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NOVEMBER/DECEMBER 2011 • VOL 12, NO. 6 • www.LMTinfo.com
Contents
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
FEATURES PROFESSIONAL DEVELOPMENT SERIES 8
Certification Matters, Part V (Conclusion): Fluid Conditioning, Key To Equipment Reliability
©Yuri Arcurs—Fotolia.com
When it comes to the cleanliness of the lubricants in your rotating equipment, you can’t be too vigilant.
Ray Thibault, Contributing Editor
THE RELIABILITY FILES 14
Lubricants Are Not Commodities: Making The Case For Superior Lubrication What’ll you have: energy savings, maintenance savings and/or improved production? Many sites note the right lubricants let them have it all.
GREASE TIPS 16
6
Bearing Grease Replenishment Intervals In simple terms, here’s what one respected bearing manufacturer has to say about a very basic, but critical, topic. Special to LMT from NSK Corporation
THE CORPORATE REPORT 20
DEPARTMENTS From Our Perspective
27
Problem Solvers
29
Classified
29
Supplier Index
30
Lube Starz
Profiles Of Leading Suppliers To Industry ■ Bel-Ray ■ HyPro Filtration ■ NSK Corporation ■ Royal Purple ■ Scalewatcher North America, Inc. ■ US Tsubaki Power Transmission, LLC ■ Des-Case Corporation
Achieving Efficiencies Through Practices & Products Apply for a free, one-year subscription at
www.LMTinfo.com NOVEMBER/DECEMBER 2011
www.LMTinfo.com | 3
Reliability: Own It
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
November/December 2011 • Volume 12, No. 6 ARTHUR L. RICE
This MARCH... Save The Date For
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
MAINTENANCE and RELIABILITY TECHNOLOGY SUMMIT
The Capacity Assurance Conference!
MARCH 12-15, 2012 • A four-day educational experience created exclusively for reliability professionals • 30 hour-long Conferences over two days – Tuesday, March 13 and Wednesday, March 14 – kicked off by Keynote speaker David Boulay, president of the Illinois Manufacturing Extension Center, and followed by reliability experts in a variety of disciplines
• 6 full-day Workshops on Monday, March 12 • 6 full-day Workshops on Thursday, March 15 • Two professional certification opportunities Now entering its ninth year, MARTS is an exciting learning event in a great location that helps reliability professionals at all levels improve their skills and excel on the job. Pricing and attendance options for every budget make it easy for individuals or groups to share the MARTS experience.
MAINTENANCE and RELIABILITY TECHNOLOGY SUMMIT
Hyatt Regency O’Hare O’Hare, Rosemont (Chicago), IL
www.MARTSconference.com For more info, enter 62 at www.LMTfreeinfo.com For more info, enter 62 at www.LMTfreeinfo.com
4|
LUBRICATION MANAGEMENT & TECHNOLOGY
KENNETH E. BANNISTER RAY THIBAULT, CLS, OMA I & II RAYMOND L. ATKINS Contributing Editors
RANDY BUTTSTADT
Director of Creative Services rbuttstadt@atpnetwork.com
GREG PIETRAS
Editorial/Production Assistant gpietras@atpnetwork.com
ELLEN SANDKAM
Direct Mail esandkam@atplists.com
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 by Applied Technology Publications, Inc., 1300 S. Grove Avenue, Suite 105, Barrington, IL 60010. Periodical postage paid at Barrington, IL and additional offices. Arthur L. Rice, III, President/CEO. Circulation records are maintained at Lubrication Management & Technology, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Lubrication Management & Technology copyright 2011. No part of this publication may be reproduced or transmitted without written permission from the publisher. Annual subscription rates for nonqualified people: North America, $140; all others, $280 (air). No subscription agency is authorized by us to solicit or take orders for subscriptions. Postmaster: Please send address changes to Lubrication Management & Technology, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Please indicate position, title, company name, company address. For other circulation information call (630) 739-0900. Canadian Publications Agreement No. 40886011. Canada Post returns: IMEX, Station A, P.O. Box 54, Windsor, ON N9A 6J5, or email: cpcreturns@wdsmail. com. Submissions Policy: Lubrication Management & Technology gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Printed in U.S.A.
NOVEMBER/DECEMBER 2011
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FROM OUR PERSPECTIVE
Ken Bannister, Contributing Editor
Run Like A Religion!
I
n today’s world, we expect to be able to step into a car, turn the key and drive virtually nonstop across the country at high speed, with little thought as to the vehicle’s ability to make the journey. Many of us remember when this wasn’t possible. A few short decades ago, the same excursion would have required significant preparatory work, coupled with plenty of automotive TLC throughout the trip! Similarly, industrial machine design has changed drastically in the past few decades, with the introduction of new materials and electronic “whiz-bang” technology that automatically micromanages our equipment systems for us. No longer do operators have to constantly adjust and tend their machinery. The net gain of this design revolution has been more reliable and operator-friendlier equipment. This relief of duty, however, has resulted in the loss of many skilled individuals who used to take care of the equipment’s needs. Ironically, enhanced equipment reliability and ease of use could be making us complacent about our approach to maintenance. Consequently, there seem to be just as many unexpected failures now as in the past. (Have you tried to get your car into the shop lately?) On a recent trip to England, I was invited to tag along as a guest operator/maintainer on the world’s oldest and largest in situ compound, double-acting, triple-expansion steam engine. My adventure was courtesy of the City of Wigan and Bill Rowland and Mike Presho, who lovingly maintain and operate the awesome, fully restored 19th-century mechanical marvel in their charge. Built at the pinnacle of the industrial revolution to power 1250 carding and spinning machines simultaneously through an elaborate line-shafting system, the 2100 hp steam-producing monster was in service at the Trencherfield spinning mill for over 60 continuous years. Because the engine supplied power to every moving piece of equipment in the mill, as well as power for a small generator for rudimentary lighting, any failure or
downtime associated with it was catastrophic to the mill and its workforce—which didn’t get paid when the engine lay idle. These days, although the engine runs in a living museum setting with only the flywheel load, it’s still cared for and operated under the same method statement as it was during its production years: “Run like a Religion!” Amazingly, the mill engine’s efficiency was 86%, which was maintained throughout its working life through never-ending attentiveness to mechanical alignment and effective lubrication of all moving parts, water cleanliness (water chemistry) and seals (to keep the precious and expensive steam in the engine). Interestingly, much of the lube oil was captured, filtered and reused, while all exhausted and unused engine steam was used to pre-heat boiler water—efficiency at its best!
