Developed and patented in the Netherlands by Mr. Jan P. de Baat Doelman, Scalewatcher technology was introduced to the European market in the 1980s. With immediate market success, Mr. Doelman brought the technology to the United States and applied for and received a patent in 1991. From that moment, Scalewatcher North America has been on the forefront of environmentally sensitive water treatment. Located in Oxford, Pennsylvania, Scalewatcher North America continues to lead the industry in descaling products that do no harm to the environment. Scalewatcher North America focuses on the elimination of scale and the problems associated with scale build-up. Industries know the costs involved in keeping their capital investments running smoothly. Scalewatcher is there to help. Scaled cooling towers, chillers and associated equipment can negatively impact a company’s bottom line, and not just in cash. The caustic chemicals used to remove scale only create more problems with the environment. Your company can “GO GREEN” and stay within your budget.
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Contents FEATURES
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
EQUIPMENT-SPECIFIC LUBE SERIES 8
Part III: Lubricating and Troubleshooting Centrifugal Pumps
©Thomas Haltinner—Fotolia.com
Your site’s hardworking pumps call for special treatment when it comes to lubrication. What you don’t know about it could break the real ‘heart’ of your operations.
Ray Thibault, Contributing Editor
TOP TIPS FOR SMART SHOPS 16
A Cool Approach To Cutting Fluids Selecting the right products and keeping them healthy while they work for your operations is crucial to your bottom line. Travis Lail, ExxonMobil Lubricants & Specialties
UTILITIES MANAGER
DEPARTMENTS
19
6
From Our Perspective
28
Problem Solvers
30
Supplier Index
31
Lube Starz
Big Money Talks William C. Livoti
20
Specify Backup Power That Fits Ensuring that your selected backup-power system can meet both current and future needs depends on a number of factors. Michael Kirchner, Generac Power Systems
TECHNOLOGY TOOLS 23
Building Reliability On A Foundation Of Lubrication The innovative approach to lubrication that one paper mill took improved the conditions of both its machines and its bottom line. Jane Alexander, Editor, with Bill Correll, Generation Systems, Inc.
DELIVERING THE GOODS 26
The Anatomy Of A Centralized Lubrication System: Air/Oil Delivery First developed as a total-loss lubrication system for high-speed bearing environments, Air/Oil is now appropriate for use in any rotary or linear machine application. Ken Bannister, Contributing Editor
Achieving Efficiencies Through Practices & Products Apply for a free, one-year subscription at
www.LMTinfo.com MAY/JUNE 2012
www.LMTinfo.com | 3
It’s Coming! Are You Ready?
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
May/June 2012 • Volume 13, No. 3 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
Presented By
Applied Technology Publications
Categories: Innovative Devices, Gizmos & Gadgets Innovative Processes & Procedures Innovative Use of Third-Party Resources Details & Entry Forms Available At www.reliabilityinnovator.com Grand Prize Winner And 3 Runners-Up Announced In Early 2013 For more info, enter 62 at www.LMTfreeinfo.com For more info, enter 62 at www.LMTfreeinfo.com
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LUBRICATION MANAGEMENT & TECHNOLOGY
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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 2012. 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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W O R R Y- F R E E
FROM OUR PERSPECTIVE
Ken Bannister, Contributing Editor
Self-Investment Is A Wise Investment
I
recently received an email from an individual working in a maintenance department as a “Lube Technician.” He had heard that he was a primary candidate for a first round of corporate layoffs. With no early-retirement option available to him, and no trade certificate or formal education to fall back on, this guy was feeling extremely vulnerable. He wanted advice on how he could prepare himself and present his strengths to a prospective employer. Regardless of the ups and downs in the economy, we all must realize that involuntary unemployment is a possibility for anyone in today’s workforce—even those in the critical maintenance and reliability arena. Preparing for this type of life-changing experience while you have a job could make it easier to deal with being laid off should it ever happen to you. Be proactive. Once you come to grips with the idea that you could lose your job some day, open your mind and “reframe” how you view your current situation. Taking the following steps will strengthen your position in any job market. 1. Embrace a different mindset, one that lets you think of yourself as self-employed, and commit to executing all future work as if you were being paid on your performance. 2. Remember that potential employees are more interested in “how” YOU personally made a difference in a past position, rather than what YOU “did.” Think back and document suggestions you’ve made that have benefitted your organization/company, and write up a case study for each instance. In the meantime, start a diary of work performed, record any innovative approach or suggestion for improvement you’ve made and chronicle your successes. If you are, in fact, laid off, and your ideas have been used to benefit your former employer, ask your former supervisor for a job reference based on these successes.
6|
LUBRICATION MANAGEMENT & TECHNOLOGY
3. Subscribe to industry publications (like LMT and Maintenance Technology, for example) to keep up-to-date on new technologies, philosophies and tools used in your type of work and industry sector. Try to visit local (but relevant) trade shows and conferences. If your company won’t let you go on work-time, consider doing so before or after your work day. I’ve met many people at these types of events who have used vacation time and paid for their entrance fees—viewing this approach as an important investment in themselves (refer to the title of this column). 4. Upgrade your professional credentials ASAP. I encouraged my “Lube Technician” correspondent to invest in the domain-of-knowledge library(ies) for the International Council for Machinery Lubrication (ICML) and/or Society for Maintenance & Reliability Professionals (SMRP) and pursue certification as a Machinery Lubrication Technician (MLT) or Machinery Lubrication Analyst (MLA) through ICML, or as a Certified Maintenance & Reliability Professional (CMRP) through SMRP. 5. Prepare (or update) a professional resume´ that highlights what makes YOU different and more hireable than everybody else who might be looking for your desired job. Understanding the worth of your contribution to your current employer is paramount to understanding yourself. Realizing how you have made a difference can give you a degree of selfesteem and confidence that sets you apart in a job interview (if you ever find yourself in one). Regardless of your situation today, investing in yourself via the above steps will make you a more valuable employee, with a brighter future— wherever you are. Good Luck! LMT kbannister@engtechindustries.com
MAY/JUNE 2012
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TECHNICAL SERVICES
Tools and techniques to optimize equipment reliability...
Part III Lubricating And Troubleshooting
Centrifugal Pumps
Your site’s pumping equipment calls for special treatment when it comes to lubrication. What you don’t know about it could break the real ‘heart’ of your system. Ray Thibault CLS, OMA I, OMA II, MLT, MLT II, MLA II, MLA III Contributing Editor
(Author’s Note: Much of the information in this series is based on the practical knowledge of real-world lubrication professionals. Once such expert is Mark Kavanaugh, who has over 42 years of experience in large manufacturing operations, and is currently responsible for coordinating the lubrication of thousands of pieces of rotating equipment in a refinery. Mark is certified as a CLS, MTL I and MLA II.)
EQUIPMENT-SPECIFIC LUBE SERIES
P
umps are an integral part of any manufacturing plant. Most operations have to move fluids from point to point. Some large end-users, like chemical plants and refineries, have thousands of pumping systems. Pump operation and maintenance should never be taken for granted. Often referred to as the “heart” of a plant, pumps are key components in a site’s overall reliability program. Table I lists various pump types classified as either positive displacement or centrifugal. This article will focus on centrifugals.
