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MARCH/APRIL 2013 • VOL 14, NO. 2 • www.LMTinfo.com
Contents
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
FEATURES
REAL-WORLD CASE STUDY Contract Services Help Deliver A World-Class Lube Program ©keller—Fotolia.com ; ©alehdats—Fotolia.com
10
You don’t have to go it alone in building and sustaining lubrication excellence. Ray Thibault, Contributing Editor
EQUIPMENT RELIABILITY BASICS 16
Adding Secondary Filtration To Lubricated Pumps This type of contamination removal pays big dividends in terms of improved equipment reliability. Dennis Morgan, Des-Case Corporation
DEPARTMENTS
ICML CERTIFICATION SERIES 20
Industrial Lubrication Fundamentals: Functions Of A Lubricant With lubricants, it’s all about control. This article captures the what, why and how of it. Ken Bannister, Contributing Editor
8 26 27 28 30 30
From Our Perspective Solution Spotlight Problem Solvers Information Highway Supplier Index Classified
®
The Maintenance & Reliability Technology Summit is: An annual, four-day educational experience and professional-development opportunity Created for plant and facility managers, maintenance leaders and crew members, reliability engineers, industrial technicians and all other capacity-assurance professionals Composed of two days of Conferences (60-minute sessions) and two days of Workshops (full-day sessions) presented by industry experts. Scheduled for April 30-May 3, 2013 at the Hyatt Regency O’Hare, Rosemont, IL.
For more information, visit www.MARTSConference.com today!
MARCH/APRIL 2013
Achieving Efficiencies Through Practices & Products Apply for a free, one-year subscription at
www.LMTinfo.com www.LMTinfo.com | 3
Dramatically extends equipment life!
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
March/April 2013 • Volume 14, No. 2 ARTHUR L. RICE President/CEO arice@atpnetwork.com
BILL KIESEL Executive Vice President/Publisher bkiesel@atpnetwork.com
JANE ALEXANDER Krytox Fluorinated Greases and Oils are: Chemically Inert. Insoluble in common solvents. Thermally stable. Temperature range (-103˚F to 800˚F). Nonflammable. Nontoxic. Oxygen Compatible – safe for oxygen service. Low Vapor Pressure. Low Outgassing. No Migration – no silicones or hydrocarbons. Krytox® offers Extreme Pressure, Anticorrosion and Anti-wear properties. Mil-spec, Aerospace and Food Grades (H-1 and H-2) available! Useful in Vacuum Systems. ®
For technical information, call: 203.743.4447 / 800.992.2424 (8 AM – 4 PM ET)
Authorized Dupont™Krytox® Distributor Since 1991 Over 100 grades in stock! No minimum quantities.
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RICK CARTER Executive Editor rcarter@atpnetwork.com
KENNETH E. BANNISTER RAY THIBAULT, CLS, OMA I & II Contributing Editors
RANDY BUTTSTADT
Director of Creative Services rbuttstadt@atpnetwork.com
GREG PIETRAS
s
Editorial/Production Assistant gpietras@atpnetwork.com
California - Illinois - Connecticut - Canada e-mail: support@miller-stephenson.com www.miller-stephenson.com m
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“Visual systems, when applied to equipment, can reduce training time by 60 to 70% and eliminate errors.” —Robert Williamson, lean equipment specialist
Our Visual Supplies Can Improve Your Equipment’s Performance! Colored gauge marking labels Problem and Opportunity Tags in English or Spanish Red Move Tags Colored paint pens Colored grease fitting caps and lube point labels Vibration analysis pickup discs and labels Proven Tips for Equipment Troubleshooting handbook Lean Machines instructional book for applying visuals Temperature indicating strips and more
Visual systems supplies that deliver results...fast! To view and order from our complete line of Visual Systems Products, go to...
www.swspitcrew.com To order by phone or fax, call (864)862-0446 Strategic Work Systems, Inc. PO Box 70 Columbus, NC 28722
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Editor-In-Chief jalexander@atpnetwork.com
LUBRICATION MANAGEMENT & TECHNOLOGY
ELLEN SANDKAM
Direct Mail esandkam@atplists.com
JILL KALETHA
Reprint Manager 866-879-9144, ext. 168 jillk@fosterprinting.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 except Mar/Apr 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 2013. 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.
MARCH/APRIL 2013
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MARTS 2013 Workshops
Yo u k r c W o R o l r l i l April 30 and May 3 d W At The Hyatt Regency O’Hare Hotel, Rosemont, IL.
Seven big names in industrial maintenance and reliability come together to give your program star power. Choose one full-day Workshop or two, but don’t miss this once-a-year opportunity to amp up your skills. This year’s lineup:
Bob Williamson
Maintenance Technology contributing editor and longtime MARTS favorite...presenting
Doc Palmer
Respected author of McGraw Hill’s Maintenance Planning and Scheduling Handbook...presenting
Maintenance Planning and Scheduling: Increase Your Workforce Without Hiring
Putting All the Pieces Together for 100% Reliability
Jim Seffrin
Howard Penrose
Level III Certified Thermographer and Director of Infraspection Institute...presenting
Vice president of Dreisilker Electric Motors and widely published industrial researcher...presenting
IR Thermography for Electrical and Mechanical Systems
Forensic Analysis of Machines: Beyond RCFA
Enrique Mora
An expert in Lean Manufacturing, Six Sigma and TPM who consults and trains worldwide...presenting
Balance the 3 Ms — Management, Maintenance and Manufacturing — to Achieve World-Class Performance
Kris Bagadia
CMMS expert and founder of PEAK Industrial Solutions, LLC...presenting
Turning Downsizing Into an Opportunity
Ed Stanek
President of LAI Reliability and renowned instructor on Maintenance & Reliability, PM Optimization and Asset Management...presenting
Productivity Optimization Workshop
For complete information and registration details:
www.martsconference.com MARTS is an annual four-day educational event for industrial maintenance professionals. In addition to two days of Workshops, MARTS includes a two-day Conference program, a three-day Professional Course for lubrication professionals, and the opportunity to take professional certification exams. For more information or to register, visit www.martsconference.com or call 1-847-382-8100, ext. 116. For more info, enter 65 at www.LMTfreeinfo.com
HOLD THESE DATES April 30 – May 3, 2013
Come Help Us Celebrate Our 10th Anniversary
As Always, You’ll Find Just What You Need: Training Networking Solutions Program Details & Registration Information Will Be Announced Soon
Plan Now To Attend MARTS 2013 The Hyatt Regency O’Hare Hotel, Rosemont, IL.
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FROM OUR PERSPECTIVE
Ken Bannister, Contributing Editor
Why State Of Tune Equals State Of Mind
F
ew things are guaranteed in life, unless you live in the continental Northeast. Up here, winter living is synonymous with bad driving conditions, lots of snow shoveling, high heating bills and, possibly, critical equipment problems. I recently have been up close and personal with all of the above. For example, about the time winter ended last year, my not-so-trusty oil furnace experienced burner problems that led to the replacement of its ignition system. Thinking this year would be easier sailing, I was surprised—and unhappy— when my refurbished heating system (which seemed to be burning 30% more oil than it had in previous seasons) inconveniently failed again during a minus-20-degree cold snap. Despite a new igniter, plenty of fuel oil in the tank and no apparent air intake restriction, I was forced to call in my “furnace guy.” He couldn’t come right away, though. In light of the bitter cold and risk of frozen water lines, I resorted to numerous borrowed electrical space heaters for almost two days while waiting for this busy man to perform his magic on my system. Ultimately, due to some scheduling backlogs, I ended up with a different service provider than my normal “go-to” guy (who my home’s former owner had recommended). New “furnace guy” began by asking if the last guy had “tuned” the furnace after replacing the igniter system. As it turned out, the igniter electrodes had been positioned too far apart—and the furnace startup “shudder,” burner inefficiency and excessive CO2 emissions were a direct consequence of that setup. The subsequent “tune-up” I paid for was a savvy investment: I now enjoy a quieter, environmentally friendly furnace that uses over 15% less fuel than it did initially (when I thought it was running well)! A few weeks later, I called my new “go-to” guy to convey some heartfelt thanks. During our conversation, we agreed that a state of tune equals a state of mind.