We know what equipment needs. Why have we become so lax about the fundamentals? As it was in the days of steam engines, much of today’s equipment is still predominantly mechanical, i.e., using seals, aligned driver/driven components and lubricated bearings. Thus, when we know that misalignment robs energy and causes premature failure, that a rolling element bearing can still fail in over 50 different ways and that we can predict and prevent virtually all mechanical failures, why have we become so lax about maintenance and reliability fundamentals? We really don’t have any excuse. If we want true reliability, availability, throughput and quality, we have to recognize what equipment still needs: That’s to be “Run like a Religion!” Good luck. LMT kbannister@engtechindustries.com
(Stay tuned for a feature article on this incredible steam engine in a future issue of LMT.) 6|
LUBRICATION MANAGEMENT & TECHNOLOGY
NOVEMBER/DECEMBER 2011
varnish · SVR Soluble Varnish Removal · gas turbines · NSD Non-Sparking Filter Elements · low ISO cod water in lube oil · VUD Vacuum Dehydrator · paper mills · coal mill gearbox failures · Filter Carts · FSL G · compressor lube oil · COT Water Removal & Filtration Skids · servo valve stiction · DFE Rated Filter El · wind turbine gearbox contamination · Dedicated Gearbox Filtration · plastic injection molding · AW h Removal · sawmill hydraulic failures · Hy-Pro Total System Cleanliness · rolling mill bearing failures · V atorHydraulic · diesel fuel contamination Off-Line Diesel Purifiers · cooling tower gearboxes · FPL Filter Pa & Lube Oil· COD Solutions mp · DFN Duplex Filters · phosphate ester acid & gels · ICB Element Technology · drilling rigs · Hy-Pro finery rotating equipmentFiltration · Hy-Pro Contamination Solutions Equipment · roll-off cleanliness requirem Innovative Products ilter Element Upgrades & FSL Skids · reservoir contamination · Hy-Dry Desiccant Breathers · hydraulic eliability · Hy-ProTotal · lube oil varnish · SVR Soluble Varnish Systems Cleanliness &· gas turbines · NSD Non-Sparking Filter Elem es · Steel Mills · water in lube oil · VUD Vacuum Dehydrator · paper mills · Filter Carts · coal mill gearb Hy-Pro Failures earbox Filtration · compressor lube oilStop · COT Water Removal & Filtration Skids · servo valve stiction · DF ement Upgrades · wind turbine gearbox contamination · Dedicated Gearbox Filtration · plastic injectio draulic Oil Varnish Removal · sawmill hydraulic failures · Hy-Pro Total System Cleanliness · rolling mill UD Vacuum Dehydrator · diesel fuel contamination · COD Off-Line Diesel Purifiers · cooling tower gea anel · boiler feed pump · DFN Duplex Filters · phosphate ester acid & gels · ICB Element Technology · d o Extends Oil Life · refinery rotating equipment · Hy-Pro Contamination Solutions Equipment · roll-off c ments · DFE Rated Filter Element Upgrades & FSL Skids · reservoir contamination · Hy-Dry Desiccant B ic, lube oil & diesel reliability · Hy-Pro · lube oil varnish · SVR Soluble Varnish · gas turbines · NSD Non ements · low ISO codes · Steel Mills · water in lube oil · VUD Vacuum Dehydrator · paper mills · VUD V r · Filter Carts · DFE Rated Filter Element Upgrades · coal mill gearbox failures · FSL Gearbox Filtration e oil · VUD Vacuum Dehydrator · servo valve stiction · DFE Rated Filter Element Upgrades · wind turbin ination · Dedicated Gearbox Filtration · plastic injection molding · AW hydraulic Oil Varnish Removal · ic failures · Hy-Pro Total System Cleanliness · rolling mill bearing failures · VUD Vacuum Dehydrator · d ination · COD Off-Line Diesel Purifiers · cooling tower gearboxes · FPL Filter Panel · boiler feed pump · phosphate ester acid & gels · ICB Element Technology · drilling rigs · Hy-Pro Extends Oil Life · refinery ent · Hy-Pro Contamination Solutions Equipment · roll-off cleanliness requirements · DFE Rated Filter es & FSL Skids · reservoir contamination · Hy-Dry Desiccant Breathers · hydraulic, lube oil & diesel reli be oil varnish · SVR Soluble Varnish · gas turbines · NSD Non-Sparking Filter Elements · low ISO codes · in lube oil · paper mills · Filter Carts · coal mill gearbox failures · FSL Gearbox Filtration · compressor l ater Removal & Filtration Skids · servo valve stiction · DFE Rated Filter Element Upgrades · wind turbin ination · Dedicated Gearbox Filtration · plastic injection molding · AW hydraulic Oil Varnish Removal · ic failures · Hy-Pro Total System Cleanliness · rolling mill bearing failures · VUD Vacuum Dehydrator · d ination · COD Off-Line Diesel Purifiers · cooling tower gearboxes · FPL Filter Panel · boiler feed pump · phosphate ester acid & geaaaaaaaaaaaaaaaa ls · ICB Element Technology · Hy-Pro Extends Oil Life · r quipment · Hy-Pro Contamination Solutions Equipment · roll-off cleanliness requirements · DFE Rated pgrades & FSL Skids · reservoir contamination · Hy-Dry Desiccant Breathers · hydraulic, lube oil & dies o · lube oil varnish · SVR Soluble Varnish · gas turbines · NSD Non-Sparking Filter Elements · low ISO co water in lube oil · VUD Vacuum Dehydrator · paper mills · Filter Carts · coal mill gearbox failures · FSL G n · compressor lube oil · COT Water Removal & Filtr · Lower ISO Codes · DFE Rated Filter Element Upg rbine gearbox contamination · Dedicated Gearbox Filtration · plastic injection molding · AW hydraulic al · sawmill hydraulic failures · Hy-Pro Total System Cleanliness · rolling mill bearing failures · VUD Vacu Tel: 317.849.3535 diesel fuel contamination · COD Off-Line Diesel Purifiers · cooling tower gearboxes · FPL Filter Panel · DFN Duplex Filters · phosphate ester acid & gels · ICB Element Technology · drilling rigs · Hy-Pro Exten www.hyprofiltration.com y rotating equipment · Hy-Pro Contamination Solutions Equipment · roll-off cleanliness requirements · info@hyprofiltration.com more info,·enter 64 at www.LMTfreeinfo.com Steel Mills · SVR Soluble Varnish Removal · VUD Vacuum Dehydrator · paperFormills Filter Carts · coal m · FSL Gearbox Filtration · compressor lube oil · COT Water Removal & Filtration Skids · servo valve stic
DISCOVER HY-PRO
Certification Matters: Part V (Conclusion)
Fluid Conditioning
Key To Equipment Reliability Ray Thibault CLS, OMA I, OMA II, MLT, MLT II, MLA II, MLA III Contributing Editor
When it comes to the cleanliness of the lubricants in your rotating equipment, you can’t be too vigilant.
T
his article is the last in our year-long series on the most important components of lubrication certification exams administered by the Society of Tribologists and Lubrication Engineers (STLE) and the International Council for Machinery Lubrication (ICM). However, even if you’re not pursuing certification, having a thorough understanding of fluidconditioning principles is crucial in dealing with rotating equipment. Here, we examine the two most destructive contaminants: particulates and water. Particulate contamination It’s been said that 75% of equipment failure in circulated systems is caused by contamination. The major cause of equipment wear is three-body abrasive wear caused by particles—according to some estimates, up to two-thirds of the wear in equipment. And, it’s what you don’t see that causes the major problems. The smallest particle size that can be seen with the naked eye is 40 microns. Unfortunately, the most destructive particles are much smaller in size: you just can’t see them.
In the previous article in this series (September/October 2011 LMT), the topic of “Pneumatics and Compressors” was inadvertently listed as the topic of Part V. The editors regret this error.
8 | LUBRICATION MANAGEMENT & TEChNOLOGy
NOVEMBER/DECEMBER 2011
PROFESSIONAL DEVELOPMENT SERIES
What you can’t see causes major problems. The naked eye can’t see particles under 40 microns in size. The most destructive particles are smaller than that. In dealing with equipment cleanliness, one must be as proactive as possible. It costs at least 10 times more to remove particles than to keep them from entering a system. The following are some of the ways to be proactive:
n Simplex or duplex n Location ◆ Pressure line ◆ Return line ◆ Off-line
n Properly flush new equipment to remove any built-in
particles that may be present. n Filter new oil going into hydraulic and turbine systems
to a minimum cleanliness standard. n Minimize outside ingression. ◆ Maintain good practices in dealing with reservoir
openings. ◆ Utilize good breathers to minimize solid ingression. ◆ Maintain rod seals in linear actuators in hydraulic systems. n Practice good storage and handling procedures. ◆ Properly store and maintain drums. ◆ Utilize proper dispensing containers such as sealed plastic ones. ◆ Utilize off-line filtration in large storage tanks to maintain proper cleanliness. n Conduct training to develop and reinforce the attitude in lubricators that oil cleanliness is vital to equipment life. General filtration principles Even if your operations are being proactive in fluid cleanliness, it’s still necessary to have proper filtration to achieve targeted cleanliness levels. Outside particulate ingression is usually not totally controlled, and wear metals from operation need to be removed. The most effective filters have the following characteristics: n Synthetic glass or metal with thin fibers n Graded density with tapered pore construction n Supported elements
The following are key factors in filter selection: n Cleanliness required n System pressure drop n Selection of fiber type to give desired performance n Bypass or non-bypass filter NOVEMBER/DECEMBER 2011
Filter sizing is extremely important. Pressure drop determines the filter’s size. The following variables determine pressure drop: n Filter housing must be sized so flow won’t blast through
the element and also to ensure that the filter functions properly during cold startups, where viscosity can be 3-30 times the operation viscosity. n Type of media grade n Fluid viscosity ◆ Oil type ◆ Temperature n Flow rate Measuring filter performance… Filter performance should be based on the absolute filter rating which is determined in a laboratory with the MultiPass Filter Performance Test. Dirt in milligrams per liter is introduced in a test fluid at a constant rate. The fluid is circulated at a constant or variable rate through a test filter. The test concludes when the terminal pressure drop of the filter is reached. This is the point when the filter manufacturer designates the filter as no longer operable and needing to be changed. The filtration efficiency of the test filter is expressed as the filtration ratio.
