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NOVEMBER/DECEMBER 2013 • VOL 14, NO. 6 • www.LMTinfo.com
contents Features
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
REAL-WORLD SUCCESSES 8 The Benefits Of Lubrication Certification Professional-development rewards run deep for both end-users and suppliers.
©ndoeljindoel—Fotolia.com
Ray Thibault, Contributing Editor
THE CORPORATE REPORT 14
Profiles Of Leading Suppliers To Industry ■ Air Sentry ■ OILSAFE by Fluid Defense ■ Royal Purple LLC ■ Scalewatcher North America, Inc. ■ U.S. Tsubaki Power Transmission ■ Des-Case Corporation ■ NSK Corporation
MAINTENANCE LOG 20
Ease Of Use Highlights New Condition-Monitoring Tools As this overview of technologies points out, today’s maintenance technicians and operators have access to capabilities that were previously limited to monitoring specialists.
DePartMeNts 4
My Take
6
From Our Perspective
27
Problem Solvers
29
Info Highway
30
Supplier Index
Jane Alexander, Editor, with Paul Michalicka, SKF USA Inc.
ICML CERTIFICATION SERIES 22
Industrial Lubrication Fundamentals: What’s In A Lubricant? (Additives) These packages are added to your lubricants to help them do all that you want them to do. Ken Bannister, Contributing Editor
HOLD THESE DATES
March 18-21, 2014 Hyatt Regency O’Hare, Rosemont, IL Go to www.MARTSConference.com for further details. NOVEMBER/DECEMBER 2013
www.lmtinfo.com | 3
MY TAKE
Jane Alexander, Editor-In-Chief
We’re Moving (And So Are You)
A
s someone who is preparing to leave one long-time home, so to speak, and move to a new one (more on that later), you might think I’m writing this column with a heavy heart. I’m not. Although Contributing Editor Ray Thibault has announced that his article in this issue is the last regular one he’ll write for us, we’re by no means saying so long. Instead, we say thanks so much, Ray, for nine years of great articles in LMT and its predecessor, Lubrication & Fluid Power. We’re hoping to see more of him, from time to time, when LMT is ensconced in its new digs: That would be Maintenance Technology & Asset Performance magazine and a power-packed, all-things-lube portal now under construction. The November/December 2013 issue is, in fact, LMT’s last as a stand-alone print publication. Starting in February 2014, it will come to you every other month as a supplement in Maintenance Technology & Asset Performance (which, if they don’t already have one, current LMT print-edition subscribers will automatically receive a subscription to). This move is a no-brainer for us: We’ve been considering it for some time. As we all know, lubrication and its associated technologies and methods are among the most important factors in assuring the levels of asset performance that today’s industries crave. LMT’s home in Maintenance Technology & Asset Performance magazine sets in place an ideal one-stop shop from which to deliver the type of comprehensive best-practice and product information that helps lubrication-management professionals successfully support their organizations’ quest for equipment and process reliability. Those of us on the LMT team thank you for your loyalty over the years. We’re also very excited about seeing and serving you in our new home. Stay tuned. You’ll be hearing from us soon. LMT jalexander@atpnetwork.com
Achieving EffiCIencies THROUGH PRACTICES & PRODUCTS
November/December 2013 • Volume 14, No. 6 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 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 except Mar/Apr by Applied Technology Publications, Inc., 1300 S. Grove Avenue, Suite 105, Barrington, IL 60010. Periodical postage paid at Barrington, IL and additional offices. Arthur L. Rice, III, President/CEO. Circulation records are maintained at Lubrication Management & Technology, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Lubrication Management & Technology copyright 2013. No part of this publication may be reproduced or transmitted without written permission from the publisher. Annual subscription rates for nonqualified people: North America, $140; all others, $280 (air). No subscription agency is authorized by us to solicit or take orders for subscriptions. Postmaster: Please send address changes to Lubrication Management & Technology, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Please indicate position, title, company name, company address. For other circulation information call (630) 739-0900. Canadian Publications Agreement No. 40886011. Canada Post returns: IMEX, Station A, P.O. Box 54, Windsor, ON N9A 6J5, or email: cpcreturns@wdsmail.com. Submissions Policy: Lubrication Management & Technology gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Printed in U.S.A.
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NOVEMBER/DECEMBER 2013
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FROM OUR PERSPECTIVE
Ken Bannister, Contributing Editor
The Importance Of Cognitive Bandwidth
A
s I recently watched a commercial for a Broadway-style production of I Love Lucy, I began to chuckle at the thought of my favorite episode of that iconic 1950s-era TV show. “Job Switching” featured Lucy and Ethel (played by comediennes Lucille Ball and Vivian Vance) trying desperately to succeed at their jobs in a chocolate factory. Their task was to take chocolates off a conveyor belt, wrap them and put them back on the belt. Simple, yes? Not if you were Lucy Ricardo! As the belt moved ever faster, the two women struggled to keep up. They didn’t have a chance, though, as they were unaccustomed to the work and speed of the equipment. To compensate, they resorted to various (funny) ways to take care of the unwrapped chocolates. Alas, Lucy and Ethel were untrained and unprepared for a work situation that literally overloaded their ability to cope. (Enjoy the chocolate factory scene yourself by calling it up through your Web search engine.) Sadly, I’m often reminded, via reports of and experience with asset failures, of similar incidences in the real world: A series of events or communications will have overloaded a maintainer’s or operator’s ability to cope, surpassing the limits of his/her cognitive bandwidth. This scenario is akin to asking an individual who only has a dial-up modem to make decisions and perform as if he/she is working with a 4G, highspeed Internet connection. As the maintenance industry loses its highly experienced workforce through attrition and retirement over the next few years, we can’t expect a broken vocational-educational and apprenticeship-training system to replace them at the same quality level. Thus, we must prepare to work with personnel that have less cognitive bandwidth than we’ve been accustomed to. Fortunately, there are a number of things we can do. In fact, much of the problem lies in the way job tasks are written— especially PM job tasks.