Table I. Pump Types PUMPS POSITIVE DISP. RECIPROCATING PISTON PLUNGER DIAPHRAGM
ROTARY GEAR SCREW LOBE VANE
CENTRIFUGAL RADIAL
AXIAL
HORIZONTAL VERTICAL
Centrifugal pump considerations The centrifugal pump family includes radial-flow types (the most common) and axial-flow types. ■ A radial-flow centrifugal pump uses a rotating impeller
to create centrifugal force on a fluid, creating energy that results in flow. The flow is accelerated in a radial, outward motion by the pump impeller into a diffuser or volute chamber and exits into downstream piping. ■ An axial-flow centrifugal pump develops flow from the
lifting or propelling effect of the vanes on the impeller. ■ In a mixed-flow variation of the radial- and axial-flow
types, pressure is developed both by centrifugal force and the lifting effect of the vanes. The two types of radial pumps are ANSI (based on the American National Standards Institute Pump Standard) and API (based on standards of the American Petroleum Institute). Standardized dimensions for ANSI pumps include: 1. The distance between the suction and discharge nozzle centerlines 2. The height of the pump coupling 3. Location of the pump hold-down bolts MAY/JUNE 2012
ANSI pumps are usually smaller, overhung units for lightduty types of service. API pumps (which meet API’s higher standards) are typically used in heavier-duty services than ANSI pumps. There’s a movement to combine both ANSI and API Standards into one standard for the U.S. ANSI pumps have both radial and thrust rolling-element bearings. Typically, the radial bearings are single-row, deep-groove ball bearings. The thrust bearings are either paired angular-contact or double-row angular-contact ball bearings. API pumps typically incorporate double-row, deepgroove ball bearings and angular-contact ball bearings for thrust load. For larger API heavy-duty pumps, radial bearings are cylindrical—for their greater load-carrying ability— and thrust bearings are paired tapered-roller types for thrust loads. Sealing for general service is moving more toward bearing isolators or magnetic seals. Lip seals are no longer approved for API pumps, but are still used in some ANSI pumps. For pumping environmentally unfriendly fluids, mechanical seals are used. Lubrication selection guidelines Most pumps are lubricated with rust and oxidation inhibited oils (R&O) that also have small amounts of antifoam and demulsifier additives. Some pump manufacturers recommend antiwear (AW) additives, but most use R&O oils. Viscosity is the most important criteria in the selection of the proper pump lubricant. Table II lists guidelines on the proper viscosity selection for rolling-element bearings. Table II. Viscosity Guidelines for the Lubrication of Rolling-Element Bearings (Source: Heinz Bloch) Bearing Operating Temperature, F
Ball/Cylindrical Bearings
Other Bearing Types
150 F
VG 46
VG 68
175 F
VG 68
VG 100
190 F*
VG 100
VG 150
*Synthetics such as PAOs are usually recommended at this temperature.
www.LMTinfo.com | 9
EQUIPMENT-SPECIFIC LUBE SERIES
Fig. 1. An oil bath fed by a bottle oiler is the most common lubrication system for centrifugal pumps.
Fig. 2. How a bottle oiler maintains the oil level in oil-bath lubrication systems (Source: Trico Mfg.)
The most common viscosity used for centrifugal pump rolling-element bearings is ISO VG 68. In some colder climates, ISO VG 32 is used. Lubrication application methods The proper application of lubricants is as important as the correct lubricant selection. The methods used are: ■ Bath ■ Bath with slinger ring ■ Circulation system ■ Pure mist ■ Purge mist
Bath method… The most common centrifugal-pump lubrication-application system is the oil bath fed by a bottle oiler. In some cases, depending on the amount of oil in the bearing housing, a slinger or flinger may be required to properly lubricate the bearing. Figure 1 depicts an oil bath in a centrifugal pump. When lubricating solely with an oil bath, the oil level should be maintained so it covers half the lower ball. In Fig. 1, the radial bearing is a deep-groove single-row ball type, and the thrust bearings are paired angular-contact ball bearings. The Trico bottle oiler is the most common method used in establishing an oil bath. An oil sight glass made of acrylic is attached to the bottom of the oiler reservoir. This type of sight glass is useful in observing the color of the oil—and, in turn, helping to determine when to drain water and debris from the bottom of the reservoir. Figure 2 shows how a bottle oiler maintains the oil level in an oil bath. As the oil level drops in the reservoir, the oiler feeds additional oil and breaks the seal in the bulb, introducing air, which allows oil to flow from the bulb. When the correct level is reached, the seal stops the oil flow. Best practices when using a bottle oiler are as follows: 10 | LUBRICATION MANAGEMENT & TECHNOLOGY
■ Correctly set the level adjuster (spider). (I have seen some
people throw them away.) ■ Mount the bottom oiler on the correct side of the pump.
The direction of rotation from the bottom of the shaft should be toward the bottle. This will prevent overfilling of the reservoir, resulting in high oil temperatures that can lead to bearing failure. ■ The bottle should be mounted straight and not cocked
or tilted. ■ A standpipe (but preferably a breather) should be attach-
ed to prevent overfilling due to the venturi effect of air currents passing over an opening. ■ Fill the bottle when the oil level gets down to one-third.
Constantly filling the bottle will introduce excess oil in the reservoir. ■ Fill the bottle nearly full, but drain from an opening in
the bottom of the reservoir. If no air bubble is seen, the line from the oiler to the reservoir is plugged and must be cleaned (not an uncommon problem). Drain enough oil to be 75% full. This important (but frequently overlooked) step, automatically resets the bath level to the correct depth. If the pump design doesn’t allow the oil to cover 50% of the bottom ball, an oil ring—preferably a flinger—should be installed. Ensuring that the oil ring/flinger is immersed at the correct oil level is crucial. API Standard 610 2.10 under lubrication recommends the level to be from .12 to .25 inches from the lower edge of the flinger, or above the lower edge of the bore of the oil ring. Pumps using oil rings can suffer the following lubrication problems: MAY/JUNE 2012
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EQUIPMENT-SPECIFIC LUBE SERIES
Fig. 3. Based on the color of the desiccant, this breather needs to be changed.