Filtration Ratio (Beta Ratio) ßx= Number of particles upstream of filter greater than µ[c] Number of particles downstream of filter greater than µ[c] For example, a filter with a beta ratio of ß6=200 indicates that for every 200 particles greater than six microns in size entering the test filter one will pass though. Therefore, 199 will be captured. The efficiency of the filter is calculated as ß-1/ß x 100. The efficiency of a filter with a beta ratio of 200 is 99.5%. www.LMTinfo.com | 9
PROFESSIONAL DEVELOPMENT SERIES
ISO Cleanliness Code… Fluid cleanliness is expressed as a three-number code according to ISO 4406. The code is expressed as all particles > 4µ[c], > 6µ[c] and > 14µ[c]. The numbers are obtained from the ISO 4406 Chart in Table I. Table I. ISO 4406 Chart
Number of particles per ml
Range Number
More than
Up to & including
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6
80,000 40,000 20,000 10,000 5000 2500 1300 640 320 160 80 40 20 10 5 2.5 1.3 0.64 0.32
160,000 80,000 40,000 20,000 10,000 5000 2500 1300 640 320 160 80 40 20 10 5 2.5 1.3 0.64
As an example, consider a fluid where the following particles per milliliter of fluid were measured:
≥ 4µ[c] 7500 particles ≥ 6µ[c] 850 particles ≥ 14µ[c] 95 particles The fluid cleanliness is expressed as 20/17/14 Find the range number that expresses the number of particles per milliliter. For instance, 7500 particles are found at the range number of 20 where the range is 5000 to 10,000 particles. Notice that for every increase in range number, the number of particles can double. Thus, even a moderate increase in the range number can result in a large introduction of particles. 10 | LUBRICATION MANAGEMENT & TEChNOLOGy
Target equipment cleanliness code… To extend equipment life, the correct cleanliness must be maintained. Different equipment components require different cleanliness levels. The clearances of the equipment determine the level of cleanliness. For example, a servo valve in a hydraulic system requires cleaner oil than a gear pump. Many tables are available as a guide to equipment cleanliness requirements. For purposes of this article, we use one from from Eaton (Table II). Table II. Target Cleanliness Codes for Different Equipment (source: Eaton)
Pumps
Pressure: <2000 psi
Fixed gear Fixed vane Fixed piston Variable vane Variable piston Valves
2000~3000
>3000 psi
20/18/15 20/18/15 19/17/15 18/16/14 18/16/14
19/17/15 19/17/14 18/16/14 17/15/13 17/15/13
Pressure:
2000~3000
>3000 psi
20/18/15 17/15/12 16/14/11 19/17/14
19/17/14 16/14/11 15/13/10 19/17/14
Directional (solenoid) Proportional (dir., press., flow control) Servo valve Flow control
18/16/13 17/15/13 16/14/12
Bearings Roller-bearing systems Journal bearing (high-speed) Journal bearing (low-speed) General industrial gearboxes
16/14/12 17/15/13 18/16/14 17/15/13
Utilizing Table II, let’s determine the cleanliness level required for a variable inline axial piston pump operating at a pressure of 3500 psig with a servo valve. The most sensitive component in the system determines the cleanliness code selected. The piston pump requires a fluid cleanliness of 16/14/12 while the servo valve requires a cleanliness of 15/13/10. Thus, the cleanliness required for this hydraulic system is 15/13/10. Filter location… Filter location placement is a key variable in achieving target cleanliness. Usually a combination of locations is employed. Work with your filter manufacturer to determine the optimum combination of filter types and location to achieve your desired cleanliness level. Figure 1 (from Pall Filters) illustrates the most common filter-placement locations. NOVEMBER/DECEMBER 2011
PROFESSIONAL DEVELOPMENT SERIES
Pressure-Line Filter
Return-Line Filter
Off-Line Filter Fig. 1. The most common filter-placement locations (source: Pall Filters)
Pressure-line filter… n Installed downstream of pump before the valves n Provides protection to valves which are usually most sensitive components in the system n Subjected to variable flows and pressure cycles n Operating pressures that can reach 450 bar and higher n Bypass or non-bypass dependent on critical nature of components n Most expensive filter in the system n Additional pressure-line filters (pilot filters) possibly required with sensitive components where finer filtration is required Continued on page 12
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PROFESSIONAL DEVELOPMENT SERIES
Return-line filter… n Installed between working components and reservoir n Usually located inside tank or outside spin-mounted on reservoir n All flow from system collected and directed through the return filter n Largest and least expensive filter on system n Must handle maximum system flow n Protects system from wear particles and particles ingressed through retracting piston in cylinders n Ensures clean fluid in reservoir n Usually the only filter for mobile equipment
The three water forms are dissolved, emulsified and free. Dissolved water usually isn’t a problem, unless the saturation point is reached at a lower temperature, resulting in free water which can become emulsified and can only be removed though vacuum dehydration or passing hot air through a special type of filter or system. The most destructive form is emulsified water, which can be removed through centrifuging, coalescing filters and vacuum dehydration. Free water is the easiest to remove: Reservoirs and sumps should be routinely drained of free water, which, if circulated, can become emulsified. The following proactive practices can help prevent water from entering a system:
Off-line filter… n Self-contained system including pump, motor and filter n Main purpose is to keep reservoir fluid clean n Can run 24/7 n Easily serviced without disrupting operation n Very fine filter elements can be used n Help extend useful life of pressure- and return-line filters n Target cleanliness codes most easily achieved with these
types of filters
n Hermetically seal bearing areas, if possible. n Repair rotary steam joints on dryers. n Routinely inspect heat exchangers, steam coils and
packing. n Build shelters to prevent water from falling on
equipment. n Use desiccant breathers on vents in tanks and reservoirs
to reduce condensation..
n Water-removal elements can be used n Can be permanent-mount or filter carts
n Train operators on proper use of cleanup hoses. n Keep hatches and covers closed on reservoirs.