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LUBRICATION MANAGEMENT & TECHNOLOGY
Most people know how a poorly tuned car engine can change one’s state of mind—especially if the vehicle begins to act up on the way to an important event. And who among us hasn’t had his/her state of mind altered by the virtuosity of a beginner musician whose instrument wasn’t quite in tune, or a “wannabe” singer with an off-pitch voice? The same holds true for machinery when it comes to lubrication. Over-lubricating or under-lubricating a bearing creates heat through metal-to-metal or excessivefluid friction that will draw more energy and alter the state of the bearing’s health. Similarly, over-filling a reservoir can lead to a lubricant “churning condition,” resulting in heat and foam that quickly deplete the lubricant’s protective capabilities. Under-filling may allow gears to run dry and cause metal-to-metal-friction failure. I’ve been fortunate in the past to be part of studies wherein power companies have worked with operations wishing to implement sustainability programs and act on energy-efficiency opportunities. Surprisingly to most of them was the fact that merely “tuning” an automated lube system to deliver the “right” amount, of the “right” lubricant, at the “right” time could deliver— at a minimum—4% in energy savings. In fact, one stamping-press application saw a whopping 18% in savings. These findings were based on beforeand-after energy consumption states. The message is clear: Spending time and effort to keep your assets in a good “state of tune” will deliver a good state of mind. That’s a good place to be any time of the year! Good luck! LMT kbannister@engtechindustries.com FYI: Ken will present “Industrial Lubrication Fundamentals: Certification Preparatory Workshop,” a three-day, ICML-related Professional Development Course, at MARTS 2013. For details on this value-added lube-training opportunity, visit www.MARTSConference.com.
MARCH/APRIL 2013
BOOSTING YOUR BOTTOM LINE
Manufacturing System Savings
H
enry Ford once said, “Quality means doing it right when no one is looking.” Sound motor management practices, like conducting a motor inventory to assess repair-replace decisions before motors fail, are done behind the scenes, but can lead to noticeable energy and cost savings. The right management practices enhance the quality of your operational processes, and serve to make your plant more lean and efficient. As you practice motor management, don’t overlook the value of assessing other equipment connected to your motor. Motor-driven systems can include adjustable speed drives (ASDs), interfaces such as belts and the driven load, for example, as well as pumps, fans, etc. As the following example shows, managing motor-driven systems yields significant process improvements, energy savings and quality. Rubber Manufacturer Extrudes System Savings [Ref. 1] An industrial rubber manufacturer found an energy savings opportunity through assessing their motor-driven system. In this case the motor system included a 1500 hp motor controlled by an electromagnetic, eddy-style clutch, which powered an extruder. By replacing the clutch with a variable frequency drive (VFD), the manufacturer was able to achieve process improvements, energy savings, reduced maintenance costs and improved power factor for the entire plant. The 24-pulse frequency drive saves more than 1.3 million kilowatt-hours per year, which adds up to over $40,000 in utility-bill savings. After the project, analysis revealed that 40% of the extruder’s electricity consumption was previously wasted using the clutch controller. Additionally, the installation of the VFD improved operations and maintenance in the plant. The VFD also increased the precision of speed control, allowing for better extruder
| MAINTENANCE 32 MARCH/APRIL 2013 TECHNOLOGY
operations. Additionally, the VFD installation increased the space around the extruder that was previously occupied by the clutch, improving the effectiveness and reducing the cost of extruder maintenance. Working with its local utility on this project, the plant realized a 5.75-year simple payback on investment, based only on electricity savings. Other returns on investment, including labor, product quality and power-factor benefits further reduced the project’s payback time. As this example shows, significant process improvement and energy-saving opportunities are the reward for sound motor system management. When it comes to assessing your system’s potential, find information on successful application of drives in the NEMA Application Guide for AC Adjustable Speed Drive Systems [Ref. 2]. To learn more about building on the basics of motor management by considering system savings with drives, visit the MDM VFD Resources Webpage [Ref. 3] that provides links to resources such as VFD savings calculators and additional case studies. LMT 1. www.motorsmatter.org/case_studies/ MidAmerican_VFD.pdf 2. www.nema.org/stds/acadjustable.cfm 3. www.motorsmatter.org/resources/asds.html For more info, enter 04 at www.LMTfreeinfo.com
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.
|9 OCTOBER 2007 www.LMTinfo.com
REAL-WORLD CASE STUDY
In the pipeline to success...
Contract Services Help Deliver A World-Class Lube Program You don’t have to go it alone in building and sustaining lubrication excellence.
Ray Thibault CLS, OMA I, OMA II, MLT, MLT II, MLA II, MLA III Contributing Editor
10 | LUBRICATION MANAGEMENT & TEChNOLOGy
MARCH/APRIL 2013
REAL-WORLD CASE STUDY
P
rogressive companies have long viewed lubrication as a cornerstone of asset reliability. Building and sustaining a world-class lube program, however, is not an easy task. Implementation can be especially difficult. Despite the best of intentions, many organizations fail in this endeavor. Being successful demands a major commitment. That means time, careful planning and, for those without adequate in-house technical resources to administer their programs, the use of outside help (a growing trend across industry).
This case study focuses on a large Gulf Coast chemical plant. Its comprehensive lube program (begun in 2009) continues to improve—even though it’s already achieved world-class status. The program is managed by RelaDyne, a contractor whose Field Reliability Management (FRM) division is helping to redefine and drive reliability in a wide range of operations across North America. The background The facility in this case study hasn’t always been a site of lubrication excellence. While it had been using lubricants from a major company for many years, the only service provided by the supplier was delivery of those products: There was no help with the selection of correct lubricants nor in keeping them clean once they were delivered. As evidenced by a large number of equipment failures— many them related to use of incorrect oils in specific applications and lack of oil cleanliness—this lube program would have been considered “poor.” Plant personnel seemed oblivious to that fact until another supplier, The Hurt Company, began seeking the site’s lubrication business. (Hurt became part of RelaDyne in 2010.) Although attempting to replace a long-time supplier with many plant contacts might seem daunting, by being
persistent and pointing out significant improvement opportunities—not simply trying to sell lubricants— Hurt (now RelaDyne) won the contract. Finalized in 2006, it called for the contractor to supply Chevron products. The scope of work didn’t include performing lubrication. The first phase of the contract involved a comprehensive two-day audit by a technical team to determine deficiencies of the existing program. The following problems were noted: 1. Lubricants were highly contaminated due to poor storage and handling procedures and lack of filtration and breathers on equipment. Oils used on compressors and pumps were found to be well above minimum recommended cleanliness levels. Even turbine oils at 22/19/17 were too dirty for the application. 2. Consolidation was needed. Many oils and greases could be eliminated with no effect on the performance. 3. Misapplication was common. The wrong oils were used in some critical applications. 4. Oil analysis was used, but not effectively. No one knew how to interpret the data.