■ Slow ring rotation and insufficient lubrication from
Fig. 4. Technicians passed by this bottle oiler many times before noticing that what appeared to be the right oil level was really a crust in a completely dry reservoir. ■ Greatly reduced bearing failures
too high of an oil level ■ A trouble-free system with no moving parts ■ Bouncing on shaft, likely caused by too low of an oil level ■ Alarm systems that monitor oil level and flow rate ■ Running against one of the bearings because the pump
is out of level. (This could starve the bearing on the opposite end, elevate oil temperatures and introduce oil-ring wear particles to the bearing from rubbing.) Check for oil rings that have become out of round. If they are found to be more than .010 out of round, replace them. Looking at Figs. 3 and 4, can you detect any problems? Oil-mist methods… (Oil mist was discussed in detail in the March/April 2012 article on lubrication of electric motors. ) An oil-mist system produces a mist that can travel 600 feet and supply hundreds of lube points. It consists of oil particles <3 microns that go through a reclassifier and deposit a very thin oil film. The refining and petrochemical sectors have used this technology for 50+ years. There are two types of oil-mist: pure and purge. Pure mist is applicable to ball bearings in pumps and electric motors. Purge mist is suited to any type of bearing. As with motors, oil-mist lubrication of pumps offers a number of benefits: ■ Bearings running significantly cooler (15-30 degrees F) ■ Clean once-through lubrication
12 | LUBRICATION MANAGEMENT & TECHNOLOGY
In pure-mist systems, pure oil is reclassified into a light film that’s continuously deposited on the bearings. Any excess liquid goes to the collection container. The sole function of purge mist is to protect against contaminants by maintaining a slight positive pressure in the headspace above an oil bath. The oil bath does the lubricating. Sometimes, two different oils are used. That’s fine as long as they’re compatible. Lubricants used for oil-mist on pumps and motors are the same. In warmer climates, a low-wax ISO 68 or 100 typically is used. In colder climates, to prevent waxing of the reclassifiers, an ISO 68 PAO or diester is recommended. Troubleshooting Be proactive in resolving any lubrication-related pump problems. Pay close attention to the following issues: Contamination… Contamination can contribute to cavitation (see pg. 13), a major cause of failed bearings. Contamination results from: ■ Poor seals ■ Improper venting ■ Loose fill plug ■ Poor storage and handling resulting in dirty oil ■ Delivery of dirty oil MAY/JUNE 2012
When vibration is caused by structural stresses on the bearing housing and misalignment results, the pump’s lubricant may not be able to do its job. Steps for ensuring clean lubricants include: ■ Following proper storage, handling and transfer
procedures (i.e., indoor bulk storage, oil safe transfer containers, filter carts and clean, dedicated hoses) ■ Testing incoming oil deliveries for particle counts and
water content ■ Installing desiccant breathers to help stop particle and
water ingression from pump aspiration. (Some new models incorporate sealed fill-ports for top offs.) ■ Replacing worn lip seals or upgrading to bearing isolators ■ Training and certifying oil technicians in best practices
Mechanical issues… While there are countless mechanical issues with pumps, two that are typically associated with lubrication are vibration and cavitation (see previous page). Pump vibration can start for a variety of reasons, but when it is caused by structural stresses on the bearing housing— which affects alignment of the pump’s bearings—the lubricant may not be able to do its job. Pipe strain on suction and discharge flanges, hollow bedplates or soft-foot on anchor bolts and misalignment of pump and driver couplings are the most common culprits. Each of these conditions twists, tweaks or pulls on the pump frame and bearing housing, causing changes in the small clearances of the bearing races. These clearance changes will have an adverse effect on lubrication film thickness and the ball’s track in its groove. Such situations lead to ball sliding or skidding and rapid overheating. Cavitation—implosion of gas bubbles on the interior surfaces of a pump or piping—is an amazingly destructive force. It can easily erode and break impellers, volutes, pump cases and piping.
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www.LMTinfo.com | 13
EQUIPMENT-SPECIFIC LUBE SERIES
Cavitation can be caused by leaking gaskets and O-rings that lead to air entrainment. A more common cause may be the effect of rising temperature and/or pressure on the vapor point of the liquid being pumped. Once vapor pressure is reached, some of the liquid flashes to a gas and the remaining pressurized liquid compresses and implodes this bubble of gas on the nearest surface. Pumps that are cavitating may sound like they are pumping rocks or marbles. Best practices for operators in early lubrication-related mechanical-problem resolution include: ■ Monitoring pumps and drivers closely to recognize subtle changes
in oil levels, color, foaming and cleanliness ■ Using infrared thermometers to check bearing and oil temperatures
and inlet and outlet temps on oil coolers to determine efficiency ■ Frequently draining small amounts of oil from bearing housings
to inspect for particle ingression, wear debris and water content ■ Noting changes in vibration, unusual sounds or oil leaks ■ Being vigilant in contamination-control practices. (It can cost
Contamination can be a factor in cavitation, an amazingly destructive force that’s one of the most frequent causes of pump-bearing failures.
10 times as much to remove particle contamination from oil as it does to prevent contamination in the first place.) ■ On oil-misted bearings, draining manifolds and collection
bottles and regularly checking mist flow at lube points ■ Learning the proper use of desiccant breathers, filter carts and
vacuum dehydrators Conclusion Pumps are an integral part of almost every plant. The key to their reliability is the early detection of potential problems. Operators and lubricant technicians are vital players in any reliability program. Utilizing some of the troubleshooting techniques discussed in this article will go a long ways in preventing premature pump failures at your site. Coming up Part IV of this series (in the July/August issue of LMT) will focus on Best Practices for Lubricating and Troubleshooting Compressors. LMT (RECOMMENDED READING: For an in-depth discussion of pumps, including more details on the lubrication issues associated with them, refer to the Pump User’s Handbook: Life Extension, 3rd Edition, by Heinz P. Bloch and Allan R. Budris, published by Fairmont Press.)
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. For more info, enter 01 at www.LMTfreeinfo.com
14 | LUBRICATION MANAGEMENT & TECHNOLOGY
MAY/JUNE 2012
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TOP TIPS FOR SMART SHOPS
Application expertise and proactive maintenance…
A Cool Approach To Cutting Fluids Selecting the right products and keeping them healthy while they work for your operations is crucial to your bottom line. Travis Lail ExxonMobil Lubricants & Specialties
T
ougher metals, severe metalworking processes and the need to increase productivity while reducing costs have helped make issues related to cutting fluids hot topics for countless machine shops. Let’s put things into perspective.
16 | LUBRICATION MANAGEMENT & TECHNOLOGY
MAY/JUNE 2012
TOP TIPS FOR SMART SHOPS
Cutting fluids perform three key functions: ■ Lubrication of the chip/tool and tool/workpiece con-
tacts to reduce friction, helping to extend tool life and improve the surface finish of the workpiece ■ Cooling of the workpiece and tool to dissipate heat in
the cutting zone, helping to prevent chip/tool welding and improve dimensional accuracy
■ Milky or conventional… A cutting fluid with a high oil
content (60-75%) that forms a milky-looking emulsion upon dilution with water ■ Semi-synthetic… A cutting fluid with a low to medium
oil content (10-50%) that, when mixed with water, forms a translucent emulsion that can be seen through ■ Synthetic… A cutting fluid that doesn’t contain any oil
(chemical solutions) and is generally used for grinding ■ Flushing and removing of metal chips (swarf) from the
cutting zone With the multitude of factors that impact such fluids, however—including the operating environment, machining application and machined-metal type—no one cutting fluid can provide the required lubrication, cooling and protection in each and every operation. That’s why leading lubricant and metalworking fluid providers have developed a range of fluids to meet the many (and varied) operations of today’s machine shops. These fluids fall into two categories. 1. Neat (straight) fluids Neat fluids, which are not mixed with water, are used in machining operations such as tapping and threading of high alloy steels—operations that are beyond the typical performance profile of aqueous coolants. Properly formulated, these products can improve machining in high-speed automated machining centers through outstanding cutting performance, reduced tool wear and enhanced surface finish. Production professionals should typically seek products that are light in color to allow clear visibility of the workpiece. Operators should also look for products with low-misting characteristics to help improve workplace safety, while minimizing product usage. Selection should focus on products that are chlorine-free to support environmental concerns, while balancing lubricity and cutting-tool performance. 2. Aqueous (soluble/water miscible) fluids While neat cutting oils are provided in packs for immediate use, aqueous cutting fluids are provided in a concentrated form that must be diluted with water onsite before use. Optimum performance for these aqueous coolants requires an ongoing partnership-type of approach by the lubricant supplier and machine shop operator to help maximize productivity and reduce unscheduled downtime. A machine shop needs to work with its lubricant supplier to identify the most appropriate type of aqueous cutting fluid for the operating conditions. There are three different types of these fluids, all with different performance characteristics: MAY/JUNE 2012