Water contamination The second most destructive contaminant—water— is introduced in the system the following ways:
The following are ways to remove and minimize effects of water ingression in a system: n Monitor and drain reservoirs frequently to remove any
n Humid air n Reservoir and tank condensation n Bearing-housing breathing n Steam leaks on dryers n Heat-exchanger leaks n Leaking pump packing and turbine steam glands n Rain n Washdowns
Water contamination manifests itself as follows: n Reduced lubricant effectiveness resulting in increased wear n Corrosion of machine components n Premature filter plugging n Increased oxidation of lubricant n Depletion of oil additives n Viscosity increase
Small amounts of water can reduce rolling-element bearing life via hydrogen blistering and embrittlement. Aim for 200 ppm or less; close to 100 ppm is better. Journal bearings in turbines should be maintained not to exceed 200 ppm. 12 | LUBRICATION MANAGEMENT & technology
free water. n Install vapor extractors on wet reservoirs. n Install centrifuges or filter-coalescers on wet systems
to remove gross water. Conclusion This entire five-installment series of articles was designed to help prepare you for the various certification exams through the STLE and ICML. Be aware, though, that “help prepare” is the operative term. Reading this series of articles will be a step in the right direction, but that alone won’t be enough. Much greater preparation—through significant self-study and formal training—will be required to seriously pursue certification. For complete details on STLE and ICML certification, go to: www.stle.org and www.lubecouncil.org. LMT Ray Thibault is based in Cypress (Houston), TX. An STLECertified Lubrication Specialist and Oil Monitoring Analyst, he conducts extensive training for operations around the world. Telephone: (281) 257-1526; email: rlthibault@msn.com. For more info, enter 01 at www.LMTfreeinfo.com NOVEMBER/DECEMBER 2011
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• Example is based on 36,000 hp (electrically driven) operating 8000 hours per year @$0.05 kwh power cost • Lubricant purchases are 3% of the maintenance costs • Lubricant purchases are 3/4% of the energy costs • Though conceptually accurate, expense ratios will vary from plant to plant
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LUBRICATION MANAGEMENT & TECHNOLOGY
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THE RELIABILITY FILES / NOVEMBER/DECEMBER 2011
“...we extended drain intervals from every 15 days to every three months AND reduced engine repairs and replacements.” Luis Garza Kingfisher Marine Most efforts to improve operating efficiency and lower maintenance costs are labor intensive and involve painful cultural changes. Numerous progressive companies have experienced significant cost savings simply by upgrading lubricants. You can learn how by reading the special report ‘Lowest Total Cost of Ownership’. This special report includes extensive case studies that document real-world savings through lubricant upgrades. Get your FREE copy of the ‘Lowest Total Cost of Ownership’ today by calling 866-447-5173 . . .
For more information on Royal Purple, visit royal-purple-industrial.com today. For more info, enter 280 at www.MT-freeinfo.com For more info, enter For more info, /enter at www.MT-freeinfo.com JULY 2011 THE280 RELIABILITY FILES280 at www.LMTfreeinfo.com
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GREASE TIPS
Bearing Grease Replenishment Intervals In simple terms, hereâ&#x20AC;&#x2122;s what one respected bearing manufacturer has to say about a very basic, but critical, topic.
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ncreased operating costs, unplanned downtime and loss of productivity can all result from premature bearing failure. Although such events can occur for a number of reasons, one of the most common is lubrication failure. Following a proper lubrication schedule and using the correct lubricant type can improve performance and extend bearing life.
Special To LMT From NSK Corporation
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LUBRICATION MANAGEMENT & TECHNOLOGY
NOVEMBER/DECEMBER 2011
GREASE TIPS
Lubrication reduces friction and wear by providing an oil coating that adheres to the rolling elements and raceways of bearings that are constantly in contact. The oil film separates the contact surfaces and prevents metal-to-metal contact, which reduces wear. Proper lubrication also helps prevent foreign material from entering the bearing and guards against rust and corrosion. Grease lubrication schedule Over time, grease will deteriorate due to physical and chemical degradation. The reduced lubrication properties will negatively impact bearing performance. Efforts must be made to renew the grease through replenishment. Figure 1 reflects the replenishment time intervals for various bearing types running at different speeds. Charts (1) and (2) in the figure are applied based on the use of high-quality lithium soap-mineral oil grease, a maximum bearing temperature of 70 C and a normal load (P/C = 0.1, meaning 10% of the bearing dynamic load rating Cr). Replenishment is ONLY an option if the bearings are not sealed and provisions exist in the equipment for adding grease. Shielded bearings must be re-lubricated carefully. Damage can occur if excessive pressure is used, causing bearing deformation. Factors affecting replenishment intervals Grease replenishment time intervals are subject to factors that vary the recommendation—factors that can either extend or diminish the period of acceptable grease performance. These include:
■ Bearing operating temperature ■ Grease type ■ Load ■ Presence of dust and moisture ■ Shock loads and vibration
Bearing operating temperature greatly influences lubrication life. As a general rule, if the bearing temperature exceeds 70 C, the replenishment time interval must be reduced by half for every 15 C degree temperature rise of the bearing. Consider this example of two electric motors: One unit operates indoors in an ambient environment of 25 C, with bearing temperatures of 60 C. The other motor operates outdoors in the Southwest United States in an ambient environment of 45 C, with bearing temperatures of 100 C. The hotter motor will require re-lubrication four times more often than the first motor to maintain the lubricant. Why four times? The motor running at a higher bearing temperature is 30 C above 70 C, meaning the replenishment interval is cut in half two times (or one quarter of the time). Grease base oil and thickener types have an impact on how often re-lubrication is necessary. For instance, a ball bearing might use grease with the same lithium soap thickener as referenced on the interval chart (shown below), or it might use a synthetic mineral base oil that can last about twice as long. Other thickeners, such as diurea, polyurea and PTFE, have properties related to operating temperature and resistance to shearing, as well as an ability to release and re-absorb base oil— which can also modify replenishment recommendations.
Fig. 1. Grease replenishment intervals NOVEMBER/DECEMBER 2011
www.LMTinfo.com | 17
GREASE TIPS
Replenishment intervals are subject to factors that can either extend or diminish acceptable grease performance. Take them into account. Load factor is a determinant of lubrication replenishment in that it corresponds to the equivalent load (P) on the bearing shown in chart (3) of Fig. 1. The equivalent load at the bearing is determined from the radial and axial loads along with relationships detailed in the manufacturer’s catalog for each bearing. For loads less than or equal to 6% of the bearing dynamic load rating (Cr), the replenishment interval increases by a 1.5 multiplier. As load increases, the load factor drops to less than one, which calls for more frequent lubrication. Should P/C exceed 0.16, it’s advisable to consult the bearing manufacturer. Environmental factors may reduce recommended replenishment intervals. Elevated vibration levels within the bearing increase the release of base oil, reducing the number of times before oil must be renewed. Dust, dirt or application contaminants such as wood fibers or metal
shavings can become trapped in the grease and come into contact between the rolling elements and raceways of a bearing. These contaminants break through the oil film, which creates more friction. Ultimately, friction damages the raceways and and reduces grease life. Another important and common environmental factor is the presence of moisture. It can occur by direct spray, vapor or condensation within the bearing. Depending on the magnitude of water present, the re-lubrication interval can be reduced by half—or more. LMT To learn more about bearing lubrication and replenishment intervals, visit www.nskamericas.com and download NSK’s Lubrication Interval Guide or contact your local NSK representative. For more info, enter 02 at www.LMTfreeinfo.com
Reliability: Own It This MARCH... Save The Date For
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• A four-day educational experience created exclusively for reliability professionals • 30 hour-long Conferences over two days – Tuesday, March 13 and Wednesday, March 14 – kicked off by Keynote speaker David Boulay, president of thehas Illinois Manufacturing hell Lubricants launched an improved range of Extension Center, and followedtobymeet the challenges Shell Gadus greases designed experts in a varietyoperating of disciplines in some of the of reliability large, fast equipment most extreme mining, • 6 full-dayconditions Workshops onimaginable, Monday, Marchincluding 12 steel-production, power-gen and marine applications, 6 full-dayThe Workshops on Thursday, March 15 it simpler for among•others. revamped lineup makes customers comparecertifi product benefits and performance • Twotoprofessional cation opportunities while taking into account variables such as compatible thickeners, base oil viscosity, NLGI grade and other For complete schedule and registration special performance characteristics. information, please go to
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MAINTENANCE and RELIABILITY TECHNOLOGY SUMMIT
MARCH 12-15, 2012 The Capacity Assurance Conference!