6|
LUBRICATION MANAGEMENT & TECHNOLOGY
Many instructions don’t contain adequate information, and many people don’t have enough experience or bandwidth-knowledge to carry out an intended task. For example, a typical call to “lubricate as necessary” is highly subjective—and often will result in no action being taken. If a job task is to be effective, it must be immediately actionable and written in an objective manner spelling out, in this case, exactly what to lubricate, when to lubricate and what to lubricant with. This approach eliminates the “crystal ball” decision-making requirement that can tax the cognitive bandwidth of even very knowledgeable and skilled personnel.
Work situations can overload an untrained and unprepared worker’s ability to to cope. Another area of change involves effectively planning and scheduling work for maintainers—and not allowing them to plan and schedule their own work. Otherwise, a maintainer is forced to logistically prepare for the job by choosing and obtaining parts and tools, setting up a safety plan, communicating for access to the job, etc., when his/her only job is to perform the repair. Worse yet is when maintainers are expected to autonomously choose and prioritize their own work from a pile of work orders with no direction or information to make that choice and no planning and scheduling training. That’s a difficult task for the most experienced among us. The bottom line is that a little change in thinking up front can prevent many types of “Lucy and Ethel at the chocolate factory” workforce problems in the future! Good Luck! LMT kbannister@engtechindustries.com
NOVEMBER/DECEMBER 2013
For more info, enter 63 at www.LMTfreeinfo.com
REAL-WORLD SUCCESSES This article is an updated follow-up to the author’s article in the 2011 March/April issue of LMT.
The Benefits Of Lubrication Certification Professional-development rewards run deep for both end-users and suppliers.
Ray Thibault CLS, OMA I, OMA II, MLT, MLT II, MLA II, MLA III Contributing Editor
C
ertification programs are an important aspect of countless professions. For example, in our personal lives, when we require information from a doctor or accountant, we want to deal with someone who will provide good information in a competent manner. There can be a wide range of competence among professionals, however: How do you know you’re getting the correct information for your situation? A service provider who has been certified in his/her respective field through rigorous preparation and the passing of a difficult exam could have a substantial edge over a provider who hasn’t. That doesn’t mean that all certified professionals are more competent than their non-certified counterparts. A recognized certification, though, can often help the individual who earned it receive stronger consideration from prospective patients, clients and/or employers. The same holds true for certifications in industrial areas—like lubrication.
8 | LUBRICATION MANAGEMENT & TEChNOLOGy
NOVEMBER/DECEMBER 2013
REAL-WORLD SUCCESSES
Certifying organizations Presently, there are two major certifying organizations for lubrication related activities: 1. The International Council of Machinery Lubrication (ICML) was formed in 2000 to promote competence in the field of lubrication through the development of certification standards. All of its certifications are in compliance with ISO 18436-4 or ISO 18436-5. 2. The Society of Tribologists and Lubrication Engineers (STLE) was established in 1944 as the American Society of Lubrication Engineers and later changed its name. Each organization offers a number of certification programs that have been described in my earlier article (and in Contributing Editor Ken Bannister’s “ICML Certification Series” that’s been running this year in LMT). I will only be discussing the two most common certifications for each organization. ICML certification programs. . . The most common lube certification is that of Machinery Lubrication Technician Level I (MLT I) offered by the ICML. Designed primarily for plant lubricators performing dayto-day lubrication activities, this certification program is international in scope and offered in 10 different languages. Table I outlines the areas and competencies that the MLT I exam measures: Table I. Areas of Competency Measured by ICML’s MLT I Exam Maintenance Strategy
(5%)
Lubrication Theory
(10%)
Lubricants
(15%)
Lubricant Selection
(15%)
Lubricant Applications
(25%)
Preventive and Predictive Maintenance
(10%)
Lube Condition Control
(10%)
Lube Storage and Management
(10%)
Requirements for taking the MLT I exam include two years of post-secondary education or on-the-job training in maintenance or lubrication. Sixteen hours of documented training in machinery lubrication are also required. The 100-question exam requires the candidate to score 70% to obtain the certification. The cost is $200. There is a onemonth waiting period to retake the exam. The MLT I certification has greatly elevated the competence of lubricators, resulting in more effective lubrication programs. There are currently 6032 people who hold MLT I certification—which translates into a 75% growth from 2011, when there were 3435 certified MLT I certifications. These numbers speak volumes in terms of this program’s success. The well-known companies listed in Table II are among the organizations that have supported MLT I certification to promote better lubrication practices and establish worldclass lube programs in their facilities. (Note: While the numbers reflect all ICML certifications in these companies, most are, in fact, MLT I.) Table II. Major Companies with Substantial Numbers of ICML-Certified Personnel
(Note: While reported data reflects all ICML certifications in these companies, most are MLT I.) Company
Individuals ICML-Certified
Georgia Pacific
435
Cargill
396
Rio Tinto Group
227
International Paper
170
Dupont
167
Oil analysis is another area of ICML certification—with Machinery Lubrication Analyst certifications for levels I, II, and III. MLA I and MLA II the most popular. Currently, there are 4177 certified individuals (mainly MLA II). Table III shows the areas of competency measured by ICML’s Machinery Lubrication Analyst exam. This certification has been adopted by many oil-analysis laboratories, as well as by end-user companies that have large oil-analysis programs. The cost is $200 for the exam.