Different concentrations are required for specific machining operations and metal types. Using the correct concentration is vital to the performance of the fluid and typically varies between 3 and 10%. For example, if a recommended concentration is 5%, the fluid has been designed to offer 100% protection and machining performance at that level. If the concentrate is just 1% outside this value, there will be 20% more or 20% fewer additives within the working fluid. With too high of a concentration, there’s the potential for issues such as skin irritation, foaming and filtration problems to occur. A concentration that’s too low can lead to severe problems such as bacteria growth, corrosion and poor surface finish. In machine-tool applications, the mixing of different lubricating oils (i.e., slideway and hydraulic) and aqueous fluids is virtually unavoidable. Using lubricants that are fully compatible with the aqueous cutting fluid is important to help remove the buildup of “tramp oil.” Tramp oil can compromise the effectiveness of a coolant by shortening its effective life and adversely altering cutting performance. High-quality, compatible metalworking fluids should be used in conjunction with a regular program aimed at removing (skimming) as much tramp oil as possible to extend the life of the coolant and avoid other potential performance, health and safety issues. Ongoing monitoring is key Once the correct type of coolant and operating concentration has been selected, it is crucial to continuously monitor the fluid’s condition. The four parameters to monitor are: ■ Fluid concentration ■ pH value ■ Bacterial and fungi count ■ Dissolved-salts concentration and hardness of water
Of these parameters, fluid concentration is the most important—and should be formally checked and recorded. During the lifetime of a coolant in service, its concentration can change greatly due to water evaporation from www.LMTinfo.com | 17
TOP TIPS FOR SMART SHOPS
Handling & Monitoring Water-Soluble Coolants Do:
■ Add the concentrate to the water. Use freshly mixed product only. ■ Ensure sufficient and correctly positioned coolant flow on the workpiece and tool without excessive pressure ■ Monitor and record coolant condition regularly and take the necessary corrective measures in a timely manner. This includes using a refractometer to monitor concentration and a pH test to monitor the acidity/ alkalinity of the product. pH levels should be kept between 8.3 – 9.5. ■ Keep systems clean by avoiding addition of contaminants, such as food, drinks, cigarettes, etc. ■ Remove tramp oil frequently ■ Ensure that all leaks of hydraulic oil, gear oils and other machine tool lubricants are attended to immediately ■ Keep coolant concentration at recommended level to help avoid slideway/ hydraulic oil contamination ■ Actively seek advice and training on coolant maintenance and control from your local lubricants supplier ■ Practice first in/first out inventory control to use the freshest concentrates possible
Don’t:
■ Use water from potentially infected sources, such as fire hoses, boreholes, header tanks, etc. ■ Put clean coolant into dirty machines. Use a system cleaner and follow the specified cleaning procedure carefully. ■ Leave machines full of coolant standing idle for long periods, particularly when contaminated with tramp oil ■ Use an aqueous metalworking fluid beyond its working life ■ Prepare diluted products in dirty or galvanized containers ■ Top up with water. Always use diluted emulsion. ■ Eat, drink or smoke near machine tools ■ Use concentrates that are beyond their rated shelf life
heat generation during the cutting process, fluid dragged by chips and losses resulting from highly pressured circulation. Consequently, close monitoring is required on a daily basis—accompanied, as needed, by carefully measured corrective actions to help control the fluid concentration. Simply approximating the amount of water and concentrate to balance the fluid can lead to problems such as lowered pH values and increased bacterial activity. These changes can lead to shorter coolant life, lower-quality machined parts and, ultimately, increased operating costs. The following actions should be carried out on a scheduled basis: ■ Check the concentration of coolant with a refractometer
at the beginning of every day/shift. ■ Check pH value with pH meter or pH paper at the
■ Every week, remove as much tramp oil as possible after
the coolant has been static for one hour. Installing an automated skimmer can help to continuously remove tramp oil from the cutting-fluid sump. ■ Always top-up with diluted coolant, never just water. ■ Use monitoring charts to keep good records of coolant
progress and take timely corrective actions as required. Get the most from your cutting fluids Selecting and monitoring cutting fluids—especially watersoluble coolants—doesn’t have to be as problematic as you might have thought. By following the suggestions in this article, your business can minimize potential issues associated with these fluids, as well as maximize overall machine efficiency and operator productivity. LMT
beginning of every day/shift. ■ Check diluting-water and coolant hardness with water-
hardness strips every week. 18 | LUBRICATION MANAGEMENT & TECHNOLOGY
Travis Lail is Industrial Marketing Advisor for ExxonMobil Lubricants & Specialties (www.mobilindustrial.com) For more info, enter 02 at www.LMTfreeinfo.com MAY/JUNE 2012
BIG MONEY TALKS XX UM UM William C. Livoti, GIW/KSB
Gearbox Efficiency: There’s Money To Be Saved
G
earing is a common way to reduce speed and boost torque. During this transformation, the gear “consumes” a certain percentage of power. This power is termed as a loss and is measured in watts. Efficiency—as it relates to enclosed gearing— is simply the ratio of the output power (power transmitted through the gearbox as usable work) to the input power. Losses can be measured by subtracting the power out from the input power. As losses are reduced or minimized, efficiency improves. Gearing losses are due to friction. Two gears in mesh generate losses and inefficiency from the sliding action of one gear tooth against the corresponding tooth of the mating gear. This action converts usable power to heat and reduces overall efficiency of the gear set. While it’s inaccurate to say that a specific gear type has a definite efficiency, some gear types typically operate at lower efficiencies than others. How to calculate these losses Keeping in mind various gearing types (right angle helical bevel; right angle worm/helical; parallelhelical; and right angle worm), it’s easy to determine gearing losses:
4. Calculate annual energy savings, cost of energy in $/kW and estimated hours of operation per year as follows: Savings / year = power saved (watts) x cost of energy ($/kW) x hours of operation 5. In justifying the cost premium of an alternative gearing selection, you can calculate simple payback (i.e., number of years required to pay off the initial investment) as follows: Simple payback = initial cost difference / savings / year Of course, common sense reduces the need to calculate losses. For example, avoid over-powering the application. The proper selection of gearing and motor to meet application requirements will save energy and keep equipment costs low. Gearing should be applied based on output capability— not on the input power required. During idle periods, consider turning off equipment. Finally, remember that proper installation and alignment are priceless, as is proper maintenance.
2. Comparing two choices of gearing for an application, the power savings is the difference in the power losses or the difference in the input power required: Power saved (watts) = input power choice 1 - input power choice 2
Conclusion Since many factors affect gearbox efficiency, it can be worthwhile to perform a system study and replace inefficient, unreliable gearboxes with more reliable units. For example, the durability and longevity of helical bevel gears often makes it possible to replace a worm gearbox/motor combination with a smallerhorsepower input-HB and produce more torque at the driven shaft. The bottom line is if you’re using the right gearing type—and following the above advice— you can expect to save money while you boost reliability and efficiency. UM
3. If data is available, converting from horsepower to watts yields the savings directly: Power saved (watts) = 746 x HP in [ 1- eff lower / eff higher ]
Bill Livoti is Power Engineering - Energy Efficiency Service Center Engineering/Manager for the GIW/KSB Florida Service Center in Mulberry, FL. Email: William.Livoti@giwindustries.com.