Tips For Finding The Right Support If your operation doesn’t have the technical resources to correctly administer and support its lubrication program, trying to achieve “world-class” status could be a rough and expensive proposition. Contracting for such services will save you money in the long run. Companies typically turn to outside support for audits and development of lubrication plans. In doing so, it’s important to work with suppliers that have strong track records in the area of implementation—the most critical step in building and sustaining a world-class lube program. If you’re considering outside help, here are some tips:
MARCH/APRIL 2013
■ Be careful in selecting your contractor. Basing your
decision on the lowest bid is usually a mistake. ■ Rigorously evaluate the technical capabilities of pro-
spective contract personnel and how well they will be able to work with your organization. ■ Designate a key in-house point of contact who understands your operation’s lubrication needs and will be able to work closely with the contractor to ensure that the program is proceeding correctly. ■ Establish Key Performance Indicators (KPIs) to track the effectiveness of your program.
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REAL-WORLD CASE STUDY
Leveraging Award-Winning ‘Been There/Done That’ Experience Before 2006, the chemical plant’s lubrication was done by eight in-house oilers who, admittedly, weren’t highly trained on best practices. Lubrication continued to be carried out by in-house personnel until 2009, when the facility contracted out some of those tasks to Hurt (which subsequently became part of RelaDyne). It is unusual for a lube supplier to perform lubrication tasks at a site, but in this case, it was the right move. A major step was to bring in John Gobert, who joined RelaDyne after retiring from Valero. Gobert is a lubrication engineer with vast experience in setting up and running a world-class program for a large Gulf Coast facility. He had selected Hurt as his supplier in 2000 when he took charge of the lube program at the Premcor Refinery—later purchased by Valero. The program was so successful that Gobert and team won the John Battle Award for excellence in machinery lubrication in 2006 from the International Council for Machinery Lubrication. Valero was the only company to win the award that year. Its success was profiled in an article entitled “Development of a World Class Lubricant Program at a Major Gulf Coast Refinery,” in the November/December 2010 issue of LMT.) The customer site in this article initially awarded RelaDyne the lubrication work in two of its units, for which Gobert hired and trained two technicians. Their basic responsibilities were to change oils, grease bearings, collect oil samples for analysis and troubleshoot equipment for lube problems. Operators were responsible for adding oil to pumps and small equipment. The program went so well in those first two units—producing substantial savings in the process— that after just one year, RelaDyne won the lubrication work for the entire site. At that point, six more techs were hired (bringing the total to eight). The program has continued to improve, and two more technicians are scheduled to be added this year. Based on this success, the same program will be incorporated in another chemical plant the customer recently acquired. 12 | LUBRICATION MANAGEMENT & technology
Following the audit, a lube survey of all rotating equipment in the plant was conducted. The resulting data, entered into an Excel spreadsheet and continuously updated, became the basis for the equipment’s lubrication schedules. First incorporated into Pride, a computerized maintenance management system (CMMS), these schedules have subsequently been incorporated into Meridium, a more powerful program. The program Once the lube-program issues that needed the most attention were identified—issues posing the greatest threat to the chemical plant’s machinery reliability—the following improvements were implemented: 1. Contamination control has become a strong focus. Storage and handling has improved significantly. Although sealed plastic dispensing containers had taken the place of metal ones at the plant, they weren’t routinely cleaned—which led to dirty oil. Storing oil in a clean environment is an important factor in keeping it clean. Now, the plastic containers are filled at the lubricant supplier’s facility and delivered to the site where they’re stored in metal cabinets, protected from the elements. One they’re emptied, they’re discarded. Labeled and color-coded, these containers correspond to color-coded tags on the lubricated equipment, and are easy to identify (and keep organized) in the storage cabinets. While the previous supplier never tested for cleanliness, RelaDyne does. With a maximum cleanliness level of 22/19/17, the previous oil was found to be too dirty to meet the standards of various types of lubricated equipment—something that was later identified as a cause of bearing failures at the site. These days, delivered oil is filtered to a 15/13/11 cleanliness level, which has led to a significant decline in contamination-related equipment failures. Because RelaDyne also performs lubrication in the plant, it’s easier to control oil cleanliness. Another improvement has been the use of filter carts for adding oil to larger sumps. Cleanliness goals for critical equipment were established, and with the help of an outside oil-analysis lab, particle counts are run monthly. Previously, only the site’s turbines benefited from system filtration. Following RelaDyne’s involvement, filters were installed in compressors and large circulation systems. Desiccant breathers (which the plant had never used) are now on many sumps. MARCH/APRIL 2013
REAL-WORLD CASE STUDY
As for the payback from these measures, it was estimated that the plant’s pump repair costs in 2010 were reduced by an average of nearly $600,000. Much of these savings can probably be attributed to use of cleaner oil.
a. Numerous pumps and small gearboxes operating at low temperatures (120-140 F) were using high-priced synthetics. They were switched to mineral oils with no effect on performance at significant savings.
2. Lubricant misapplication/consolidation is now a major consideration. (The former supplier had not provided technical services to ensure that the right lubricants were used.) One of RelaDyne’s first steps was to reduce the number of lube products in the plant, without compromising equipment/process performance. To that end, the number of mineral-oil-based lubricants was reduced by 50%. As an example, blowers had previously been lubricated with mineral oils from ISO 68 to ISO 150. After a Chevron synthetic ISO 150 was specified for all blowers—a move that eliminated three lubricant types—performance improved. The following are other examples of misapplication problems and consolidation strategies at the plant:
b. Many gearboxes using non-EP oils were experiencing problems. This was resolved by using a Chevron EP gear oil, resulting in better gearbox reliability. c. Incorrect oil viscosity was identified as a problem with Bird centrifuges at the plant. Although the bearing OEM had recommended the use of an ISO 68 mineral oil, John Gobert believed that was too low, based on the equipment loading. After further discussions with the OEM, the centrifuges were switched to an ISO 150. During a one-year period from 2009 to 2010, repair and production costs were reduced from over $500,000 to $0.
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REAL-WORLD CASE STUDY
3. Training has taken on new importance at the site. Gobert is certified as an MLT I and MLA II. He requires all of his lubrication technicians to obtain MLT I certification within a year of employment. This has led to the development of a highly competent group that not only lubricates equipment properly, but is proactive in early identification of lube-related problems. Ongoing training at the plant also involves the site’s engineers and operators. (Note: Following a 2012 lubrication training class, 10 plant employees received their MLT I certifications.) 4. Oil analysis is now viewed as a major component in the plant’s condition-based maintenance program. Previously, the site had not fully leveraged the power of such analysis. Following RelaDyne’s involvement, MRT Laboratories was chosen for the facility’s oil-analysis work. The decision was based on MRT’s proximity to the site, quick-response capabilities and ISO 17025 certification. John Gobert coordinates the oil-analysis program, working closely with the lab, reviewing reports and making lubrication and equipment decisions based on the results. The plant plans to purchase its own testing equipment for quick onsite analysis (i.e., particle counts, viscosity and water). The outside laboratory will be used primarily for wear-debris analysis and special tests on equipment condition.