The benefits of lubrication certification can best be summed up in three words: credibility, confidence and competence. NOVEMBER/DECEMBER 2013
www.LMTinfo.com | 9
REAL-WORLD SUCCESSES
Table III. Areas of Knowledge Measured by ICML’s MLA Exam Lubricant Roles and Functions Oil-Analysis Maintenance Strategies Oil Sampling Lubricant Health Monitoring Lubricant Contamination Measurement and Control Wear Debris Monitoring and Analysis
(4%) (4%) (29%) (21%) (25%) (17%)
STLE certifications programs... The Society of Tribologists and Lubrication Engineers offers the oldest certification—that of Certified Lubrication Specialist (CLS), introduced in 1994. There are currently 1162 certified individuals worldwide (an increase of 27% since 2011). You must have a minimum of three years’ experience in lubrication-related activities to take this exam, which is currently offered only in English. (Work is progressing in offering the exam in other languages.) The cost is $470 for non-STLE members and $350 for members. There is a oneyear waiting period to retake the exam. The CLS exam was originally developed to certify manufacturing plant personnel involved in lubrication, such as lubrication engineers—which were popular around the time the exam was introduced. That focus, however, is not particularly relevant now, as very few lubrication engineers remain in manufacturing plants. Instead, CLS certification has become popular with supplier marketing and technical personnel, in that it helps provide a competitive advantage in the sale of industrial lubrication products. This certification has become important for plant lube specialists overseeing lubrication programs. This exam covers 16 areas. Table IV. Topics Covered by STLE’s CLS Exam ■ Lubrication Fundamentals ■ Fluid Conditioning ■ Storage, Handling and Application of Lubricants ■ Monitoring and Reducing Consumption of Lubricants ■ Gears ■ Bearings ■ Seals ■ Fluid Power ■ Lubricant Manufacturing ■ Pneumatics ■ Transportation Lubricants ■ Metalworking ■ Solvents and Cleaners ■ Problem Solving ■ Lubricant Analysis ■ Lubrication Programs
10 | LUBRICATION MANAGEMENT & technology
Chevron made a commitment over 10 years ago to have most of its technical sales personnel and marketer/distributors CLS-certified. It currently has 89 CLSs—more than any other lubricant company. ExxonMobil is second with 70. Both Chevron and ExxonMobil have promoted CLS with their distributor/marketers and have many more certified individuals outside of company employees. For example Parman Energy, a large Chevron marketer, has 12 CLScertified people on staff. Two of the second-tier lubricant companies after the majors have also made commitments in the area of CLS certification. Schaeffer Manufacturing and Lubrication Engineers have been very successful in developing training programs to help their personnel achieve certification. Currently, Schaeffer has 42 CLSs and Lubrication Engineers has 38. Oil-analysis labs have found CLS certification beneficial because it demonstrates an overall knowledge about lubrication. (Some large projects have required at least two CLSs on staff to bid.) ALS and Polaris with 13 and 8 have the largest number of CLSs. The Oil Monitoring Analyst (OMA) certification is also offered by STLE. With 410 certified individuals today, it’s the Society’s second most popular program after the CLS. That number reflects an increase of 30% since 2011. The OMA certification is specific to oil analysis. To take the exam, one must have 16 hours of oil-analysis training (which can include in-house company courses). Furthermore, those taking the exam must have one year of active employment utilizing oil analysis. The cost is the same as for the CLS ($470 for non-STLE members and $350 for members). There also is a waiting period of one year to retake the exam. Several years ago, Chevron embarked on a program to make its field people more competent in working with customers on the use of oil analysis as a condition-monitoring tool. This program has resulted in Chevron now having 40 OMA-certified individuals (not including its lubricant marketers). The company has more OMAs than all other major lubricant manufacturers combined. The major oil-analysis laboratories have utilized OMA certification for their staffs as well. Polaris and Analysts, Inc., have the most OMA-certified personnel—at 16 and 13 respectively. Reaping the rewards ICML and STLE have both seen substantial growth in certification of lubrication professionals (which should continue well into the future as companies—end-users and suppliers alike—realize the importance of technically competent individuals administrating the use and sale of lubricants. How well certification can pay off from both demand- and supply-side perspectives is reflected in the following examples and remarks. NOVEMBER/DECEMBER 2013
Real-world success. . . An outside lubricant contractor along the Gulf Coast has been responsible for all lubrication activities in a major chemical facility for four years with excellent results, which were discussed in a previous article, more than justifying the cost of the program. The success in large part is due to the competency of the lubrication technicians who perform all the lubrication activities. They also are proactive in working with plant personnel in reporting any equipment problems observed during lubrication. A rigid standard has been set by the program manager. He requires all his lube technicians to undergo training and pass the MLT I one year after employment. This has resulted in a highly motivated competent group. The following comments came from several individuals regarding the benefits of their CLS certifications:
our group. With these certifications, we are confident that we now know more than 95% of the people we deal with on a daily basis about lubrication reliability and world-class contamination control. This ability to educate the masses on lubrication best practices leads to sales generation without the use of a sales pitch. The people who ‘don’t know what they don’t know’ now have a better understanding of how a world-class lubrication reliability program can find hidden profits within their facility. Asset management actually means something now! Without these type certifications for our consultant and management group, we would not have the competitive advantage we currently enjoy as an organization in the world of industrial lubrication.” ■ “Since I have gained my CLS, my confidence, as well as my
■ “First and foremost, it is the confidence to go educate
the rest of ‘our’ world on lubrication best practices and asset management that passing these exams provides to