1. Measure losses by subtracting the power out from the input power: Power losses (watts) = input power (watts) - output power (watts)
For more info, enter 261 at www.LMTfreeinfo.com
VOLUME 72 / NO. 2
UTILITIES MANAGER | 19
UM Editor’s Note: This article is based on one that first appeared in the March 2012 issue of Commercial Building Products, a sister publication of Lubrication Management & Technology.
Specify Backup Power That Fits Ensuring that your selected backup-power system can meet both current and future needs depends on a number of factors. Michael Kirchner Generac Power Systems
P
eace of mind is a priceless and coveted commodity in today’s business environment. Adequate backup power contributes to that peace of mind, because downtime means lost revenue. Thus, specifying a backup-power system that’s appropriate to a particular application requires attention to several details.
The first thing to consider when specifying a backuppower system should be obvious: power demand— the amount of electricity needed to back up all necessary circuits. However, what’s often not so obvious are the future power needs for the application. Over time, the power demands of a building (or the tenants in that building, if applicable) will likely change. The demands won’t get smaller, either. According to a commentary by Max Schultz on Forbes.com, ( h t t p : / / w w w. f o r b e s . co m / 2 0 0 9 / 0 6 / 0 4 / a m e r i c a power-grid-opinions-contributors-energy.html), the U.S. economy will require 30% more electricity by 2030. Increased power needs place more demand on a backup20 | UTILITIES MANAGER
power system in emergency situations and can reach a point where the system is no longer capable of supplying the necessary amount of power. Additionally, because backup-power systems have an effective life of several decades, it’s important to build in scalability so as not to replace a perfectly good—not to mention costly—system before its effective life has been exhausted. Scalability can be addressed in a single-generator solution by designing extra capacity into the specification to allow for future power needs. This approach, while often acceptable, has its drawbacks. First, it requires an accurate estimate of what the maximum power needs of an application will be over the course VOLUME 7 / NO. 2
UM
of the generator’s life. It also ties up capital in the backuppower system at the outset—monies that might be better invested elsewhere. Additionally, because large generators use equally large engines that are manufactured in relatively small volumes, turnaround time for such a system can be longer than anticipated, which can cause problems from a project-scheduling standpoint. An excellent alternative to this approach is a modular power system, in which several smaller generators are connected in parallel to provide the necessary output. Such systems are becoming increasingly cost-effective and space-efficient, thanks to new digital technologies that control all generator functions and switchgear integrated into the generators themselves. As the power needs for the application grow, other generators can be easily added to the system to provide extra capacity. This allows for a less-accurate initial estimate of how power needs will grow, since more capacity can be added in relatively small increments. A modular system also offers installation flexibility not found in a single-generator (genset) solution, because the units need not be installed side by side. Furthermore, because these smaller generators typically use high-volume, on-highway truck- and automotive-derivative engines, instead of the lower-volume large engines mentioned earlier, most manufacturers can fulfill modular powersystem generator orders in a shorter time. That means additional capacity can be added very quickly to a system to accommodate growth. Build in reliability Reliability is also a key factor in specifying a backup-power system. Nothing is worse than expecting a backup-power system to protect your investment, only to have it fail when it’s needed most. While on the surface, reliability sounds subjective—related exclusively to one’s belief in a brand name or faith in a particular system’s components—there are some concrete ways to evaluate reliability in a backup-power system. Consider the single-engine vs. modular-power system example described above. Large single-engine gensets can offer reliability on the order of 98% to 99%, which is acceptable in many applications. However, there are applications, such as those associated with mission-critical data, where a power failure means a business failure— not just a loss of revenue. In such cases, maximizing reliability should be the goal. Modular power systems can do that, as well, through increased redundancy. Unlike a single-generator solution, no one generatorfailure results in the failure of the entire backup-power system. As previously mentioned, if the reliability of a standby generator is defined at 98%, a modular power system with an N + 1 configuration has a reliability of 99.96%, and an VOLUME 7 / NO. 2
N + 2 configuration has a reliability of 99.999%. Therefore, when power absolutely, positively must remain on, it might be wise to eschew a single-generator solution in favor of a modular power system. The fuel supply is another reliability factor. Diesel fuel has been the traditional choice for backup power because its high thermal efficiency typically results in a lower cost/kilowatt in larger applications. On-site emergency-system fuel storage also tends to be preferred by many authority-having-jurisdiction (AHJ) agencies. Issues of fuel storage, contamination and breakdown, however, can have an impact on system reliability. If ongoing fuel maintenance will be a challenge, a diesel-fueled genset might not be the best choice. Natural gas is being considered more often for standby applications because it avoids the diesel-fuel storage issues. The natural-gas infrastructure is generally not affected by utility failures. The natural-gas supply, though, can be affected in situations such as seismic activity, raising questions of suitability for code-required emergency systems. The AHJ can address the reliability of natural gas in a given area. If on-site fuel storage is required for the application, dual-fuel gensets that can operate on both natural gas and on-site LP fuel are an option. Bi-fuel generators, which simultaneously burn diesel and natural gas, effectively capitalize on the benefits of diesel and gaseous fuels while minimizing drawbacks that affect reliability. They offer the extended run times of natural gas, but can operate on 100% diesel fuel, if necessary. The amount of diesel fuel stored on site is significantly reduced as well, because natural gas is the dominant fuel. Other benefits include reduced maintenance costs, lower emissions and reduced operational costs. Explore standards compliance As clear from the previous discussion, it’s always wise to consult with the appropriate AHJ regarding specific code questions. For example, the key NFPA (National Fire Protection Association) standard for backup-power generation is NFPA 110, which addresses the assembly, installation and performance of backup-power supplies for emergency systems and legally required standby loads. Compliance with NFPA 110 is compulsory in those jurisdictions that also have adopted NFPA 101 (life-safety code) or NFPA 99 (healthcare facilities), as both of those standards require NFPA 110 compliance. The local AHJ can advise as to whether NFPA 110 compliance is required for a facility backup-power system. But even if it is not, NFPA 110 compliance goes a long way toward ensuring that a backup-power system is adequate for supporting key building systems in particular applications. It can also help you determine the size and type of system you will specify for a given application. UTILITIES MANAGER | 21
UM
Consider maintenance requirements Preventive maintenance is the most effective and important tool for ensuring the reliability and adequacy of any backup-power system. However, different backup-power systems will require different amounts of maintenance. The ability of the end-user to comply with the system’s maintenance schedule should be considered when specifying a system. Single-engine gensets offer the benefits that come from having only one unit that needs maintenance. On the other hand, such units incorporate engines built in lower volumes, so consumable preventive-maintenance components tend to be more costly. Moreover, singleengine gensets require large volumes of oil and coolant— which are also pricey items. Before specifying such a unit, it’s important to make sure that the end-user is willing to bear these maintenance costs. Note, too, that since just a single generator will be providing all backup power, the facility won’t be protected during any maintenance that calls for taking the unit offline Modular power systems, by comparison, are multiple in number and offer the advantage of units that can be taken offline—one at a time—for extensive maintenance without eliminating the facility’s backup-power protection. Moreover, because they are powered by engines that are produced in much higher volumes, preventive-maintenance consumables are more cost-effective.