DIY Lubrication Program Evaluation Ask yourself the following questions about your site’s lube program. If you can answer “yes” to 80% of them, your program is probably moving in the right direction: 1. Do you have a separate lubrication group? 2. Is it located in the maintenance organization? 3. Do lubricators perform other functions? 4. Have you conducted a lube survey in the last 5 years? 5. If you answered yes to #4, do you keep the survey current? 6. Are you using less than 5 different types of grease? 7. In the past year, have you reduced the number of lubricant types used at your site? 8. Does your organization have a lubrication expert on staff to resolve lubrication problems? 9. Do you have a computerized lubrication-scheduling program and is it used to create work orders? 10. Does your CMMS incorporate lubrication scheduling? 11. If you change lubricants on a timely basis, are these intervals evaluated and updated? 12. Have you had an onsite lubrication training class in the past year? 14 | LUBRICATION MANAGEMENT & technology
Conclusion Development of a world-class lubrication program is an ongoing process. For organizations without the interest, knowledge and/or in-house resources to build and sustain these programs, outside help is readily available. As shown by this case study, if developed, implemented and managed correctly, such programs can be quite cost-effective for an operation. That said, the selection should never be based on the lowest bid. Other criteria are more important. The program in this article is unique in the fact that the contract-services provider not only manages and performs lubrication at the chemical plant, it supplies the lubricants. The goal, though, has not been one of selling lubricants, but rather delivering the most cost-effective lubrication program possible. Consider, for example, the plant’s earlier use of synthetics in applications where they weren’t justified: Synthetics were replaced with lower-priced mineral-based products, without compromising performance. The key to any successful program is the technical expertise of the group that manages it. The RelaDyne team assigned to the chemical plant’s lube program is a highly competent one. In addition to Gobert and his well-trained, experienced technicians, it includes Sania Harvey, CLS, an experienced sales representative who is responsible for the lubricants coming into the plant.
13. Have any of your personnel attended an offsite lubrication training class in the past year? 14. Have any of your personnel attended a lubrication conference in the past two years? 15. Do you have an MLT or CLS at your site? 16. In the last three years, have you found the wrong lubricant being used and has it it been corrected? 17. Do you use sealed plastic containers to dispense lubricants? 18. Do you check lubricants that come into your plant for water and cleanliness? 19. Do you filter hydraulic oils before adding to reservoirs? 20. During the past year, have you upgraded your lubrication program by improving an application method or switching to a better product like a synthetic? 21. Do you currently use an oil-analysis laboratory? 22. Do you receive your reports electronically? 23. Can someone on your team evaluate reports? 24. Has someone on your team had oil-analysis training? 25. In the past three years, has oil analysis identified a potential problem that was effectively resolved? MARCH/APRIL 2013
REAL-WORLD CASE STUDY
Finally, no account of this plant’s journey to lubrication excellence would be complete without mentioning the important role that teamwork has played in the process. Today, in-house staff and RelaDyne’s FRM-division personnel continue to work together in writing a remarkable story of world-class lubrication success. LMT Acknowledgement John Gobert and Sania Harvey of RelaDyne provided much of the information for this article. Without their assistance, it would not have been possible.
Long-time Contributing Editor Ray Thibault is based in Cypress (Houston), TX. An STLE-Certified Lubrication Specialist and Oil Monitoring Analyst, he conducts extensive training for operations around the world. Telephone: (281) 250-0279. Email: rlthibault@msn.com.
Lubrication-Success Points 1. Continue to establish cleanliness standards for all critical equipment and monitor through oil analysis. 2. Continue to develop KPIs on program performance. 3. Implement onsite oil analysis. 4. Change oil based on condition. 5. Implement use of handheld recorders for monitoring lubrication activities on equipment and utilize for lubricant scheduling. 6. Continue evaluating lubricants for best cost/performance. 7. Investigate major issues and bring in outside support to address them, if needed (i.e., mitigating varnishing on gas turbines and compressors).
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EQUIPMENT RELIABILITY BASICS
Adding Secondary Filtration To Lubricated Pumps ﾂｩProfotokris窶認otolia.com
This type of contamination removal pays big dividends in terms of improved equipment reliability. Dennis Morgan Des-Case Corporation
I
t has been well established that contamination is the primary reason for a mechanical system, such as a pump, to fail. According to MIT professor Ernest Rabinowicz, approximately 70-80% of lost usefulness of industrial machinery can be directly or indirectly attributed to contamination from mechanical and corrosive wear mechanisms (Fig. 1).
16 | LUBRICATION MANAGEMENT & TECHNOLOGY
MARCH/APRIL 2013
EQUIPMENT RELIABILITY BASICS
Primary Wear Mechanisms
Fig. 1. According to a joint study by STLE and NRCC, as much as 82% of mechanical wear in industrial machinery is caused by particle contamination of the lubricating oil.
66%
3 Body Abrasion
8%
8%
Erosion
Fatigue
The predominant root cause for both types of wear is contamination of the lubricating oil in the machine. In fact, a study conducted jointly by the Society of Tribologists and Lubrication Engineers (STLE) and the National Research Council of Canada (NRCC) found that as much as 82% of mechanical wear of industrial machinery is due to particle contamination of the lubricating oil [Ref. 1]. Removing this contamination is key to significantly extending the life of machines, including oil-lubricated pumps—and adding secondary filtration is an effective way to do it. The importance of this technology for pumps Secondary filtration is a contamination removal system that exists outside of the primary lubrication circuit of the machine, typically in a kidney-loop fashion. It’s a filtration system that only filters and cleans the oil and does not directly lubricate the bearings. This is also sometimes referred to as oil purification, the advantage of which is not only extending the life of the oil, but also extending the life of the equipment by continuously cleaning the lubricating oil. There are several methods of oil purification. Although OEMs will sometimes incorporate secondary filtration in their products, this type of filtration typically will be an add-on aftermarket system—in an off-line, side-stream or kidney-loop configuration. Secondary filtration will also usually clean oil down to very low ISO cleanliness levels that primary or OEM filtration cannot. Most pumps aren’t designed with oil-purification or contamination-removal capabilities. The result is that, over time, contamination has a large negative impact on pump wear. As a pump ages, more contamination is introduced MARCH/APRIL 2013
12% Adhesion
4%
2%
Other
Fretting
into its lube system, which can cause the pump to fail faster and in a more catastrophic way. Maintenance personnel across several industries have extended the life of their pumps by adding secondary filtration to their lubricating systems, thus saving not only the costs of replacement or repair of the equipment, but also preventing what’s even more costly—plant downtime. Consider the following real-life examples of operations that have added secondary filtration to their pumps. Chemical plant chooses secondary filtration to reduce pump service intervals… Downtime was the primary concern for one chemical plant that added secondary filtration in a kidney-loop fashion to two of its process pumps. The units are used to move one of the plant’s most profitable products—a highly abrasive one—through the production process. During normal operation, the product will migrate past the pumps’ packing seals and contaminate the lubricating oil. Once that begins to happen, the contamination in the oil causes the packing seals to fail more quickly, which, in turn, causes progressively more product to leak past the seals and contaminate the oil even more. Prior to the addition of secondary filtration on these two pumps, the maintenance department was changing out 15 gallons of lube oil in each of them every two weeks (on average)—at a cost of at least four hours of downtime each time. (That amount of downtime was due to the complex work required to completely rebuild the displacement sides of these pumps, including re-packing, changing their lubricating oil and cleaning their lube-oil reservoirs.) www.LMTinfo.com | 17
EQUIPMENT RELIABILITY BASICS
Before Filtration
After Filtration
Fig. 2. As shown in these before and after secondary-filtration shots, maintenance personnel at the chemical plant can now re-use lubricating oil over multiple pump service procedures.