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Now entering its ninth year, MARTS is an exciting learning event in a great location that helps reliability professionals at all levels improve their skills and excel on the job. Pricing and attendance options for every budget make it easy Shell Lubricants Houston, TXRegency O’Hare, Rosemont (Chicago), IL Hyatt for individuals or groups to share the MARTS experience.
www.MARTSconference.com
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LUBRICATION MANAGEMENT & TECHNOLOGY
NOVEMBER/DECEMBER 2011
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THE CORPORATE REPORT 2011
BEL-RAY
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t’s been a long time coming. A package, unique to the lubricants industry, with innovative labeling technology that allows products to be easily identified, internationally compliant and multilingual for service around the globe. Bel-Ray, the leading specialty lubricants company to the mining, industrial and powersports markets, launches its new package, label and enhanced product lines for 2012. According to Bel-Ray Chief Operating Officer Jennifer Liquori, the 2012 launch will include innovation at multiple levels. “The markets we serve have become more discerning and sophisticated, demanding not only highly engineered product technology, but also a package that’s more userfriendly. We are using brand new technology to create our new package, and we are thrilled to be ‘first,’ once again. Last year, we launched our new motorcycle line, with a pull-out spout and multilingual packaging, also a first. Now, our mining and industrial products will receive a similar upgrade, with labels that clearly identify the product, its application and grade, all colorcoded for ease of selection and use,” said Liquori. Making the launch even more powerful are upgrades to Bel-Ray’s biodegradable technology and the company’s industry-leading SF100 line of mining lubricants. Brand new motorcycle products for the V-twin market and an all-new Marine line will also make their debut in 2012. “For more than 40 years, Bel-Ray has been making marine products for the U.S. Navy and the largest
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marine-equipment manufacturers in the world,” Liquori says. “We’ve taken our high-performance marine-related formulas and given them a technical facelift. In some cases, we will launch the most high-end, high-performance racing fluids the market has ever seen, using technology not yet exploited in that market and giving consumers the same Bel-Ray standard we’ve delivered for decades to the motorcycle arena, which, in turn, has delivered champion after champion.” Located in Farmingdale, NJ, all Bel-Ray products are made in the USA by the finest team of professionals in the business. For more than 65 years, Bel-Ray has stood at the forefront of lubrication technology.
New products... New packaging.... Same commitment to innovation. Bel-Ray Total Performance Lubricants. It just keeps getting better. Bel-Ray Company, Inc. P. O. Box 526 Farmingdale, NJ 07727 Ph: 732. 938.2421 www.belray.com
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THE CORPORATE REPORT / NOVEMBER-DECEMBER 2011
THE CORPORATE REPORT 2011
HY-PRO FILTRATION
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Keep Your World Turning Our expertise and shoulderto-shoulder commitment to solving your fluid-contamination challenges truly set Hy-Pro apart. Put us on your lube team, and we’ll help you develop a total system-cleanliness approach that leads to a more reliable plant—and keeps your world turning as required!
t Hy-Pro Filtration, our objective is to optimize the reliability of hydraulic and lubrication assets to keep plants operating at peak productivity. Our innovative filtration products solve a range of contamination challenges that plague hydraulic and lube systems, including: ❖ Particulate contamination—Hy-Pro’s DFE-rated filter element upgrades for all international filter manufacturers and OEMs drop ISO codes and yield optimum system performance. Consolidate filter-element specs to Hy-Pro, the brand that delivers industry’s lowest ISO codes and best element value. ❖ Removing water from lube oil— Hy-Pro Vacuum Dehydrators remove all water (including dissolved) to achieve water levels < 30 ppm in lube oil up to ISO VG600. Hy-Pro’s coalesce technology for turbine oil rapidly removes free and emulsified water for water ppm level < 150. The two technologies can be combined for the ultimate in turbine-lube-oil purification. ❖ Varnish removal—Lube-oil varnish continues to be a major problem for both combustion and steam turbines as Group II base stock oils replace Group I. Hy-Pro manufactures the proven varnish prevention and removal solution: SVR soluble varnish removal. ❖ Total phosphate-ester-fluid maintenance—Proper care of phosphate ester requires acid remediation, dissolved metal removal, maintaining water < 300 ppm, high-efficiency filter elements and solution-driven strategies to prevent servo-valve failures and premature fluid replacement. To get it all, make the call to Hy-Pro.
❖ Mobile filter carts for particulate and water control ❖ Dedicated off-line lube-filtration systems (gearboxes and steel-mill lube) ❖ Preventing servo-valve failures ❖ Oil-reclamation equipment and other oil-reclamation solutions ❖ Extending useful phosphate-esterfluid life
Get The Full Support Of Hy-Pro Nation Together with our global distribution network, our expert team of Hy-Pro technical, field and sales engineers is ready to implement proactive strategies that solve your hydraulic, lube-oil and diesel-fuel problems. Experienced in lubrication, filtration and fluid power, they carry the highest industry certifications (including CFPS and CLS).Our engineering staff is available—and eager—to support your application needs with expert product and industry knowledge to make condition-based recommendations for standard or customized contamination solutions. Hy-Pro Filtration 12955 Ford Drive Fishers, IN 46038 Ph: 317.849.3535 www.hyprofiltration.com
❖ Extending overall useful life of combustion-turbine-oil antioxidants ❖ Explosion-proof equipment complying with U.S. and EU (ATEX) standards ❖ Diesel-fuel conditioning for particulate and water removal
NOVEMBER-DECEMBER 2011 / THE CORPORATE REPORT
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THE CORPORATE REPORT 2011
NSK CORPORATION
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n today’s tough economy, NSK offers solutions that help cut costs, increase efficiency and maximize uptime. Our comprehensive Asset Improvement Program (AIP) provides world-class engineering and technical support for customers looking to maximize their competitive edge. AIP provides a real opportunity to unlock additional profitability via improved machine reliability and increased working knowledge. This well-proven Asset Improvement Program combines customers’ knowledge of the working environments, cultures, processes and problems within their businesses with NSK’s engineering expertise and innovation. Through close working dialogs with our customers, we identify and address the issues that impact their businesses and their bottom lines. NSK approaches each AIP project with three value-added objectives designed to maximize the productivity and uptime of each and every customer: #1. Reduced Maintenance Costs NSK specialists review each application and its working conditions to provide solid recommendations for the most effective bearing option to suit each particular piece of machinery. When the most appropriate bearings possible are used, customers benefit from increased bearing life and lowered maintenance and repair costs. Not all bearings are created equal; whether you’re facing high temperatures, contamination issues, vibration or high speeds, the correct bearing choice can significantly impact the failure rate and maintenance commitment. #2. Improved Machine Reliability Support from NSK offers customers insight into the efficiency and reliability of their in-use machinery and
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processes. NSK offers a variety of review options: ■ Bearing-failure analysis to identify the cause of premature failure ■ Maintenance schedules for achieving optimum results ■ On-site inspections to ensure best-practice techniques are followed in inspection, assembly and strip-down processes ■ Diagnostic and vibration analysis to review specific application challenges #3. Increased Staff Knowledge After providing the correct motion and control product and verifying that the machinery is working at maximum efficiency, NSK also engages staff in the installation and maintenance procedures required to keep those machines running smoothly. Training courses cover all areas of bearing use and are available in any combination, depending on the particular needs of each customer. NSK offers hands-on education in: ■ Bearing uses and applications ■ Bearing diagnostics ■ Best practices for the fitting and removal of bearings ■ Segment-specific solutions, including machine-tool, papermaking, minerals and utilities, primary metals and more NSK is a key driver of technological advancement in the motion and control industry, investing
NSK Molded-Oil™ Bearings
significant R&D to create innovative, high-performance, products. For example, our Molded-Oil™ Bearings are designed especially for corrosive and dust-contaminated environments. The K1™ Lubrication Unit provides long-term, maintenancefree operation in conditions where grease cannot easily be replenished. These industry-leading solutions are effectively supported by NSK’s AIP program, designed to help you reduce costs, improve machine reliability and increase the working knowledge of your engineering and maintenance personnel. Successful participation in the program can enhance profitability and improve operational competitiveness. For more information on the NSK Asset Improvement Program, contact an authorized distributor or visit www.nskamericas.com/aip. NSK Corporation 4200 Goss Road Ann Arbor, MI 48105 Ph: 800.675.9930 Fax: 734.913.7510 www.nskamericas.com
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THE CORPORATE REPORT / NOVEMBER-DECEMBER 2011
THE CORPORATE REPORT 2011
ROYAL PURPLE When is it Appropriate to Use a Synthetic Oil? By Lee Culbertson, President, Royal Purple, Inc.