Keep in mind that the chosen fuel supply also affects preventive maintenance. Diesel fuel, for instance, requires more maintenance than gaseous fuels. Unless properly maintained, diesel fuel will lose its efficacy. Maintenance requires the removal of water and dirt from the diesel tank. Water must also be drained from the tank monthly/ weekly in more active systems or in areas with large daily temperature changes. If the end-user operation is unable to perform this type of maintenance, a diesel-fueled genset might not be appropriate. The value in peace of mind There’s no doubt that backup-power systems mean peace of mind for building owners. Selecting the right system requires planning for those things that truly matter: current and future power needs, reliability, standards compliance and ongoing maintenance. Specifiers and endusers need to stay mindful of these items while maintaining a strong working relationship with the local AHJ to ensure that the right system for the application is installed. UM Michael Kirchner is Technical-Support Manager for Generac Power Systems in Waukesha, WI. A 12-year veteran of the company, he holds both an Electrical Engineering degree and Master’s in Business Administration from the University of Wisconsin. For more info, enter 262 at www.LMTfreeinfo.com
Varnish-Dissolving Compressor Fluid
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ccording to Sullair, its synthetic, polyglycol-based SullubeTM compressor fluid can dissolve varnish buildup in fluid components. This high-flashpoint (505 F/263 C) product helps keep rotors clean, reduces energy consumption and removes heat, thus allowing compressors to run cooler. The manufacturer notes that the product can run continuously in any rotary screw compressor, regardless of make or model, for up to 8000 hours without fluid changes or fluid-related maintenance. Based on the fact that Sullube is biodegradable in compressor condensate, it can eliminate some of the time and costs associated with disposal of other compressor fluids.*
Gadgets adgets
Efficient
*When disposing of SullubeTM, always comply with applicable regulations.
Sullair Corp. A subsidiary of Hamilton Sundstrand A United Technologies company Michigan City, IN For more info, enter 03 at www.LMTfreeinfo.com
22 | UTILITIES MANAGER
For more info, enter 74 at www.MT-freeinfo.com
VOLUME 7 / NO. 2
TECHNOLOGY TOOLS
Source : NewPage Corporation
Building Reliability On A Foundation Of Lubrication The innovative approach to lubrication that one paper mill took improved conditions of its machines and its bottom line. That type of success is why a similar approach was rolled out to seven other sites across the corporation. Jane Alexander, Editor with Bill Correll, Generation Systems, Inc.
A
lthough plants spend billions of dollars annually on equipment reliability initiatives, many overlook lubrication as an area of opportunity worthy of renewed focus. One notable exception is the NewPage Paper Mill, in Duluth, MN*, which considers lubrication to be a foundational component of its equipment-reliability and best-practices program.
*The New Page Duluth Paper Mill is owned by NewPage Wisconsin System Inc., an affiliate of NewPage Corporation, a leading North American producer of printing and specialty papers.
MAY/JUNE 2012
www.LMTinfo.com | 23
TECHNOLOGY TOOLS
These days, the mill is enhancing plant performance with an approach to lubrication that provides benefits and efficiencies that extend well beyond traditional approaches such as using spreadsheets or the preventative maintenance (PM) capabilities of CMMS or ERP systems. 100,000+ annual lube tasks Lubrication is often viewed as nothing more than a quick series of simple, repetitive tasks like hitting a grease point or topping off a reservoir. However, a single plant can have hundreds to thousands of pieces of equipment, each with multiple lubrication points. In turn, each lubrication point can have multiple tasks, all performed at varying intervals. From daily lubing, to semi-annual oil sampling, to yearly tank draining/replacement, the lubrication tasks that must be performed annually in a facility can—amazingly— number in the hundreds of thousands. To address this issue, many plants utilize spreadsheets or CMMS systems in an effort to manage lubrication. Unfortunately, although CMMS systems work very well for managing PM and corrective jobs at the equipment level, they are not built for detailed tracking of individual lube tasks. On the other hand, information contained in such details—when properly structured to the specifics of lubrication—can enable best practices to improve machine condition, extend life and uptime, identify equipment issues early and boost employee productivity (and can do so in a way that both experienced and inexperienced personnel can easily follow). Case in point “With the volume of activities that need to be performed and the complexity of managing all these different types of activities with different lubricants, time frames and procedures, we have to be able to store and easily access detailed information on each lube point,” says Tammy Needham, Machinery Lubrication Technician at NewPage’s Duluth operation. NewPage is the leading producer of printing and specialty papers in North America, with a total annual mill production capacity of about 3.5 million tons of paper. Needham oversees all aspects of lubrication including lube tasks, inventory and testing for the site’s paper machine. In addition to having 25 years of real-world experience, Needham has continually sought out training opportunities to upgrade her lubrication knowledge and is certified as a Machinery Lubricant Technician (MLT) and Machinery Lubricant Analyst (MLA). “When I started in lubrication, I immediately realized the benefit of handling all the lubrication tasks on time and getting the right amount of grease into the right place every time to increase the longevity and reliability of our equipment,” recalls Needham. 24 | LUBRICATION MANAGEMENT & TECHNOLOGY
Several years ago, her manager decided it was time for the Duluth plant to upgrade to comprehensive lubrication tracking and management software. After investigating several options on the market, the mill selected LUBE-IT, from Generation Systems. With the LUBE-IT system, each lube point is inventoried by component type, location, capacity, number of fittings and lubricant to be used. Each lube point is then associated with the individual tasks required. Details for each task include the activity to perform, frequency, duration of each task, route, procedures and shutdown requirements. Using this essential information, the software continuously manages lubrication throughout the plant by tracking the status of each individual task. This is in contrast to outmoded approaches such as spreadsheets, or tracking collections of tasks across an array of CMMS PMs. Each week, the LUBE-IT system’s automatic work planning process evaluates every task, individually releasing only those that are appropriate. Tasks not previously completed are highlighted as past-due and included within the current week’s work. For Needham, the advantage of this type of approach is to reinforce a culture of excellence and protect the accumulated knowledge and best practices of the lubrication program at NewPage’s Duluth site—instead of depending on human memory. With all of the details documented in the system, plant personnel and management also have one-click access to the history of any lubrication point, which can be invaluable for failure analysis. This includes when individual tasks were completed, a reason if not completed, the number of weeks past-due, who was assigned, the lubricant used and notifications of equipment issues identified during the lubrication activity. Benefits of optimization Optimized lubrication routes are another benefit of having detailed lube-point information and can dramatically increase the speed and efficiency of maintenance. Using information in the system, the LUBE-IT program sets up a labor-efficient, step-reducing route from a start to an end point assigned to specific personnel. Each lube task along that path—incorporating all tasks due to be completed regardless of frequency—as well as the various types of lubricants that will be required are outlined in a logical walking sequence. That’s a real boon from the standpoint of technician efficiency. According to Needham, “You can move from a pump to an agitator to a hydraulic system all in walking sequence with detailed information on each lube point on the route, what lubricant is required and so on.” MAY/JUNE 2012
TECHNOLOGY TOOLS
Needham's success with this lubrication-related information technology system helped her company decide to obtain the
Management feedback Needham points to the fact that NewPage management now has access to detailed reports and KPI information relating to the lubrication effort that it never had before. The feedback she has received from management has been extremely positive. Although she's been working with LUBE-IT for over a decade, the capabilities and detail in the program have dovetailed nicely with NewPage’s recent corporate initiative to improve efficiency and equipment reliability in all of its seven plants. “There has been a big push lately to really get everything documented,” Needham says. “Management felt that by really looking closely at the lubrication aspect of all its plants they could discover some cost savings and ensure the equipment lasts longer.” She clearly credits management support for the site’s ability to accomplish many of it lubrication goals. Needham’s success with LUBE-IT was instrumental in NewPage’s decision in early 2012 to purchase the software for additional sites. “Being able to put down all this detailed, documented information in one place that was easily accessible is a tremendous benefit to our company,” she observes. “It is so foundational to our entire lubrication effort that I don’t believe you could put a price tag on it.” LMT Bill Correll is Vice President of Business Development for Generations Systems, Inc., based in Issaquah, WA. For more info, enter 04 at www.LMTfreeinfo.com
software for additional sites in early 2012.