Initially, the facility added these filtration systems to 11 of their hydraulic units in the sheet-metal press area of the plant. Prior to that, the hydraulic systems were averaging an ISO particle count of 24/20/13. As a component of the equipment reliability plan, maintenance personnel set a cleanliness target of 17/15/12. Adding the secondary filtration systems—at a cost of about $10,000 per hydraulic system including installation—resulted in immediately meeting or exceeding that target. Five months after implementation, there was a 53% reduction in breakdown frequency and a 54% reduction in plant downtime. However, since reductions in component failure from the addition of secondary filtration generally take time to develop, plant personnel believe that their already noteworthy results will only improve. Overall, the plant’s comprehensive reliability plan, of which secondary filtration is the key component, is expected to return approximately $685,000 per year in reduced production losses and an additional $250,000 per year in reduced maintenance costs. [Ref. 1]
Working with its lubrication supplier, the chemical plant added a secondary filtration system that incorporates a simple first-stage bag filter to remove the bulk of the particles larger than 50 microns, and a second-stage microfiberglass filter for finer cleanliness. The result was that the pump service interval is now no less than every 12 weeks. The primary driver of the pump maintenance procedure now is wear of the packing seals from the highly abrasive product being pumped—not contamination of the lubricating oil. Moreover, as shown in the before and after images in Fig. 2, maintenance personnel can now re-use lubricating oil over multiple pump service procedures. The secondary filtration system that led to this dramatic improvement cost approximately $6000, including installation. It saved the facility no less than $25,000 in direct maintenance costs during just the first 12 weeks of implementation. [Ref. 2] Filtration cuts automobile-plant production losses and maintenance costs… An automobile manufacturing facility wanted to extend the life of their critical hydraulic systems and reduce plant downtime. As part of a proactive and comprehensive equipment reliability upgrade plan, and for trial purposes, this facility added secondary filtration to some of these hydraulic systems. The added secondary filtration systems included a first-stage bag filter followed by second-stage micro-fiberglass filter elements for fine filtration (Fig. 3). 18 | LUBRICATION MANAGEMENT & TECHNOLOGY
Fig. 3. The secondary systems on the hydraulic-pump units at the referenced automobile plant feature first-stage bag filters along with second-stage micro-fiberglass filter elements for fine filtration. MARCH/APRIL 2013
EQUIPMENT RELIABILITY BASICS
Filtration reduces pump failures in a steel plant… In a steel plant, the presence of mill scale, dust, dirt and water means contamination is always a major problem. In one plant with approximately 2200 hydraulic pumps, system failures were out of control. The facility’s reliability team attacked the issue by adding secondary filtration to all of their hydraulic pump systems. Incorporating wound-cellulose depth-filter elements, this secondary filtration has reduced pump failures at the site by 96%. Secondary filtration makes a big difference There are countless examples of equipment-life extension and downtime reductions resulting from the addition of secondary filtration to critical fluid-handling systems, including screw pumps (and compressors), boiler feed pumps and process pumps, among others. The fact is that any oil-lubricated pump can benefit from the removal of dirt, dust, wear metals, water, process materials, etc.
Pump users have always looked for effective ways to protect and get the most out of their equipment. As the realworld examples in this article show, secondary filtration offers one of the best solutions for doing both. LMT References 1. Crane, C., Potteiger, J., “Optimizing Equipment Performance with Precision Lubrication,” 2013. 2. Lubrication Engineers, Inc., “AMS Filtration System, a Customer Testimonial,” 2009. Dennis Morgan is the Vice President of Technical Services for Des-Case. The founder of Axle Machine Services, Ltd. (in 1992) and AMS Filtration (in 1997), he joined Des-Case in 2011 when it acquired AMS Filtration. Author of the book, Basic Principles of Vacuum Dehydration, Morgan holds a BSBA degree from Ashland University. Email: dennis.morgan@descase.com. For more info, enter 02 at www.LMTfreeinfo.com
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MARCH/APRIL 2013
www.LMTinfo.com | 19
ICML CERTIFICATION SERIES
Domain of Knowledge Element #2
Industrial Lubrication Fundamentals:
FUNCTIONS OF A LUBRICANT With lubricants, it’s all about control. This article captures the what, why and how of it. Ken Bannister Contributing Editor
T
he old adage “oil is oil, so any old oil will do!” may have had merit a hundred years ago, but in today’s world of sophisticated machinery and demand for asset reliability, choosing the correct lubricant is now an important and informed decision. Whether in the form of a liquid, solid or gas, modern lubricants are pure liquid engineering. Through the blending of additives into a variety of base stocks, they can be designed to perform up to eight functions simultaneously in a host of different environments.
20 | LUBRICATION MANAGEMENT & TECHNOLOGY
MARCH/APRIL 2013
ICML CERTIFICATION SERIES
Webster’s Dictionary defines a lubricant as “a substance (e.g. oil, grease or soap) that when introduced between solid surfaces which move over one another reduces resistance to movement, heat production and wear (i.e. friction and its effects) by forming a fluid film between the surfaces.” Essentially, a lubricant’s job is to control and minimize the sacrificial harmful effects of moving surfaces passing over one another under load and at speed. It does this in eight ways. Function 1: Control and minimize friction The primary function of any lubricant is to control and minimize the effects of friction. When two solid surfaces passing over one another are allowed to come into contact under load, they rub together and produce dry friction, requiring considerable energy to keep the surfaces moving. With no lubricant to separate the moving surfaces from one another, surfaces quickly degrade and can weld or lock together resulting in a “seize.” The indiscriminate sacrifice of wear surfaces produces rapid wear and loss of energy to heat, resulting in poor performance, reduced reliability and increased energy use. The introduction of a lubricating film between the two wear surfaces creates a fluid barrier that prevents surface contact. Although a small amount of fluid friction is still present in the film, the energy required to move the surfaces over one another is but a small fraction of that required to overcome surface-to-surface dry friction. Function 2: Control and minimize wear Knowing that a full lubricant film may not always be possible and that some metal-to-metal contact may occur under slow-moving, heavy-load, lubricant-loss conditions, additives that act as chemical “softening” agents on the metal surfaces can be blended into the lubricant. The lubricant coats the two surfaces with soft layers of metallic salts (sulfides and phosphate additives). As they slide over one another, alternating load cycles can cause the softened high points (asperities) on each surface to collide with one another due to reduced film thickness. When the unit loading exceeds the sulfur-phosphide film, a rupture occurs, creating a small area of metal-to-metal contact. Localized heat builds up, causing the two surfaces to weld and break, which leads to a small metal particulate or asperity release into the lubricant film. Many lubricants are designed to control wear by promoting minute surface degradation to allow asperity “tips” to be sacrificed easily without "tearing” the parent metal, thereby minimizing surface wear under varying lubricant-film conditions. MARCH/APRIL 2013
Function 3: Control and minimize heat Whenever friction and wear levels are controlled and minimized, the amount of heat is also reduced. Excessive heat can “cook” the lubricant and cause it to oxidize, rendering it less effective; to combat this, an anti-oxidant additive is added to the lubricant base stock. Recirculating oil- and air/oil-system designs take advantage of a lubricant’s ability to transfer localized heat buildup at a bearing load point and prevent any thermal runaway at the bearing surfaces. To facilitate the heat transfer/cooling process, the oil may be pumped through a heat-exchange unit (oil cooler) and/or reservoir baffle system.