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hen I hear this question posed in lubrication training classes, it really drives me crazy. Why? Let me count the ways… First, the question presumes that the word “synthetic” is synonymous with a higher level of performance. It’s like asking, “When is it OK to upgrade lubricant quality?” It’s like asking “How good is good enough?” Though well intentioned, it paints far too simplistic a picture, panders to misguided beliefs and obfuscates the more fundamental issue. A better question would be, “When is it appropriate to upgrade lubricant quality?” If you believe as I do that a lubricant is a critical reliability component and not a commodity, then you are probably a results-oriented person like me. In my world, lubricant quality only has relevance in respect to how it performs in the equipment it lubricates. Assuming a correlation between purchase price and performance, the final selection criteria regarding a lubricant upgrade should hinge on whether the lubricant provides valueadded performance that exceeds its premium price. It’s that simple. The value can be in the form of extended oil drains, maintenance savings, improved reliability or energy savings. Synthetic oils may or may not outperform their mineral oil counterparts, as lubricants derive much of their performance from their additive chemistry. Don’t get me wrong: I’m a huge proponent of formulating with synthetic base oils. But additives contribute in these same areas and provide other much-needed properties unattainable from any base oil. Therefore, a wellformulated mineral oil might often outperform another synthetic oil.
To get the right answer we have to start with the right questions. How about asking, “Why would anyone NOT want to upgrade lubricant quality, if the value of the upgrade greatly
Assuming a correlation between purchase price and performance, the final selection criteria regarding a lubricant upgrade should hinge on whether the lubricant provides value-added performance that exceeds its premium price.
NOVEMBER-DECEMBER 2011 / THE CORPORATE REPORT
exceeded the lubricant’s premium cost?” If you know the answer to this question, Royal Purple would like to hear from you. Chances are, you’re our kind of people. Royal Purple One Royal Purple Lane Porter, TX 77365 Ph: 888.382.6300 www.royalpurple.com
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THE CORPORATE REPORT 2011
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.
If our product does not work for your application, we will buy it back! With our “Performance Guarantee,” you never have to worry about losing cash on a product that does not work.
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THE CORPORATE REPORT / NOVEMBER-DECEMBER 2011
THE CORPORATE REPORT 2011
U.S. Tsubaki Power Transmission, LLC
U
.S. Tsubaki Power Transmission, LLC is a leading manufacturer and supplier of state-of-the-art power transmission and motion control products and is a global leader in roller and conveyor chain production. U.S. Tsubaki is the largest global subsidiary of Japan’s Tsubakimoto Chain Company, which was founded in 1917. Today, Tsubaki’s products are marketed in over 70 countries. U.S. Tsubaki’s corporate headquarters and main distribution warehouse are just outside of Chicago, in Wheeling, IL, and it has full manufacturing facilities in Holyoke, MA, and Sandusky, OH. In addition to this it has service centers strategically located in Los Angeles, CA, Dallas, TX, Atlanta, GA, Philadelphia, PA, Charlotte, NC, and Anoka, MN. The TSUBAKI name is synonymous with excellence in quality, dependability and customer service. An intense focus on research and development, along with constant modernization of its production facilities, are among the key components in Tsubaki’s ability to successfully meet the ever-changing needs of the marketplace. Leveraging its vast, international network of corporate and industrial resources, U.S. Tsubaki offers customers the finest power transmission products in the world. According to the company, it is well positioned to meet the challenges of the 21st century and beyond as it strives to be the “Best Value” supplier in the industry. Tsubaki’s global presence affords the company with unprecedented opportunities to market advanced new products and technologies, and to utilize the intellectual assets of what it characterizes as “some of the brightest minds in business and engineering from around the world.” This strength, combined
with its continuous improvement of quality and processes, has U.S. Tsubaki poised for lasting growth now, and well into the future.
U.S. Tsubaki’s industrial group is currently comprised of four business units: the Roller Chain Division, Engineering Chain Division, Power Transmission Components Division (which includes Sprockets) and the KabelSchlepp Cable & Hose Carrier Division. The Roller Chain Division provides some of the most versatile products on the market. Tsubaki innovations have yielded popular problem solvers such as self-lube Lambda® series chain, corrosion-resistant Neptune® chain, fatigue-resistant Super Chains, and rugged Energy Series™ oilfield chains and attachment chains. U.S. Tsubaki’s Engineering Chain Division offers heavy-duty chains designed specifically to meet the demanding needs of a vast array of industries, all designed to prolong wear life under rigorous operating conditions. They use various grades of steel, heat-treated to precise specifications
NOVEMBER-DECEMBER 2011 / THE CORPORATE REPORT
and assembled with accurate pressfits to withstand the requirements of today’s powerful, high-production equipment. Tsubaki Sprockets are built from top-grade, heat-treated carbon steel to offer long wear life, resist abrasion, and withstand heavy shock loads. Precision manufacturing at their ISO-certified facilities ensures that every U.S. Tsubaki sprocket stands up to critical design specifications and meets the highest quality standards. Tsubaki’s Power Transmission Components products include all Tsubakimoto products other than chain and sprockets. A partial listing includes belts, cam clutches, actuators, dampers, overload protection and reducers. And in the past year, U.S. Tsubaki Power Transmission, LLC has announced the integration of KabelSchlepp America into its operations as part of the Tsubakimoto Chain Company’s global acquisition of the German-based Cable & Hose Carrier manufacturer. KabelSchlepp America will now operate as the fourth division of U.S. Tsubaki and will expand Tsubaki’s presence in the U.S. market by adding cable & hose carrier systems to its already extensive product lineup. Tsubaki is an ISO 9001:2000 and ISO 14000 registered company. U.S. Tsubaki Power Transmission, LLC. 301 E. Marquardt Dr. Wheeling, IL 60090 Ph: 800-323-7790 www.ustsubaki.com
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THE CORPORATE REPORT 2011
DES-CASE CORPORATION
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es-Case understands the importance of fluid cleanliness and the role it plays in helping equipment investments last longer. For more than 25 years, we’ve pioneered solutions to help maintain lubricant quality specific to your applications. Featuring designs unparalleled in the marketplace, Des-Case products are used wherever lubricant life and performance are essential to daily operations. Industry-Leading Manufacturer of Desiccant Breathers ◆ Continuous innovation. Des-Case invented the desiccant breather and continues to design new innovations. ◆ Widest variety of high-value solutions. From small gearboxes to large hydraulic systems or storage tanks, Des-Case breathers are engineered to last and matched with your specific needs.