Needham also finds the routing feature to be a useful reminder with regard to tasks that are required less frequently (like semi-annual or annual lubrication activities). Moreover, the routing system is so efficient that basic care tasks not related to lubrication, such as cleaning a piece of equipment or adjusting a shim along the route, can be incorporated. With LUBE-IT, safety-related procedures and requirements also be associated with a specific task and clearly presented to personnel prior to performing the task. Needham explains it this way: “If there is a safety procedure that needs to occur before the lube task, a technician can look at the sheet and see exactly what steps needs to occur first. I want to make sure that nobody is going to get hurt.” MAY/JUNE 2012
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California - Illinois - Connecticut - Canada e-mail: support@miller-stephenson.com www.miller-stephenson.com m more info, enter 86 at www.MT-freeinfo.com For more info, For enter 68 at www.LMTfreeinfo.com
s
www.LMTinfo.com | 25
DELIVERING THE GOODS
The Anatomy Of A Centralized Lubrication System
Air/Oil Delivery Air In
Oil In
Mixing Valve Oil Metering Valve
Oil Pump Reservoir
Air/Oil Out Air/Oil Nozzle
Flow Airflow Streaked Oil Droplets
Bearing Point
Ken Bannister Contributing Editor
T
he Air/Oil system was first developed as a total-loss oil system to meet the specific needs of the high-speed bearing environment. It’s now been refined to the point where it is a viable and effective lube system for any rotary or linear machine application. Development of these systems was fueled by a number of issues.
In today’s high-speed rotating-equipment applications (i.e., those with machine spindles, turbines, blowers, etc.), bearings and gearing can reach surface-speed values of up to 2.2 million DN. (DN value is calculated by multiplying the bearing diameter in mm [D] by the rotational speed of the spindle in RPM [N]) Traditional wet-sump oil and grease lubrication methods cope poorly in high-speed environments as they struggle to dissipate the additional heat load created by speed and fluid friction, leading to energy loss and reductions in lubricant life and machine speed capability. Although mist-lubrication systems allow for higher rotating speeds over traditional lube systems, they’re not able to provide the exact metering 26 | LUBRICATION MANAGEMENT & TECHNOLOGY
requirements needed for extended bearing service life. Furthermore, as mist is in a micro-droplet form and susceptible to becoming airborne in the plant environment, some operations consider it to be a health and safety problem. Air/Oil technology has been able to address these concerns. How the System Works A relative newcomer on the block, the Air/Oil lubrication system can best be described as a hybrid system incorporating the metering capability of existing single-line resistance, positive-displacement injector in conjunction with progressive-divider delivery technology. Oil is metered in the traditional manner in minute quantities to a mixing block MAY/JUNE 2012
connected to a clean, dry compressed-air supply. Individual oil drops are dispensed into a small-diameter (usually 4mm or 3/16 in.) delivery tube where they are “streaked” by the air into macro-droplets and transported along the tube’s inner walls to a dispensing nozzle located at each lubrication point. The small diameter of the nozzles creates a venturi effect, allowing the air and oil droplets to envelop the bearing surface in an almost oil-free manner. The air forces the lubricant film across the bearing surfaces, producing additional cooling and a positive pressure in the bearing area that aids in sealing out external contaminants such as coolant and dirt. Pros & Cons When set up correctly the Air/Oil system boasts an impressive number of benefits, including: • The ability to deal with the highest possible bearing surface speeds • Bearing-temperature rises over ambient of less than half those of traditional lubrication methods • Reduced energy consumption
For more info, enter 69 at www.LMTfreeinfo.com
• Continuous fresh-oil delivery • Up to a 90% reduction in lubricant use compared with mist-lubrication systems • Up to a 99% reduction in lubricant use compared with grease systems • Extended bearing and seal life expectancy • Small environmental impact compared with that of other lubrication cleanup/disposals methods Because the Air/Oil system is a hybrid system, it requires the purchase of a traditional lubrication system and the additional costs of adding mixing control valves and a clean and dry air-supply network to each mix valve assembly. Due to the small aperture of the delivery nozzle, use of solids additives such as moly and PTFE is discouraged, since they can “bridge” across the nozzle, form deposits and cause an oil starvation situation. The Air/Oil system is more difficult to design as an add-on to an existing system than it is to incorporate in the machine design stage. LMT For more information regarding automated lube systems, check out Ken Bannister’s best-selling book Lubrication For Industry, published by Industrial Press. Telephone him at (519) 469-9173, or email: kbannister@engtechindustries.com. For more info, enter 05 at www.LMTfreeinfo.com MAY/JUNE 2012
For more info, enter 65 atenter www.LMTfreeinfo.com For more info, 70 at www.LMTfreeinfo.com
www.LMTinfo.com | 27
PROBLEM SOLVERS
Monitoring Wear Debris In Hazardous Environments
Easy, Less-Messy Oil-Sampling
K
ittiwake’s ATEX Metallic Wear Debris Sensor facilitates realtime wear debris monitoring for both ferrous and non-ferrous metals in hazardous areas. Capable of being mounted within any lubrication system, on any type of asset, it uses a combination of inductive-coil technology and algorithms to provide a particlesize distribution count. ATEX and IECEx certifications allow the product to be used in environments where explosive gases are likely to be present.
Kittiwake Americas Houston, TX
For more info, enter 30 at www.LMTfreeinfo.com
A
ccording to JLM Systems, the Pass-Thru technology on its recently introduced OILMISER™ Pass-Thru Sampling Valve (SV-PT) is a game changer for oil sampling. Designed with a plated steel body and Hex cap with chain tether, the device’s Pass-Thru feature allows a ¼” OD plastic tube or the OILMISER™ pass-through pitot tube to be inserted from the outside into the machine from which oil is being sampled. A tube seal/wiper strips surface oil from the sampling tube. The new SV-PT is available with a ¼”, ⅜”, ½” or ¾” NPT male pipe thread.
JLM Systems Ltd. Richmond, BC, Canada For more info, enter 31 at www.LMTfreeinfo.com
Stop Guessing! How many times have you thought, “How much grease and how often?” Ever wonder how accurate your current re-lubrication schedule is? Stop guessing and know! The Ultra-Lube provides instant, real-time user feedback on all types of rotating equipment.
The Ultra-Lube Acoustic Monitor Safe and simple to use Extremely durable and rugged Reveals existing bearing problems Prevents over and under-lubrication Eliminates grease gun calibration Environmentally conscious Excellent with gearboxes 20 Year Limited Warranty!!