In short, a lubricant's job is to control and minimize the sacrificial harmful effects of moving surfaces passing over one another under load and at speed. Function 4: Control and minimize contamination As described above, a lubricant can become contaminated when wear asperities are introduced into it. Other forms of contamination, such as silica (dirt), can be introduced through the reservoir-filling process when proper storage, transfer and cleanliness practices are not observed, or through compromised sealing systems. To combat contaminant solids, lubricant additives can be used to coagulate particulate matter, making them heavy enough to “drop out” into the sump. Other additives can attach to asperities and stay colloidal, suspended in the lubricant so they can be extracted under pressure by an in-line system oil filter. Failure to refresh oil filters on a regular basis will cause the contaminated lubricant to act as a “lapping” paste and accelerate the wear process in bearing areas. In the case of water or glycol contamination, additives are added to facilitate release of moisture in the sump or filter. These additive types are more prevalent in automotive oils. Lubricants can also act to seal out contamination ingress around shafts. This is the case with a labyrinth type of seal that depends on grease to fill up a series of annular grooves cut into a non-moving shaft housing designed to act as a live shaft seal. www.LMTinfo.com | 21
ICML CERTIFICATION SERIES
Function 6: Control and minimize shock Readers of this magazine are no doubt familiar with the quieting effect from adding lubricant to a gear train—wherein a lubricant acts as a hydraulic shock absorber between mating gears as they mesh. When they are poorly lubricated, those gears set up shock waves as they start to mesh, resulting in a “chattering” sound that can fracture the gear teeth. FYI: The very phrase “shock absorber” is synonymous with automobile suspension systems that employ hydraulic oil to dampen and absorb the effects of road shock on the vehicle. Function 7: Control and transmit power In a typical hydraulic system, oil is used to transmit force and motion from a single source (usually a pump) into multiple sources, pistons, accumulators, etc. Hydraulic oil is also used to transmit power in soft-start devices such as fluid couplings, automatic transmissions and torque converters. Function 8: Control and minimize energy consumption Effective lubrication practice dictates use of the Right lubricant, in the Right place, at the Right time, in the Right amount, using the Right method. Doing so will ensure that the lubricated equipment is using the least amount of energy in terms of moving parts. In studies conducted on behalf of various electric power companies,* effective use of lubricants, delivery systems and methods were shown to significantly reduce energy consumption of lubricated equipment: For example, an energy reduction of 7.3% was documented when a synthetic replaced a standard compressor oil, and a reduction of 17.92% was achieved on a stamping press when the automated oil delivery system was “tuned” and a more appropriate oil was chosen.
Boundary BL
Mixed MF
Hydrodynamic HDL
4x Relative Bearing Life
Function 5: Control and minimize corrosion Oxygen may be a basic human life force, but it is a mortal enemy of lubricants. When present, it acts as catalyst to combine certain metals and organics that generate corrosive acids harmful to the bearing surfaces. If the wear surfaces are ferritic (iron-based), the acids attack the metal and form rust on the bearing surface. A lubricant is designed to cling to the metal surfaces and prevent moisture and oxygen from reacting with the surface. Given the fact that not all lubricants are created equal, if the bearing surfaces are iron-based, a lubricant with anti-corrosive additives must be employed.
3x
2x
1x 2.0 3.0 4.0 5.0 6.0 7.0 0.4 0.6 0.8 1.0 Lamba 1 (Working Film Thickness)
10
Fig. 1. Lubricant film lamda l thickness curve
The fluid film To combat friction and wear successfully, a lubricant film must be present at all times between the mating bearing surfaces. The degree of protection—and subsequent bearing surface life—is directly related to the lubricant’s working film thickness, load, speed and lubricant viscosity or “stiffness” (to be discussed in a later installment). The minimum working film thickness required to achieve full surface separation is also known as the lamda l thickness ratio. Because the degree of surface separation is dependent on the surface “roughness” (Ra), it must be determined by measuring the profile (peaks and valleys of the surface) of both mating surfaces and by defining a centerline through them so that the areas above and below the centerline are equal. The lamda ratio is then defined as the ratio of lubricating film thickness to surface roughness, which is a lubricant film thicker than the combined height of both surface asperities enough to completely separate both surfaces. Figure 1 shows the lamda l ratio thickness curve that depicts the relationship between the working film thickness and the resulting life expectancy of the lubricated component. Note that once the lamda ratio is thicker than four times, life expectancy remains constant. The figure also references the different film types—or stages—known as Boundary Layer, Mixed Film and Hydrodynamic Film. These important film types will be discussed relative to the different types of wear conditions in the next installment of this series.
*Bannister, Kenneth E., Energy Reduction Through Improved Maintenance Practices, Industrial Press, NY.
22 | LUBRICATION MANAGEMENT & TECHNOLOGY
MARCH/APRIL 2013
ICML CERTIFICATION SERIES
Recapping Lubrication Certification Opportunities Today, there are three lubrication certifying bodies: STLE (Society of Tribologists and Lubrication Engineers); ICML (International Council of Machinery Lubrication); and ISO (International Organization for Standardization). Originally designed for engineers, STLE's Certified Lubrication Specialist (CLS) program has been offered since 1993. ICML now offers two certifications for “hands-on” lubrication practitioners: the MLT (Machine Lubrication Technician) and MLA (Machine Lubrication Analyst) designations. A relative newcomer, ISO’s lubrication certification program has adopted the ICML model (and collaborated with that organization to use its domain of knowledge). Participants who attend the requisite preparatory formal training associated with ICML certification are also eligible to take corresponding ISO exams (upon payment of the appropriate examination fees). Of these three programs, ICML’s (currently offered in nine languages) has issued the most certifications around the world. For more information on this program, visit: www.lubecouncil.org. For more info, enter 03 at www.LMTfreeinfo.com
FYI: Ken will present "Industrial Lubrication Fundamentals: Certification Preparatory Workshop," a three-day, ICML-related Professional Development Course, at MARTS 2013. For details on this value-added lubrication-training opportunity, visit www.MARTSConference.com.
Reliable
A
Air Sentry® A Division of Whitmore Rockwall, TX
For more info, enter 68 at www.LMTfreeinfo.com
MARCH/APRIL 2013
SPONSORED INFORMATION
ir Sentry® is a leading developer of contamination control products that keep particulate matter and excess moisture from the headspace inside vessels like gearboxes that hold lubricants, greases, hydraulic fluids and fuels. This extends the life of critical machinery and equipment, and significantly reduces lifecycle costs. The company’s innovative products have been the gold standard in contamination control since 1997. Its line includes nine series of desiccant breathers, anodized color-coded closed system adapter kits that prevent crosscontamination, manifold adapters and pressure-vacuum-indicating gauges. Air Sentry has recently introduced a revolutionary new line of desiccant breathers called Guardian™. These “next-generation” contamination control products are the first breathers constructed of Tritan™. This patented material provides the most chemical-, temperatureand impact-resistant casing on the market. Guardian also is the first desiccant breather to incorporate an isolation check valve that protects the adsorbent from exhaust air and volatile splashing fluids. This lengthens the desiccant’s service life and reduces replacement frequency. Learn more about how Guardian increases fluid life, improves lubrication and lowers maintenance costs by visiting www.airsentry.com/air-sentry-breathers/guardian.htm.