A Full Line of Fluid-Handling Products & Adapters ◆ Easily customizable. Des-Case filtration systems can be easily configured to your exact needs. Larger systems are also designed to your specs. ◆ Rugged designs/thousands of options. Des-Case systems incorporate smart technology to make contaminant filtration a simple task, requiring less equipment and labor, while reducing system contamination. Lubrication TransformationSM : Putting Best Practices Into Practice Des-Case Lubrication TransformationSM Services help companies further develop world-class lubrication practices. Managed by experienced lubrication engineers, the Lubrication Transformation process can help you and your team
implement best-in-class lubrication practices. Visit descase.com to learn more about the variety of plant-survey, design and training options available. Whenever you’re in need of contamination control, rely on Des-Case to provide the right products to keep you up and running. Des-Case Corporation 675 N. Main Street Goodlettsville, TN 37072 Ph: 615.672.8800 www.des-case.com
TM
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7-Step Best Practice Lubrication Program Professional Self-Directed Implementation ToolKit
Tap into your Liquid Gold for less than $20 per day!* Whether you’re looking to increase asset utilization and maintainability, reduce contamination, downtime, energy consumption and/or your carbon footprint, or simply cut your maintenance and operating costs, you’re ready for a 7-Step Best Practice lubrication program! For more information on this “expert in a box” approach to successful lubrication programs, contact ENGTECH Industries at 519.469.9173 or email info@engtechindustries.com * Amortized over one year
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THE CORPORATE REPORT / NOVEMBER-DECEMBER 2011
PROBLEM SOLVERS
Metalworking Oil Mist And Smoke Cleanup
R
oyal Filtermist units from Royal Products have been collecting oil mist and smoke generated by metalworking machinery for 30 years. The latest offering, the Filtermist FX-Series, is the product of extensive computer-aided modeling and laboratory testing. Still based on the principle of centrifugal impaction, this lineup is available in four sizes ranging from 275 - 1200 cfm. Their flexible design allows these products to be mounted directly to the top of a machine tool, on a stand or suspended from a ceiling. The manufacturer says maintenance and operating costs are minimal. Royal Products Hauppauge, NY For more info, enter 30 at www.LMTfreeinfo.com
Special Gear Oil Series
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el-Ray notes its series of Molylube Special Gear Oils is specially compounded with colloidal molybdenum disulfide to provide superior hightemperature stability, outstanding extreme pressure properties and excellent rust and corrosion protection. They’ve been formulated to improve the viscosity temperature slope by reducing the change in viscosity with an increase in temperature under isothermal conditions. Their non-Newtonian behavior and properties, including an ability to retard leakage, reduces friction and wear by maintaining greater film thickness on gear teeth. According to the manufacturer, when a severe rise in temperature is reached, these products will carry greater loads because of the flatter viscosity temperature slope. Applications include make-up and refill in spiral, bevel, hypoid rear axle service, heavyduty worm gear operations, heavy-duty industrial transmissions and gear trains.
Bel-Ray Co., Inc. Farmingdale, NJ For more info, enter 32 at www.LMTfreeinfo.com
100+ Maintenance Tips For Free
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revised brochure featuring more than 100 tips from real-world maintenance and operations personnel is now available at no charge from Kano Laboratories.Included are ideas for handling frozen bearings, loosening corroded bolts and frozen brake cables, removing rust, improving belt power transfer, improving engine performance, increasing gas mileage and much more.
Chevron U.S.A., Inc. San Romon, CA
Kano Laboratories, Inc. Nashville, TN
Punch-Packing Gear Lubricants hevron’s Meropa® gear lubricants are designed for a wide range of industrial applications. The manufacturer points to special additives that not only provide extreme pressure protection and antiwear properties, but also high thermal and oxidation stability and excellent foam control and demulsibility. According to the company, these products offer exceptional load-carrying capabilities; micro-pitting protection; long-term rust and corrosion protection; good seal compatibility; excellent filtration properties; improved system cleanliness; and long equipment life.
For more info, enter 31 at www.LMTfreeinfo.com NOVEMBER/DECEMBER 2011
For more info, enter 33 at www.LMTfreeinfo.com www.LMTinfo.com | 27
PROBLEM SOLVERS
Productivity-Enhancing Retaining Ring Pliers
M
artin Sprocket offers a line of retaining ring pliers that, according to the company, are the most user-friendly and efficient tools of their kind on the market. Patented jaws provide positive tip retention and alignment. Users need only to switch a tab and squeeze the handles. Model P1421 features an adjustable stop for small rings. Model P75 incorporates an automatic ratchet lock that keeps rings locked open or closed. Made in the USA, these productivity enhancers are suitable for rings up to 4”. Martin Sprocket Tool & Forge A Division of Martin Sprocket & Gear, Inc. Fort Worth, TX
Herringbone, Straight & Spiral-Bevel Gear Oils
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astrol’s Molub-Alloy range of mineral-based extreme pressure gear oils is recommended for spur, helical, herringbone and straight or spiral bevel gears. According to the company, good shock load carrying capabilities come from a special formulation and a proprietary blend of metallic lubricating solids, treated to increase their natural affinity for metal surfaces. Rust and oxidation inhibitors ensure long service life, while the high viscosity index allows use over a wide temperature range. Castrol Industrial North America, Inc. Naperville, IL
For more info, enter 34 at www.LMTfreeinfo.com
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CLASSIFIED
Specializing In
Machinery Health Personnel PM & PdM Field Service • Mgt • Sales • Hrly
OFF Button
Nationwide • Confidential • All Fees Company Paid
www.lineal.com lisalineal@lineal.com
TOLL FREE 877-386-1091 For rate information on advertising in the Classified Section Contact your Sales Rep or JERRY PRESTON: Phone: (480) 396-9585 e-mail: jpreston@atpnetwork.com
Safety Shutter � Disconnect Switch Rated � Simplifies NFPA 70E compliance www.meltric.com • 800.433.7642
Customized, Targeted Lists For Your Marketing Needs Ellen Sandkam www.atplists.com
847-382-8100 x110 / 800-223-3423 x110
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28 | LUBRICATION MANAGEMENT & TECHNOLOGY
NOVEMBER/DECEMBER 2011
Index
NOVEMBER/DECEMBER 2011 Volume 12, No. 6 •
ADVERTISER
WEBSITE
CIRCLE #
PAGE #
Abanaki Corporation ...............................www.abanaki.com/203 .................... 69................... 28
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
1300 South Grove Avenue, Suite 105 Barrington, IL 60010 PH 847-382-8100 FX 847-304-8603
Bel-Ray Company .....................................www.belray.com............................... 61,261 ........2,20
www.LMTinfo.com
Des-Case Corporation .............................www.descase.com/sample............... 65................... 11
SALES STAFF
Des-Case Corporation .............................www.descase.com ............................ 267................. 26 Engtech Industries Inc..............................www.engtechindustries.com........... 68................... 26 Hy-Pro Filtration ......................................www.hyprofiltration.com ............... 64,262 ........7,21 LubeStarz ...................................................www.lmtinfo.com/lubestarz ........... 70................... 30
OH, KY, TN 135 N. Rocky River Road Berea, OH 44017 440-463-0907; Fax 440-891-1254 JOHN DAVIS jdavis@atpnetwork.com
MARTS ......................................................www.martsconference.com ............ 62,66 ..........4,18 NSK Corporation .....................................www.nskamericas.com.................... 63,263 ........5,22 Royal Purple ..............................................www.royalpurpleindustrial.com .... 260,280 ....14,15 Royal Purple ..............................................www.royalpurpleindustrial.com .... 264,72 .....23,BC Scalewatcher ..............................................www.scalewatcher.com.................... 67,265 ......19,24 U.S. Tsubaki Power Transmission, LLC ..www.ustsubaki.com/lm .................. 71................... 31 U.S. Tsubaki Power Transmission, LLC ..www.ustsubaki.com......................... 266................. 25
Access LMTfreeinfo.com and enter the circle number of the product in which you are interested, or you can search even deeper and link directly to the advertiser’s Website. Submissions Policy: Lubrication Management &Technology gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish, and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned.