reputation within the industry, has grown. Today companies actually call me to assist with their lubrication programs in design and trouble shooting. Rarely am I called in to just ‘sell’
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REAL-WORLD SUCCESSES
lubes. I am sought after as an information source in building a Lubrication Excellence Program.” ■ “The most surprising thing that the CLS has done for me is
with our competition. I was at a trade show where another salesman was giving a seminar. I asked him if I could attend. He was very gracious and said of course. While he was giving his seminar on lubrication, he recognized me and mentioned that I had my CLS. He said he was still studying for his and it was a great accomplishment. He invited others to ask me questions, too. We actually were able to answer all questions posed. The CLS does garner respect from those who know what the designation is!” ■ “I initially took the CLS 14 years ago in 1999 after working
in the lubricant business for three years. Preparing for the exam on my own was a challenging undertaking, but passing it gave me confidence when calling on customers who had been around lubricants all of their working lives. I knew it would show them that I had a level of professionalism that many others who would call on them
didn’t have. I even have one manufacturing customer that uses the CLS certification as a guideline as to whether he will take the time to meet with other sales people. I also wanted the certification because I knew that one day I would be calling on someone who would have the CLS, and how would it look if I didn’t have it?” ■ “I have been selling lubricants for over 20 years. It wasn’t
until I received my CLS that I became a lot more successful. Previously I sold on price and didn’t have the technical skills to call on certain industries such as construction and power generation. After the CLS I was able to get into accounts that previously turned me away. The training and hard work I did in preparing for the CLS exam resulted in dramatically increasing my technical competence and confidence, which resulted in a large increase in sales.” ■ “Because of the training I received in obtaining my CLS,
I was able to solve a gearbox problem at a large potential account. The solution to this problem resulted in sales, which increased my yearly compensation by 39%.”
Getting The Sale: Be A Problem-Solving Partner And Keep On Learning It’s a fact of life: The lubricants business is declining. Companies that survive will be those with quality products and a high level of technical service. Technical service starts with the technical skills of the sales representatives to help the customer solve problems. These days, end-user organizations are relying on lubricant suppliers to make decisions that can directly impact the bottom line. Making the wrong decision can result in equipment failure and expensive machinery downtime. Is it any wonder, therefore, that companies want to work with the most competent people possible? End-users across industry are under more time pressures than ever before—and they certainly don’t have inordinate amounts of excess
time to spend with sales people. That goes double for sales people who are considered to be “peddlers.” Demonstrating little technical competence, peddlers give the lubrication industry a bad name, and make it difficult for competent reps to get appointments with plant personnel who remember bad experiences with unprepared, technically deficient sales people. One way a sales person can get in the door is by a having a certification demonstrating technical knowledge in the lubrication field: Plant personnel who can deal with a certified individual have more confidence their time will not be wasted. Lubricant sales people need to elevate themselves along the following continuum with their accounts: Peddler Vendor Supplier Partner
12 | LUBRICATION MANAGEMENT & TEChNOLOGy
If you work in a lube-related sales area, let’s hope you’ve never been referred to as a “peddler.” Your goal should be to partner with your accounts as a “problem-solver.” That will require you to develop technical skills for solving your customers’ problems. Although obtaining a certification demonstrates technical knowledge, it doesn’t guarantee success. I’ve seen certified individuals who never improved their technical skills. Years of experience don’t always translate into technical competence. Some people can claim 30 years experience, while others may have one years’ experience 30 times over. Who would you rather deal with? For yourself, certified or not, you need to continue learning. . . . RT
NOVEMBER/DECEMBER 2013
REAL-WORLD SUCCESSES
Conclusion Lubrication is a key component in achieving the highest level of equipment reliability in all industries but in some cases is relegated to a secondary role. We need more technically competent individuals both using and selling lubricants. Training is very important in improving technical skills. Training should be combined with accountability—through demonstration of knowledge gained by passing a certification exam. Certified individuals are able to earn more money. A recent survey conducted by Machinery Lubrication magazine found that ICML-certified plant personnel earned 7% more than their non-certified peers. A survey conducted by STLE in 1996 and published in TLT magazine indicated that CLS-certified distributor sales representatives earned on average 30% more. It pays to be certified. Also, there is a matter of pride that you have elevated yourself to the top of your profession, but remember to continue to learn and grow. The benefits of lubrication certification can best be summed up in three words: credibility, confidence and competence. In some ways, though, the road to becoming
certified can be more important than the certification. That’s because knowledge gained in passing the exam will help candidates become more effective in their jobs. LMT Acknowledgement This is my final regular article for LMT. I’ve been writing for this publication under its current title and its former one (Lubrication & Fluid Power) for nine years. I don’t know where the time went. I enjoyed very much trying to impart some of my knowledge, and hopefully provided some measure of help in your lubrication endeavors. I learned a great deal from writing the articles and thank you for reading them. I appreciated your comments. Feel free to continue to contact me as shown below. Long-time Contributing Editor Ray Thibault is based in Cypress (Houston), TX. An STLE-Certified Lubrication Specialist and Oil Monitoring Analyst, he conducts extensive training for operations around the world. Telephone: (281) 250-0279. Email: rlthibault@msn.com.
