-Noise Communication System
Easy Oil Sampling In Mobile, Off-Highway & Mining Environs
S
T
Sensear Pty Ltd. Larkspur, CA
JLM Systems Limited Richmond, BC Canada
ensear says its Intrinsically Safe Smart Muff provides an advanced level of hearing protection in conjunction with a high-noise communication system. The company’s own SENS™ (speech enhancement and noise suppression) technology facilitates clear, safe communication in loud environments. The product features two-way radio and Bluetooth.
he OILMISER™ Plug & Sampling Valve offered by JLM Systems is a rugged, all-steel, low-profile assembly designed specifically for the harsh realities of mobile, off-highway and mining applications. A virtually bullet-proof external hex-head cap protects against the daily hazards found in these tough environments. With no countersunk hex or square cavities to get plugged with debris or peened over, the cap can be removed with a handheld wrench. A large, clean cavity provides easy access to the high-flow, high-viscosity sampling valve.
For more info, enter 41 at www.LMTfreeinfo.com
INFORMATION HIGHWAY Web Spotlight: LUDECA,
INC.
For more info, enter 42 at www.LMTfreeinfo.com
For rate information on advertising in the Information Highway Section, Contact your Sales Rep or JERRY PRESTON at: Phone: (480) 396-9585 E-mail: jpreston@atpnetwork.com
PIP is a consortium of process plant owners and engineering construction contractors harmonizing member’s internal standards for design, procurement, construction and maintenance into industry-wide Practices. PIP has published over 450 Practices. A current listing of published Practices is available on the PIP website at: http://pip.org/practices/index.asp. For more info, enter 74 at www.LMTinfo.com www.pip.org
! RRY OW! U H RN E T GIS
RE
LUDECA, INC. - Preventive, Predictive and Corrective Maintenance Solutions including laser shaft alignment, pulley alignment, bore alignment, straightness and flatness measurement, monitoring of thermal growth, online condition monitoring, vibration analysis and balancing equipment as well as software, services and training. For more info, enter 73 at www.LMTinfo.com www.ludeca.com
28 | LUBRICATION MANAGEMENT & TECHNOLOGY
The Maintenance & Reliability Technology Summit is the #1 learning venue and source of practical solutions for anyone concerned with the reliability, maintenance and the overall capacity assurance of critical equipment systems. Register Now! MARTS 2011 is taking place April 26-29, 2011 at the Hyatt Regency O’Hare in Rosemont, IL. For more info, enter 75 at www.MT-freeinfo.com www.MARTSConference.com
MARCH/APRIL 2011
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
MARCH/APRIL 2011 Volume 12, No. 2
WEBSITE
•
CIRCLE #
PAGE #
ATP Lists .................................www.atplists.com .............................. 71..................................... 26 Des-Case Corporation ..........www.descase.com/flowguard .......... 64..................................... 13
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
Engtech Industries Inc...........www.engtechindustries.com............ 72..................................... 27 Hy-Pro Filtration ...................www.hyprofiltration.com ................ 63....................................... 7 LubeStarz ................................www.lmtinfo.com/lubestarz ............ 70..................................... 25 LUDECA, INC........................www.ludeca.com ............................... 65,73...........................14,28 MARTS ...................................www.martsconference.com ............. 66,68,69,75 ......15,19,23,28 NSK Corporation ..................www.nskamericas.com ..................... 61....................................... 2 OILMiser Technology............www.oilmiser.com ............................ 67..................................... 17 Plews/Edelmann ....................www.ultralube.com .......................... 76.................................. IBC Process Industry Practices.....www.pip.org ...................................... 74..................................... 28 Royal Purple ...........................www.royal-purple-industrial.com .. 77....................................BC Shell .........................................www.shell.com/lubricants................ 62....................................... 5
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. MARCH/APRIL 2011
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) www.LMTinfo.com | 29
WE’RE BUILDING A TEAM...
e b Meet Our L u rz a t S
©
We like hearing about LMT readers, including what they do in the field of lubrication and what they like about their jobs. Here’s what our March/April Lube Starz told us: Dave Maki
Title: Head Oiler, St. Mary’s Paper,
a mill located in Sault Ste Marie, Ontario, Canada Background: Dave has spent 35 years at St. Mary’s, with 34 of those years in his current position.
When he first began working there, it was as a mechanical helper with the maintenance department. He then moved into lubrication work and soon found himself heading up that area. According to him, he’s “never looked back.” What Dave Likes Most About His Work: Taking a proactive approach to maintenance and being the front-runner in equipment reliability, as well being able to maintain the mill’s hydraulics and lube system at a world-class level.
Mike Graves, P.Eng. Title: President, Coastal Engineering Services,
a consulting firm based in New Brunswick, Canada Background: Mike has spent 23 years in the maintenance and/or lubrication field, including
7 in his current position. He looks on lubrication as a specialized field that has often been ignored or not given much attention. He wants to enhance and promote its importance, not just to industry, but to the public. What Mike Likes Most About His Work: Helping to improve equipment function, prevent costly production stoppages, reduce lube consumption by improving lubricant storage, application and oil condition and save operators’ money.
Sandor Mercz Kerek Title: Industrial Mechanical Technician, Ingenieria Proactiva Ltda.,
a consulting operation in Cali-Valle, Colombia Background: Sandor has put in a total of 25 years in the maintenance and/or lubrication field,
including 15 with hisCompany current employer. In his former job with a Colombian Info Company manuInfo facturer, he performed preventive maintenance on 800 machines. Since retiring Contact Info Here Contact Info Here from that job, he’s consulted for other businesses in the region. www.websitehere.com www.websitehere.com What Sandor Likes Most About His Work: Being able to solve problems and suggest equipment improvements with the assistance of technologies like vibration analysis, as well as using TPM principles to teach lube practices to others.
L utbaerz S
30 |
©
Our hats are off to these hardworking Lube Starz, who’ll receive their own baseball caps for making this team. Up for the game? Go to www.lmtinfo.com/lubestarz or www.lubestarz.com to tell us about yourself!
LUBRICATION MANAGEMENT & TECHNOLOGY
Follow the instructions for submitting your own application and photo and you might find your work-related profile in a future LMT issue. We look forward to hearing from you ! MARCH/APRIL 2011
UltraLube® LMX “Red” Grease
UltraLube® H1 Food Grade Chain & Cable Lube
UltraLube® Multi-Purpose Lubricant & Penetrant
UltraLube® H1 Food Grade Chain & Cable Lube
UltraLube® offers 4 TIMES more lubrication than petroleum lubricants.* Reduce friction, heat and wear with plant-based greases, oils and spray lubricants. UltraLube.com | facebook.com/UltraLube *Based on ASTM Falex Pin and Vee Block Test D3233. © 2011 Plews, Inc. DBA Plews & Edelmann.
For more info, enter 76 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.
For more info, enter 77 at www.LMTfreeinfo.com