Ph - 360-736-2333 Fax - 360.736.1579
800-736-3757 www.uvlm.com
For more info, enter 71 at www.LMTfreeinfo.com
28 | LUBRICATION MANAGEMENT & TECHNOLOGY
Severe-Service Rotary Shaft Seals
K
alsi Enginering’s 568-Series Enhanced Lubrication rotary shaft seals were developed to reduce torque and seal-generated heat in the type of high-pressure surface applications where higher hydrodynamic leakage can be tolerated and thinner viscosity lubricants may be encountered. Dual Durometer configurations are available to augment highpressure extrusion resistance. These seals are suited to oilfield surface applications like rotary blowout preventers, rotary heads and multi-port hydraulic swivels. Kalsi Engineering, Inc. Sugar Land, TX For more info, enter 32 at www.LMTfreeinfo.com MAY/JUNE 2012
PROBLEM SOLVERS
Cleanliness Indicators For Hydraulic Filters
S
chroeder Industries’ MS Electrical Dirt Alarm® Indicator Series is suited for use with a range of the company’s hydraulic filters. The products alert users of the need to change out an element, thus helping maintain crucial fluid cleanliness. A crimped body design eliminates the need for the four bolts used in the product’s existing design, reducing cost and assembly time. A thermal lockout option can help prevent false indications during cold starts.
Schroeder Industries Leetsdale, PA For more info, enter 33 at www.LMTfreeinfo.com
Quick-Working Leak Sealant
S
topIt HP™ from InduMar Products is a leak sealant for working pressures up to 2000 psi. To apply, users mix a premeasured, two-part sealant, wet a fibrous reinforcement tape and wrap it around the pipe surface. The sealant can be applied regardless of pipe orientation, and provides a durable coating approximately 5 mm thick. It has a working time of 8-10 minutes and requires as little as four hours to cure.
InduMar Products, Inc. Houston, TX For more info, enter 34 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!* Looking to increase asset utilization and maintainability, reduce contamination, downtime, energy consumption and/or your carbon footprint? You’re ready for a 7-Step Best Practice lubrication Program! For more information on this “expert in a box” approach, 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 MAY/JUNE 2012
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www.LMTinfo.com | 29
Index ADVERTISER
MAY/JUNE 2012 Volume 13, No. 3 •
WEBSITE
CIRCLE #
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Abanaki Corporation ...............................www.abanaki.com/166 .................... 72................... 29 ATP Lists ....................................................www.atplists.com ............................. 74................... 30 Baldor Electric Company.........................www.baldor.com .............................. 76................... 32 Des-Case Corporation .............................www.descase.com ............................ 66................... 13 EASA ..........................................................www.easa.com .................................. 67................... 15 Engtech Industries Inc..............................www.engtechindustries.com........... 73................... 29 Maintenance & Reliability Innovator .....www.reliabilityinnovator.com ........ 62..................... 4 LubeStarz ...................................................www.lmtinfo.com/lubestarz ........... 75................... 31 Miller-Stephenson Chemical Co. ............www.miller-stephenson.com.......... 68................... 25 NSK Corporation .....................................www.nskamericas.com.................... 64..................... 7 OilMiser .....................................................www.oilmiser.com ........................... 69,70 ............. 27 Panasonic Computer Solutions Co.........www.panasonic.com/toughpad ..... 65................... 11 Scalewatcher ..............................................www.scalewatcher.com.................... 61..................... 2 U.S. Tsubaki Power Transmission, LLC ..www.longlifelambda.com ............... 63..................... 5 UVLM, Inc.................................................www.uvlm.com ................................ 71................... 28 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.
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SALES STAFF OH, KY, TN 135 N. Rocky River Road Berea, OH 44017 440-463-0907; Fax 440-891-1254 JOHN DAVIS jdavis@atpnetwork.com AL, 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 IA, MN, NE, ND, SD 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 847-382-8100 x116; Fax 847-304-8603 BILL KIESEL bkiesel@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 IL, IN, MI, WI 1173 S. Summit Street Barrington, IL 60010 847-382-8100 x108; Fax 847-304-8603 TOM MADDING tmadding@atpnetwork.com AR, KS, LA, MO, NM, OK, TX 5930 Royal Lane, Suite E #201 Dallas, TX 75230 972-816-3534; Fax 972-767-4442 GERRY MAYER gmayer@atpnetwork.com
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LUBRICATION MANAGEMENT AND TECHNOLOGY
AZ, CA, CO, ID, MT, NV, OR, UT, WA, WY, AB, BC, MB, SK 3605 N. Tuscany Mesa, AZ 85207 480-396-9585 JERRY PRESTON jpreston@atpnetwork.com CLASSIFIED ADVERTISING 3605 N. Tuscany Mesa, AZ 85207 480-396-9585 JERRY PRESTON jpreston@atpnetwork.com
MAY/JUNE 2012
WE’RE BUILDING A TEAM...
e b u Meet Our L arz St
©
We love to learn about LMT readers, including what they do in the field of lubrication (and what they like about their jobs)! Here’s what our May/June Lube Star told us:
Jim Harris Title: General Manager, CCECO Lab & Filtration, a manufacturer of fine-micron oil-filtration equipment with oil-analysis and lab services, headquartered in Kent, WA. Background: Jim began working as a machinist at Star Iron and Steel, in Tacoma, WA, where he ran all aspects of building parts for container cranes and straddle carriers. From there, he moved to the Maintenance Department at the Port of Tacoma. At the time of his retirement (after 32 years of service), he was Lead Equipment Foreman for all Port Operations. During his time at the Port, Jim was responsible for implementing an oil-analysis program on all fleet vehicles and equipment (including installation of over 270 CCECO bypass filter systems). This successful program led to over $1.5 million in savings from reduced maintenance costs and extended oil-drain intervals for engines and hydraulic systems. As Jim describes it, once retired, he couldn’t sit still. Equipped with the in-depth knowledge, skills and expertise in oil-contamination issues that he had built at the Port of Tacoma, he joined the CCECO organization in 2009. This career move has allowed him to continue doing what he likes best: providing training to and sharing his experiences with others. That includes presenting at industry events like the University of Washington’s Vehicle Maintenance Management Conference and the Kelmar Oil Analysis International Conference, among others. Why He Became A Lubrication Professional: According to Jim, early in his career he could see how important clean oil was to reducing costs and extending the life of equipment. He notes that he “was trained by the best” in oil analysis and reasons for component failure, and the more he learned, the more he wanted to extend his work in the field. What He Likes Most About His Work: Jim says he particularly enjoys the opportunity to educate others and see the light bulbs go off in their eyes. “Customers love seeing the positive impact of clean oil on their operations and contributing to reducing the United States’ dependence Company on foreignInfo oil,” he explains. In turn, he continues, “I love helping them become better stewards of the environment Contact Info Here that God has entrusted to us, and significantly reducing the use of a natural resource… OIL.” www.websitehere.com Congratulations to Jim for being selected to our Lube Starz team! Our congratulations (and thanks) also go out to CCECO Lab & Filtration © for helping us put a spotlight on Jim, as well as for helping grow the maintenance/lubrication profession.
e b u L tarz S
Our caps are off to all hardworking Lube Starz, who’ll receive their own baseball caps for making the team. Up for the game? Go to www.lmtinfo.com/lubestarz or www.lubestarz.com to tell us about yourself!
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 soon!
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For decades, ABB variable speed drives and Baldor motors have set the standard for quality, reliability and energy savings. Now, industrial customers in the U.S. can buy these products and receive expert support from a single source. Call 479-646-4711 to locate the district office nearest you. Two trusted names. One local source for sales and support. Only from ABB and Baldor. baldor.com
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©2011 Baldor Electric Company
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