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CORPORATE REPORT 2013
Air Sentry
A
ir Sentry® is a leading manufacturer of contamination control products, preventing cross contamination of lubricants and keeping particulates and moisture from entering industrial machinery: Gearboxes, reservoirs, and storage tanks that hold lubricants and fuels that utilize our products are kept clean and dry, allowing for optimum lubricant performance. Air Sentry is an advocate of Reliability Centered maintenance— teaching and assisting customers in improving facilities and maintenance programs, conducting plant surveys and increasing awareness to improve lubrication practices and reduce maintenance costs. By providing devices designed to keep dirt and moisture out of lubricating fluids and fuels, Air Sentry products ensure longer fluid life. This extends the life of critical machinery and equipment, and significantly reduces costs for equipment repair and replacement, and unplanned downtime.
to prevent cross contamination. Customers can filter, fill and sample lubricants, through quick connects, without opening the vessel to atmosphere. This streamlines maintenance and eliminates fluid handling issues. Drum, hydraulic-reservoir, domed-flange and gearbox adapter kits are available in eight distinct colors.
Innovation Drives Us Air Sentry’s history of innovation dates back to the very beginning. We were first to design solid desiccant beds, allowing for more desiccant, longer life, and better value for the end-user. We were the first to design breathers with replacement cartridges to further reduce costs and environmental waste. We were first to integrate check valve technology into breathers to extend the life of the desiccant. Older designs resulted in desiccant being wasted drying air around the equipment. Air Sentry check valve designs dry only air drawn into equipment, significantly extending the life of the device and reducing costs. ColorGuard®—aluminum color-coded adapter kits—work with other colorcoded storage and transfer systems and allow visual identification of contents
New Breather. New Rules. New Standard. With the launch of a revolutionary new series, we’ve taken the gold standard to the next level. Guardian® incorporates prior innovations and several industryfirst features, enabling it to last longer and significantly reduce cost and maintenance intervals. The Modular Stack Ring allows for multiple configurations specific to our customer’s needs. The Isolation Check Valve protects the adsorbent from exhaust air and allows installation over fuels and volatile fluids without harm to the desiccant. Guardian is the first breather constructed of Tritan™ for the best combination of chemical, temperature and impact resistance on the market, allowing installation in the harshest environments.
14 |
Whitmore corporate headquarters in Rockwall, TX. Air Sentry is a division of Whitmore.
The Guardian Shield prevents free water from equipment wash-down or driving rain from forcing open the airflow check valves and excessive dust and dirt from settling on the valves in harsh environments like paper mills or coal mines. Value Every innovation has been made to reduce the cost of employing worldclass maintenance practices. Air Sentry has been setting the bar for longer breather, fluid and equipment life since 1997, and we’re just getting started. Air Sentry 930 Whitmore Drive Rockwall, Texas 75087 855.242.2792 www.airsentry.com
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CORPORATE REPORT / NOVEMBER-DECEMBER 2013
CORPORATE REPORT 2013
OILSAFE by Fluid Defense
T
he OilSafe® Visual Lubrication Management System from Fluid Defense Systems is the company’s easy-to-implement, flagship innovation that helps users keep their storage areas clean and safe and prove their commitment to best practices.
Providing a Range of Benefits Customizable, visually intuitive labels ensure consistent fluid identification throughout the manufacturing environment. The OilSafe Work Center provides safe, compact bulk storage and contamination control to promote best practices for lean manufacturing, 5Rs, 5S and OSHA® right-toknow compliance. In-line filtration and precise-pour transfer containers simplify maintenance and safeguard workflow. As a result, plants benefit from a complete system that covers the entire process loop and works with any existing maintenance process. “Our OilSafe transfer containers and labels have long been the industry standard to reduce contamination and spills. We recognized a need in the market to add bulk storage and dispensing to create a fully integrated system for managing lubrication from delivery to point of application,” explains John Gillian, Chief Executive Officer for Fluid Defense. “That’s why we’re proud to introduce the OilSafe Work Center.” The OilSafe Work Center is the only modular, scalable bulk system of its kind. Each tank has its own pump and built-in filtration to prevent fluid crosscontamination and keep fluid storage areas organized, clean and free of the 55-gallon drums that are commonly used. According to Gillian, “It’s a safe and reliable solution that helps companies across the world instantly establish bulk-storage best practices on the plant floor and prevent the inefficiencies, downtime and lost production that can cost hundreds of thousands of dollars.”
The only modular, scalable, bulk-fluid storage solution of its kind, the OilSafe® Work Center can prevent costly inefficiencies, downtime and lost production.
Serving a Range of Applications The OilSafe Work Center has been successfully implemented in applications such as manufacturing, mining, food and beverage, defense and more. Available in multiple configurations, each system is customizable to suit the application and budget. The scalable, plug-andplay design extends the life of the Work Center, minimizing downtime and increasing efficiency. In addition, the palletized, fully assembled pods allow for quick set-up and efficient transport. After years of delivering strong results, OilSafe has become the recognized standard in several key industries. Fluid Defense’s dealer network has a distribution reach into more than 45 countries and is partnered with worldclass suppliers.