Gadgets adgets
Next-Generation, Extended-Life Contamination Control Products
Ken Bannister is a certified Maintenance and Lubrication Management Consultant for ENGTECH Industries Inc. He is the author of the Machinery’s Handbook Lubrication chapters, as well as the bestselling Lubrication for Industry textbook recognized as part of the ICML and ISO’s Domain of Knowledge. Bannister also teaches numerous formal certification preparatory training courses for the ICML MLT/MLA and ISO LCAT certification programs. Telephone: (519) 469-9173; email: kbannister@engtechindustries.com.
For more info, enter 77 at www.LMTfreeinfo.com
www.LMTinfo.com | 23
• • • INNOVATOR • • • • INNOVATOR • • • • INNOVATOR • • • • INNOVATOR • •
It Takes One...
An Innovator That Is!
©
The Innovators At Presented By
Applied Technology Publications
Scalewatcher North America, Inc. Oxford, PA www.scalewatcher.com
Developed and patented in the Netherlands by Mr. Jan P. de Baat Doelman, Scalewatcher™ technology was introduced to the European market in the 1980s. Based on its immediate market success, Mr. Doelman brought the technology to the United States, whereupon he applied for and received a patent in 1991. From that point on, Scalewatcher North America has been on the forefront of environmentally sensitive water treatment. Scalewatcher’s innovative products are no-maintenance, environmentally friendly descalers that do not change water composition. Scales and stains disappear gradually and completely, without further action required, guaranteed. The units work by way of magnetic and electric fields and a continuously changing frequency. The process forces dissolved minerals such as calcium and magnesium to crystallize before mineral ions (the cause of hard scale) can settle on surfaces. This stops or reduces buildup of hard scale, and because the water is better able to dissolve minerals, existing hard-scale layers are softened and eventually disappear. Scalewatcher technology has been used by more than 250,000 satisfied customers worldwide. These maintenance-free products prevent corrosion in pipework; prevent settlement of zebra mussels in plants using sea or river water for cooling; reduce bacterial counts in cooling systems; reduce water and energy bills; extend the life of water-using equipment (especially boilers); can be installed without plant shutdown; and last 20+ years.
The Innovators At Scalewatcher will award individual water-treatment units to the 2012 Maintenance & Reliability Innovator of the Year and 3 Runners-Up For more info, enter 70 at www.LMTfreeinfo.com
• • INNOVATOR • • • • INNOVATOR • • • • INNOVATOR • • • • INNOVATOR • • •
To Know One
To See Who Won, Go To: www.MT-online/innovatorwinners
©
The Innovators At Presented By
Dreisilker Electric Motors, Inc. Glen Ellyn, IL www.dreisilker.com Henry Dreisilker came to America from Germany in 1954 seeking opportunity and gainful employment. Hard work and integrity landed him his first job in a small motor repair and appliance business. Seven months later, he purchased the business, founded Henry Dreisilker Electric Motors and Appliance Service and began by specializing in commercial motor repair and sales. Combining old-world craftsmanship with advanced technology, the company grew steadily from three employees to over 120. Today, Dreisilker Electric Motors, Inc. provides complete electric motor solutions to commercial, industrial and municipal customers nationwide. It distributes new electric motors, parts, accessories and controls from major OEMs and offers a range of value-added, reliability-related services. Among its many offerings is Dreisilker Total Motor Management (DTM2), a comprehensive program that incorporates expert technical coordination of an operation’s motor database, inventory recommendations, energy analysis, repairversus-replacement decisions, exchange motor options and maintenance training on motor systems. Expert field technicians are available for scheduled maintenance or to respond quickly to emergencies 24/7/365. The company’s innovative and exclusive Motor-Safe™ Repair 2.0 process uses special induction technology stripping, accurate and precise rewinding, advanced varnishing, dynamic balancing and thorough testing. Dreisilker never uses the “burnout oven” methods practiced by other motor shops. Motors repaired by Dreisilker improve reliability, increase uptime and save energy. The reliability of your motors, in turn, translates directly into productivity and profitability.
The Innovators At Dreisilker will award individual iPads to the 2012 Maintenance & Reliability Innovator of the Year and 3 Runners-Up For more info, enter 71 at www.LMTfreeinfo.com
Applied Technology Publications
SOLUTION SPOTLIGHT
©danieldefotograaf—Fotolia.com
Automated Lubrication System Improves Container-Crane Efficiency Special to LMT
B
elgium’s Port of Antwerp (“Antwerp”) is Europe’s second largest and the fourth largest in the world. Thousands upon thousands of ocean-going vessels call at this busy facility each year, and containers are a huge (and growing) component of its maritime traffic. As it is around any port, each hour saved in handling freight that moves through this one—even an hour spent maintaining freighthandling equipment—can be important to the bottom lines of the companies doing it. That includes MSC (Mediterranean Shipping Company), one of the biggest players in the container-transport arena. MSC’s terminal operation in Antwerp is the site of a notable lubrication success story. Since SKF installed SKF ProFlex automated lubrication systems in the MSC Home Terminal at the Port of Antwerp, the customer has been able to reduce manual maintenance on its cranes by about 1900 hours annually. It previously spent, on average, about 90 hours per year/per crane to perform lubrication routines manually—which had to be done when the cranes weren’t in operation. With container traffic through Antwerp experiencing explosive growth, terminal personnel were coming up against ever-shorter maintenance windows for completing that work. According to Henrik Lange, SKF President Industrial Market, Strategic Industries, automating its lubrication process was an ideal solution for the MSC Home Terminal. The SKF ProFlex systems not only support crane availability and help reduce downtime, they have eliminated the safety risks that workers used to be exposed to when they conducted manual lubrication work on the cranes. Solving the problem at the port The SKF ProFlex system features a pump unit that delivers grease to a series of progressive feeders that can automatically provide a defined amount of lubricant for up to 150 lube points. The systems installed at the Port of Antwerp lubricate the cranes’ wheelbases, winches and trolleys—providing the exact amount of lubricant to over 60 points on each unit. Additionally, SKF fitted each of these ProFlex systems with
26 |
LUBRICATION MANAGEMENT AND TECHNOLOGY
The SKF ProFlex Systems on the MSC Home Terminal cranes lubricate the units’ wheelbases, winches and trolleys. They’ve not only helped increase uptime, they’ve eliminated safety risks that workers had previously been exposed to while performing manual lubrication work on the cranes.