1. Publication Title
Statement of Ownership, Management, and Circulation (Requester Publications Only)
LUBRICATION MANAGMENT & TECHNOLOGY
4. Issue Frequency
2. Publication Number _
1 9 4 1 4 4 4 7
5. Number of Issues Published Annually
6
Bi-Monthly
7. Complete Mailing Address of Known Office of Publication (Not printer) (Street, city, county, state, and ZIP+4®)
1300 S. Grove Ave., Suite 105, Barrington, IL 60010 8. Complete Mailing Address of Headquarters or General Business Office of Publisher (Not printer)
3. Filing Date
09/27/11
6. Annual Subscription Price (if any)
$50.00
Contact Person
13. Publication Title 15. Extent and Nature of Circulation
a. Total Number of Copies (Net press run)
847-382-8100
1300 S. Grove Ave., Suite 105, Barrington, IL 60010 9. Full Names and Complete Mailing Addresses of Publisher, Editor, and Managing Editor (Do not leave blank) Publisher (Name and complete mailing address)
Bill Kiesel, 1300 S. Grove Ave., Suite 105, Barrington, IL 60010 Editor (Name and complete mailing address)
Jane Alexander, 1300 S. Grove Ave., Suite 105, Barrington, IL 60010
(4)
1300 S. Grove Ave., Suite 105, Barrington, IL 60010
(1)
Outside County Nonrequested Copies Stated on PS Form 3541 (include Sample copies, Requests Over 3 years old, Requests induced by a Premium, Bulk Sales and Requests including Association Requests, Names obtained from Business Directories, Lists, and other sources)
d. Nonrequested Distribution (By Mail and Outside the Mail)
(2)
In-County Nonrequested Copies Stated on PS Form 3541 (include Sample copies, Requests Over 3 years old, Requests induced by a Premium, Bulk Sales and Requests including Association Requests, Names obtained from Business Directories, Lists, and other sources)
(3)
Nonrequested Copies Distributed Through the USPS by Other Classes of Mail (e.g. First-Class Mail, Nonrequestor Copies mailed in excess of 10% Limit mailed at Standard Mail® or Package Services Rates)
(4)
11. Known Bondholders, Mortgagees, and Other Security Holders Owning or Holding 1 Percent or More of Total Amount of Bonds, Mortgages, or Other Securities. If none, check box None Full Name
Complete Mailing Address
None
15,622
18,958
14,900
Requested Copies Distributed by Other Mail Classes Through the USPS (e.g. First-Class Mail®)
c. Total Paid and/or Requested Circulation (Sum of 15b (1), (2), (3), and (4))
Same as Editor
Arthur L. Rice, III
19,746
b. Legitimate Paid and/or In-County Paid/Requested Mail Subscriptions stated on PS Form 3541. Requested (Include direct written request from recipient, telemarketing and Internet reDistribution (2) quests from recipient, paid subscriptions including nominal rate subscriptions, (By Mail employer requests, advertiser’s proof copies, and exchange copies.) and Outside Sales Through Dealers and Carriers, Street Vendors, Counter the Mail) (3) Sales, and Other Paid or Requested Distribution Outside USPS®
Managing Editor (Name and complete mailing address)
10. Owner (Do not leave blank. If the publication is owned by a corporation, give the name and address of the corporation immediately followed by the names and addresses of all stockholders owning or holding 1 percent or more of the total amount of stock. If not owned by a corporation, give the names and addresses of the individual owners. If owned by a partnership or other unincorporated firm, give its name and address as well as those of each individual owner. If the publication is published by a nonprofit organization, give its name and address.) Complete Mailing Address Full Name
September/October 2011
Average No. Copies Each No. Copies of Single Issue Published Issue During Preceding Nearest to Filing Date 12 Months
Outside County Paid/Requested Mail Subscriptions stated on PS Form 3541. (Include direct written request from recipient, telemarketing and Internet re(1) quest s from recipient, paid subscriptions including nominal rate subscriptions, employer requests, advertiser’s proof copies, and exchange copies.)
Bill Kiesel
Telephone (Include area code)
Nonrequested Copies Distributed Outside the Mail (Include Pickup Stands, Trade Shows, Showrooms and Other Sources)
e.
Total Nonrequested Distribution (Sum of 15d (1), (2), (3) and (4))
f.
Total Distribution (Sum of 15c and e)
g.
Copies not Distributed (See Instructions to Publishers #4, (page #3))
h.
Total (Sum of 15f and g)
i.
Percent Paid and/or Requested Circulation (15c divided by f times 100)
16. Publication of Statement of Ownership for a Requester Publication is required and will be printed in the issue of this publication.
17. Signature and Title of Editor, Publisher, Business Manager, or Owner
18,958
14,900
361
551
200 561 19,519 227 19,746 97.13%
0 551 15,451 171 15,622 96.43%
Nov/Dec 2011 Date
09/27/11
12. Tax Status (For completion by nonprofit organizations authorized to mail at nonprofit rates) (Check one) The purpose, function, and nonprofit status of this organization and the exempt status for federal income tax purposes: Has Not Changed During Preceding 12 Months Has Changed During Preceding 12 Months (Publisher must submit explanation of change with this statement)
PS Form 3526-R, September 2007 (Page 1 of 3 (Instructions Page 3)) PSN: 7530-09-000-8855 PRIVACY NOTICE: See our privacy policy on www.usps.com
NOVEMBER/DECEMBER 2011
I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading information on this form or who omits material or information requested on the form may be subject to criminal sanctions (including fines and imprisonment) and/or civil sanctions (including civil penalties). PS Form 3526-R, September 2007 (Page 2 of 3)
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, IA, MI, MN, NE, ND, SD, WI 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 847-382-8100 x108; Fax 847-304-8603 TOM MADDING tmadding@atpnetwork.com
14. Issue Date for Circulation Data Below
LUBRICATION MANAGEMENT & TECHNOLOGY
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
AR, KS, LA, MO, NM, OK, TX 5930 Royal Lane, Suite E #201 Dallas, TX 75230 972-816-6745; Fax 972-767-4442 GERRY MAYER gmayer@atpnetwork.com 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
www.LMTinfo.com | 29
WE’RE BUILDING OUR 2012 TEAM...
Here Are e b u Our 2011L rz
a t S
Henry Neicamp
Let’s Build Our 2012 Team
Steve Vaughan, MLT I
Field Services Manager, Polaris Laboratories, the well-known, full-service fluid-analysis provider, headquartered in Indianapolis, IN
e b u L tarz S
©
Mark L. Graham, CLS, CLGS, OMA
Maintenance Mechanic Alcoa – Mt. Holly Goose Creek, SC
Technical Services Manager, Lubricants O’Rourke Petroleum Products, based in Houston, TX
Dave Maki
Mike Graves, P.Eng.
Head Oiler, St. Mary’s Paper, a mill located in Sault Ste Marie, Ontario, Canada
President, Coastal Engineering Services, a consulting Info firm based Company in New Brunswick, Canada Contact Info Here
Sandor Mercz Kerek Industrial Mechanical Technician, Ingenieria Proactiva Ltda., a consulting operation in Cali-Valle, Colombia
www.websitehere.com
©
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!
For more info, enter 70 at www.LMTfreeinfo.com
30 |
LUBRICATION MANAGEMENT & TECHNOLOGY
NOVEMBER/DECEMBER 2011
T H E U LT I M AT E P O W E R T R A N S M I S S I O N C O M P O N E N T PA C K A G E
Tsubaki components.
Your lifeline to less downtime. Productivity is profitability. The right products make the difference between sinking and swimming. Let Tsubaki’s family of Chains, Sprockets, Power Locks®, and Overload Protection products keep your operation above water with optimum drive-system components, support and strategies.
Find your perfect configuration faster with our singlesource solution. Tsubaki components combine superior design, performance and compatibility for smooth sailing. Let Tsubaki come to the rescue. www.ustsubaki.com/lm
© 2011 U.S. Tsubaki Power Transmission, LLC. All Rights Reserved.
RIGHT CHAIN
•
RIGHT SPROCKET
•
RIGHT PROTECTION
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•
RIGHT CALL
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Most efforts to improve operating efficiency and lower maintenance costs are labor intensive and involve painful cultural changes. Numerous progressive companies have experienced significant cost savings simply by upgrading lubricants. You can learn how by reading the special report ‘Lowest Total Cost of Ownership’. This special report includes extensive case studies that document real-world savings through lubricant upgrades. For the complete story about attaining the ‘Lowest Total Cost of Ownership’ from your lubricant purchases, that included extensive corroborating case studies, call 866-769-3518 . . .
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