NOVEMBER-DECEMBER 2013 / CORPORATE REPORT
To learn more about the OilSafe Work Center and the OilSafe Visual Lubrication Management System, visit www.oilsafe.com. OILSAFE by Fluid Defense 2001 Greenfield Road Montgomery IL, 60538 Ph: 630.280.8930 www.oilsafe.com
For more info, enter 261 at www.LMTfreeinfo.com | 15
CORPORATE REPORT 2013
Royal Purple LLC
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◆ Long Oil Life: Synfilm GT has outstanding oxidation stability that greatly extends oil change intervals while keeping equipment clean.
oyal Purple was founded as an industrial lubricants company by John Williams, a pioneer in developing synthetic lubricants. In the early 1980s, Williams was asked by an oil production company to solve chronic bearing failures in their large compressors. He set out to produce a lubricant with the ability to handle the extreme demands of equipment. New Lubricant Technology Williams’ work resulted in a new additive technology that fortified lubricants with an unusually high film strength capable of protecting rotating-equipment components under extreme operating conditions. In addition, the technology had exceptional oxidation stability for long oil life and provided outstanding protection against rust and corrosion in both wet and high temperature applications. This new additive technology—called Synerlec®—became the cornerstone of the Royal Purple product line. Synfilm® GT is one of the innovative products that uses Synerlec technology.
◆ Saves Energy: Synfilm GT has an extremely low coefficient of friction that is proven to save energy over conventional oils. In rotating equipment these savings frequently exceed the total cost of the oil within several months making what was once an oil expense a profit.
Royal Purple’s blending and storage tanks
◆ Synthetic Solvency: Synfilm GT’s natural solvency cleans up dirty equipment and keeps it clean. Though the Synfilm GT formulation has the ability to reliably lubricate many different types of equipment, Royal Purple produces a complete range of high performance lubricants for nearly every industrial application.
Versatility ◆ Synfilm® GT is Royal Purple’s most versatile lubricant. In the appropriate viscosity grade, it is recommended for use in gas and steam turbines, centrifugal compressors, pumps, vacuum pumps, blowers, bearings, gears, worm gears and more. It is a long-life, high-film-strength, energyefficient, synthetic lubricant that significantly increases bearing life and equipment reliability. ◆ Synfilm GT gains its performance advantages over competing mineral and synthetic oils through its superior blend of synthetic base oils plus Royal Purple’s proprietary Synerlec additive technology. This unique 16 |
◆ Excellent Corrosion Protection: Synfilm GT’s tough oil film forms an ionic bond on metal surfaces, which acts as a preservative oil during shutdown and provides instant lubrication at startup.
Royal Purple LLC 1 Royal Purple Lane Porter, TX 77365 Ph. 888.382.6300 www.royalpurpleindustrial.com
additive technology is proven to make equipment run smoother, cooler and quieter, as well as more reliably and efficiently. Performance Advantages ◆ High Film Strength: Synfilm GT protects bearings far beyond the ability of other turbine oils, carrying significantly greater loads.
For more info, enter 262 at www.LMTfreeinfo.com
CORPORATE REPORT / NOVEMBER-DECEMBER 2013
CORPORATE REPORT 2013
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.
For more info, enter 263 at www.LMTfreeinfo.com
NOVEMBER-DECEMBER 2013 / CORPORATE REPORT
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CORPORATE REPORT 2013
U.S. Tsubaki Power Transmission
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.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; 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 18 |
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. The 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 and assembled
with accurate press-fits 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 line includes all Tsubakimoto products other than chain and sprockets. A partial list consists of belts, cam clutches, actuators, dampers, overload protection and reducers. The KabelSchlepp Division produces world-class cable and hose carriers in a wide range of sizes and types for a variety of environments. From lightweight microsized mono cable carriers to enormous super-duty steel chain designs, Tsubaki KabelSchhlepp has the perfect solution for any application. Wherever shorter production times, faster installation, higher machine cycles, longer service life and better overall value are desired, Tsubaki KabelSchlepp can help. *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
For more info, enter 264 at www.LMTfreeinfo.com
CORPORATE REPORT / NOVEMBER-DECEMBER 2013
CORPORATE REPORT 2013
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 are 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 design/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.
◆A knowledgeable team: Our Lubrication Transformation program is managed by lubrication engineers with years of in-plant experience. Visit our Website to learn more about how we can help you take the next step in your bestpractice journey.
Lubrication Transformation: Putting Best Practices into Practice ◆Consultation services and in-depth training: We specialize in helping companies pinpoint lubrication issues and identify ways to address them, including plant surveys, one-day best-practice overviews and intensive training classes with ICML certification options.
Des-Case Corporation 675 N. Main Street Goodlettsville, TN 37072 Ph: 615.672.8800 www.des-case.com
Whenever you’re in need of contamination control, you can count on Des-Case to provide the right products and services to keep you up and running.
TM
For more info, enter 265 at www.LMTfreeinfo.com
CORPORATE REPORT 2013
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SK’s Asset Improvement Program (AIP) provides real answers to real problems. Our AIP program is not a disguised attempt to sell you so-called “solutions”; it is in fact, a well-proven platform that combines your own knowledge of the working environment, culture, processes and problems in your business, with the engineering expertise and innovation of NSK. Our solutions are quantifiable and measureable in terms of lowered costs, increased efficiencies, and reduced downtime; resulting in increased profitability. What makes NSK’s AIP program different and more successful is the close working dialogue we have with our clients to identify and understand the problems that affect them, as
NSK Corporation well as the impact of these problems on their business financially. We are committed to helping solve problems that are costing you valuable time and money, by offering you a real opportunity to unlock additional profitability through improved machine reliability and increased working knowledge. Our AIP program works with you through a structured, pre-planned approach called the AIP Value Cycle. The Value Cycle consists of five stages: Situational Analysis, Value Proposition, Value Implementation, Value Measurement and Shared Best Practice. NSK progressively works with you at every stage of the AIP Value Cycle to help you see the potential savings available and ensures that you achieve the stated benefits.