control options on the pumps, distributors and feeders, thus allowing personnel to monitor units from the office (and help keep the cranes in optimal condition). Other applications
Capable of handling oil, semi-fluid grease and hard grease NLGL grades 000 to 2, SKF ProFlex systems are designed for small and medium-sized applications. Typical applications include printing equipment, construction machinery, industrial presses and wind turbines, among others. Advantages include. . . ■ Continuous delivery of lubricant during pump running time ■ Simple system blockage control ■ Easy system monitoring via series connection of metering pistons SKF Lansdale, PA For more info, enter 30 at www.LMTfreeinfo.com MARCH/APRIL 2013
PROBLEM SOLVERS
Air Coolant For Machining Operations
E
XAIR’s Cold Gun Aircoolant SystemTM produces a cold, quiet stream of air to reduce heat buildup on machining operations. According to the company, the product is an alternative to mist systems and helps reduce costs associated with the purchase, filtration and disposal of liquid coolants. Features include an improved hot-air exhaust muffler that reduces the operating noise level to 70 dBA. Exair Corp. Cincinnati, OH
Compact High-Viscosity Filter Cart
T
he OilMiser 15V456 High Viscosity Filter Cart features a compact design and a high-efficiency TEFC motor. Its color-coded Filter Condition Indicator signals a needed filter change. Quick-disconnects comply with ISO-7241-1B Interchange Standards, and are supplied with dust caps on suction and discharge ports. The cart’s low flow rate of 1.9 gpm (7 L/m) minimizes filter media stress and maximizes contamination retention on the oil filter. JLM Systems Ltd. Richmond, BC, Canada
For more info, enter 31 at www.LMTfreeinfo.com
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Ultrasound Data Collector
S
Cordless Grease Gun
M
ilwaukee Tool’s M18™ Cordless 2-Speed Grease Gun delivers up to 10,000 psi operating pressure and includes a pre-set grease counter to dispense exact amounts of grease. Other features include an on-board LED light, a lock-on/off trigger and a plunger rod with markings to gauge remaining grease. The tool has a stand-up design and shoulder-strap capability, while a 48” flexible hose offers accessibility to hard-to-reach fittings. Milwaukee Tool Corp. Brookfield, WI MARCH/APRIL 2013
For more info, enter 32 at www.LMTfreeinfo.com
DT has added an acceleration feature to its SDT270 ultrasound data collector, allowing inspectors to measure, log, alarm and analyze vibration data. It also features surveydriven temperature, tachometer and static/dynamic measurements powered by an on-board synchronous database. Data can be further analyzed through the company’s Ultranalysis Suite software. SDT Ultrasound Solutions Cobourg, ON, Canada For more info, enter 34 at www.LMTfreeinfo.com www.LMTinfo.com | 27
PROBLEM SOLVERS
Semi-Permanent Spill Containment Solution
Low-Temp Food Grade Lubricant
N
ew Pig’s crush-resistant Build-A-Berm® Barrier Kit lets facilities create semi-permanent spill containment barriers around machinery or storage areas. This pliable, open-cell barrier can be shaped to suit the application and springs back into shape after being walked on or rolled over with light, wheeled equipment. It features a high-visibility yellow color and 18-oz all-vinyl covering that resists oils, coolants and most chemicals. The kit includes straight sections, corners and sealant, and the barrier is easily removed with a flat-bladed shovel.
L
U™214 Food Grade Low Temperature Lubricant from Sprayon® Products is NSF® H1-rated and suited for extended service under low-temperature conditions (down to -78 F). Its blend of synthetic oils includes extreme-pressure corrosion inhibitors, anti-oxidant, anti-foam and anti-wear additives. Kosher-approved, this non-staining formulation with a high load capacity is suited for use on compressed air systems, gears, chains and more. Sprayon Cleveland, OH
New Pig Corp. Tipton, PA For more info, enter 35 at www.LMTfreeinfo.com
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INFORMATION HIGHWAY
ATP List Services Customized, Targeted Lists For Your Marketing Needs www.atplists.com Contact: Ellen Sandkam 847-382-8100 x110 800-223-3423 x110 info@atplists.com esandkam@atplists.com 1300 S. Grove Ave., Suite 105, Barrington, IL 60010
Air Sentry® is a leading developer of contamination control products that keep particulate matter and excess moisture from the headspace inside gearboxes, drums, reservoirs, oil tanks, etc. that hold oils, greases, hydraulic fluids, and fuels. Air Sentry breathers and adapters ensure longer fluid life, better lubrication and lower maintenance costs.
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 in a plant or facility. Mark your calendars! MARTS 2013 is taking place April 30-May 3, 2013 at the Hyatt Regency O’Hare in Rosemont, IL.
For more info, enter 73 at www.LMTfreeinfo.com www.airsentry.com
For more info, enter 74 at www.LMTfreeinfo.com www.MARTSConference.com
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28 | LUBRICATION MANAGEMENT & TECHNOLOGY
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 For more info, enter 31 at www.LMTfreeinfo.com MARCH/APRIL 2013
PROBLEM SOLVERS
Lube-Additive Diagnostic Tool With Wi-Fi Connectivity
F
luitec’s RULER View™ diagnostic tool provides the type of critical insight into the health and remaining useful life of the antioxidant additives in lubricants that heretofore hasn’t been available through other condition monitoring and analysis technologies. An advancement of the company’s flagship condition monitoring product, the RULER, it features a microphone for real-time dictation of data relevant to the sample and an integrated camera to capture an image of the MPC patch (Membrane Patch Colorimetry, ASTM D7843) when testing for varnish potential. Technology-friendly Wi-Fi connectivity allows for seamless software upgrades and product support. The built-in report template and integrated software lets users quickly produce high-value, professional reports on the remaining useful life of their critical lubricating assets. Fluitec International Jersey City, N.J. For more info, enter 37 at www.LMTfreeinfo.com
“Industrial Lubrication Fundamentals” 3-Day, On Site, Certification Preparation Training Program
With over 70% of all mechanical failures attributed to ineffective lubrication practices, you will want to have professionally trained and certified lubrication personnel working on your reliability efforts!
Unlock the Secrets that let you Tap your True Maintenance Potential and Maximize Asset Reliability! World Class organizations know that increased asset reliability, utilization and maintainability, reduced operating costs, downtime, contamination, energy consumption and carbon footprint all commence with a best practice lubrication program! Course design is based on ISO 18436-4 and the ICML body of knowledge and exceeds minimum training requirements to write the ICML, MLT1, MLA1 and ISO LCAT1 International lubrication certification exams. Exams can be arranged to take place at your site immediately following the training. For more information on this unique training program developed and delivered by internationally accredited lubrication and maintenance expert Ken Bannister, author of the best selling book Lubrication for Industry endorsed by ISO and the ICML as part of their certification Domain of Knowledge Content. Contact ENGTECH Industries Inc at 519.469.9173 or email info@engtechindustries.com For more info, enter 75 at www.LMTfreeinfo.com
MARCH/APRIL 2013
www.LMTinfo.com | 29
Index ADVERTISER
MARCH/APRIL 2013 Volume 14, No. 2 •
WEBSITE
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
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Air Sentry ..................................................www.airsentry.com..................................77,73 .......... 23,28 ATP Lists....................................................www.atplists.com ....................................72 .................... 28 CIM ...........................................................www.cim.org/toronto2013 .....................64 ...................... 5 Des-Case Corporation .............................www.descase.com ....................................67 .................... 13 Dreisilker Electric Motors Inc..................www.dreisilker.com .................................71 .................... 25 Engtech Industries Inc..............................www.engtechindustries.com ..................75 .................... 29 Fluid Defense ............................................oilsafe.com/seevalue ................................61 ..................IFC MARTS ......................................................www.martsconference.com ....................65,66,74 .... 6,7,28 Miller-Stephenson Chemical Co. ............www.miller-stephenson.com..................62 ...................... 4 RelaDyne ...................................................www.reladyne.com ..................................69 .................... 19 Royal Purple Inc. ......................................www.royalpurpleindustrial.com ............76 ...................BC Scalewatcher..............................................www.scalewatcher.com ...........................70 .................... 24 Strategic Work Systems, Inc. ....................www.swspitcrew.com ..............................63 ...................... 4 UVLM, Inc. ...............................................www.uvlm.com........................................68 .................... 15
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