NOVEMBER-DECEMBER 2013 / CORPORATE REPORT
For more information on how NSK’s AIP Program can benefit your company, including real-world industry success stories, go to: http:// www.nskamericas.com/cps/rde/xchg/ na_en/hs.xsl/AIP.html. NSK Corporation 4200 Goss Rd. Ann Arbor, MI 48105 Ph: 800.675.9930 www.nskamericas.com
For more info, enter 266 at www.LMTfreeinfo.com | 19
MAINTENANCE LOG Editor's Note: This article is based on one that first ran in the November 2013 issue of Maintenance Technology.
Ease Of Use Highlights New Condition-Monitoring Tools As this overview of technologies points out, today’s maintenance technicians and operators have access to capabilities that were previously limited to monitoring specialists. Jane Alexander, Editor With Paul Michalicka, SKF USA Inc.
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eaturing streamlined designs and improved factory-floor functionality, next-generation condition-monitoring instruments and devices stem from advances in digital technology and electronics. Typically lightweight and portable, they require no special technical skills to operate. Personnel can, thus, become proficient in their use with little training and after only an hour or two of practice. These innovations include durable vibration analyzers, portable lube-analysis kits, versatile stroboscope/tachometers, non-contact thermometers and many more. Leveraging such tools, users can perform a range of basic monitoring activities and obtain valuable data on operating conditions with regard to the following issues: Vibration Maintenance technicians and machine operators can now take vibration readings during routine inspections using powerful handheld analyzers. One type, for example, takes both overall velocity and enveloped acceleration readings at each point on targeted machines. The velocity vibration measurements are automatically compared with pre-programmed ISO standards, triggering an alarm when the measurements exceed the guidelines. The enveloped acceleration measurements are compared with established bearing vibration guidelines. This analyzer is extremely durable and rated for use in industrial environments. Weighing less than a half-pound, the device fits in a pocket or on a tool belt and can be easily carried on inspection rounds. 20 | LUBRICATION MANAGEMENT & TECHNOLOGY
Lubricant quality Monitoring oil samples in the field has long been standard practice, but grease analysis has usually proved difficult. The introduction of modern grease-analysis kits, however, makes quick evaluation more feasible and affordable than in the past. In a recent case, a pulp and paper mill in Brazil implemented on-site grease analysis to speed up decision-making and reduce costs. The facility already had a fully functioning lube-analysis program in place. Grease samples were collected and forwarded to an independent laboratory at a cost of almost $60 per sample. Testing was completed in about a week. But the turnaround time caused delays and affected plant operations. Looking for a solution, the mill’s lubrication manager acquired two portable grease-test kits to let in-house personnel analyze fresh grease on the spot. The kits contained three different tests of grease quality: consistency, oil bleeding and contamination. No special expertise was needed to perform the tests—and they each required only 0.5 grams of grease for sampling. The testing was able to clear some samples immediately and identify others that required lab analysis. NOVEMBER/DECEMBER 2013
MAINTENANCE LOG
This on-site analysis program helped reduce the number of samples sent out for testing by 25%, which, in turn, helped cut overall costs. It has also given the mill greater control over lubrication decision-making.
One such thermometer has dual-laser sighting to precisely define the area being measured. It senses temperatures ranging from -60 to 1000 C (Fig. 2). Users can program this instrument to emit audible alarms at specified high or low temperatures.
Motion and speed Technicians monitoring the motion of operating machines can turn to portable stroboscopes that “freeze” the movement of rotating or reciprocating machinery like fan blades, couplings, gear wheels and belt drives. Doing so allows machines to be safely inspected while they are running. The latest offerings include a new instrument that functions as a dual stroboscope and tachometer (see Fig. 1). The device has a stroboscopic flash rate of nearly 300,000 pulses per minute, enabling it to monitor most high-speed applications. Its ergonomic design allows users to set the flash rate in seconds. The versatility of this device is enhanced by a remote optical sensor that allows the tool to operate as a tachometer. In this mode, the instrument measures rotational speeds up to 300,000 rev/min with an accuracy of +.01%. Fig. 2. A non-contact infrared thermometer makes accurate measurements by sensing thermal energy radiating from machines. (Source: SKF USA Inc.)
Another heat-sensing technology, thermography, has also been improved—and become more affordable—over the last decade. Thermal cameras with imaging capabilities allow technicians to visualize machine hot spots from a safe distance. Some cameras can even operate unattended with images taken and saved at regular intervals.
Fig. 1. This versatile stroboscope monitors the motion of rotating machines and, with the help of its optical sensor, can operate as a tachometer. (Source: SKF USA Inc.)
Temperature There are a number of new-generation devices for remotely sensing heat and thermal energy. These include noncontact infrared thermometers that provide accurate measurements from a distance. They incorporate an infrared detector to sense thermal energy radiating from operating machinery. The detector produces a signal that is translated into a reading on the device’s display screen. NOVEMBER/DECEMBER 2013
Sound Air leaks in HVAC systems and other applications produce high-frequency sounds due to turbulence near the leak site—sounds that can be pinpointed by ultrasonic detectors. One such instrument has a sensor mounted on a long flexible tube, allowing access to hard-to-reach areas. It helps guide the operator to the loudest point, revealing the leak’s location. This detector is compact enough to use with one hand and requires no special training. There are also handheld instruments for measuring noise levels in industrial facilities. The instruments, usually battery-operated, pick up sound using built-in microphones and indicate the sound level in decibels. LMT Based in Ontario, Canada, Paul Michalicka is a North American Area Manager for maintenance products, SKF USA Inc. For more info, enter 01 at www.LMTfreeinfo.com www.LMTinfo.com | 21
ICML CERTIFICATION SERIES
Domain of Knowledge Element #6
Industrial Lubrication Fundamentals:
WHAT'S IN A LUBRICANT? (ADDITIVES) These packages are added to your lubricants to help them do all that you want them to do. Ken Bannister Contributing Editor
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esigning a lubricant requires the tribology chemist to start with a performance specification sheet outlining parameters and conditions the lubricant must meet and exceed in its finished commercial form. Typical design parameters include: ■ Lubricant type (gear oil, hydraulic oil, etc.) ■ Application requirements (load, speed, bearing surface
motion [sliding, rolling, combination], delivery method) ■ Lubricant quality (viscosity index [VI], lubricant life
expectancy, selling point) 22 | LUBRICATION MANAGEMENT & TECHNOLOGY
■ Operating environment (moisture, chemicals, ambient
temperatures, etc.) ■ Operating temperature range ■ Biodegradability
These typical design parameters are technically known as the “Tribological System” within which the lubricant must perform. Lubricant type, application, quality and operating temperature range are primarily used to determine an appropriate base stock that is then supplemented with a variety of lubricant additives to strengthen or modify the product’s characteristics to meet the finished design specification. Lesser-quality base stocks can be significantly modified to meet specifications with additive packages. NOVEMBER/DECEMBER 2013
ICML CERTIFICATION SERIES
Table I. Oil Additive by Function
Enhancers
New Properties
Suppressants
Anti-Foam Antioxidant Demulsifier Rust Inhibitor
Anti-Wear Detergent Dispersant Dye EP Friction Modifier
Pour Point Viscosity Improver
What additives do Additives play an important role in letting us know when the lubricant is no longer useful, as they are sacrificial in nature: Once depleted, the oil must be replaced or replenished again with the necessary additive(s). By monitoring and comparing the additive package “signature” of the virgin stock oil against a used oil sample through the use of oil analysis, we can tell when oil is degraded and ready to be changed. Oil additives serve three functions: 1) to enhance; 2) to promote new properties; and 3) to suppress undesirable base-oil properties. Different lubricant types require different formulation packages. Table I depicts which additive performs what function. Additives can be organic or inorganic compounds and, depending on their physical size, will dissolve in the oil (i.e. sub-micron) or remain as suspended solids. These solids are often visible to the naked eye when decanting new oils from one container to another. Additive-package types Although there are many additive types available to the lubricant chemist, the following 12 are used to make up the core additive package for most commercial lubricants. 1. Anti-Foam Agent. . . When a fluid is moved quickly through a pumping action, it can entrain small air bubbles in the lubricant. These air bubbles are detrimental to a lubricant as air contains oxygen that will attack the base oil (see Antioxidant). Aerated fluids can also cause pump cavitation. Also known as defoamants, or foam inhibitors, anti-foam agents are designed to increase a lubricant’s surface tension and enlarge the bubble size, allowing them to collapse more easily. 2. Antioxidant Agents. . . Oxygen is base oil’s primary enemy, especially at higher temperatures, when in combination with contaminants such as water can lead to sludge and viscosity thickening, tar, varnish and corrosive acid formation within the oil and on the bearing surfaces. Antioxidant agents, also known as oxidation inhibitors, can successfully improve oxidation NOVEMBER/DECEMBER 2013
stability by more than 10 times by deactivating catalytic metallic contaminants and by decomposing any formed reactive hydroperoxides within the oil. The most common antioxidant is Zinc dialkyldithiophophate, or ZDDP. 3. Anti-Wear Agents. . . These types of additives activate when boundary lubrication conditions occur due to metal-to-metal contact under heavy loads and slow rpm. Agents such as ZDDP or Tricresylphosphate (TCP) react chemically with the surface to form a softened ash-like lubricant film. 4. Demulsifiers. . . Known as emulsion breakers, these types of additives are used where water contamination is expected. They are designed to chemically prevent the formation of any water/oil emulsion by altering the surface tension of the oil, allowing the water to separate easily and be drained off. 5. Detergents. . . Detergent-type additives are used where combustion takes place. They perform as a chemical cleaner to keep combustion surfaces free from harmful deposits and to neutralize any combustion acids. Developed specifically for crankcase and compressor oils, detergent additives are made up from over-base (alkaline) organic metallic soaps such as barium, calcium and magnesium. 6. Dispersants. . . Dispersant-type additives are also used in crankcase and compressor oils, often in conjunction with detergents. They chemically disperse and attach themselves to and suspend combustion and contaminant particles like dirt, soot, glycol and depleted additives, to extract them by the oil-filtration system. 7. Dyes. . . Used in transmission fluids and greases, dye-type additives are used to help identify products and differentiate them from other lubricants. www.LMTinfo.com | 23
ICML CERTIFICATION SERIES
Table II. Typical Oil-Type Additive Packages* (courtesy of EngTech Industries, Inc.)
Additive Anti-Foam Antioxidant Anti-Wear Demulsifier Detergent Dispersant Dye Extreme Pressure Friction Modifier Pour Point Rust Inhibitor Viscosity Improver
Bearing Oil
Compressor Oil
Crankcase Oil
Gear Oil
Hydraulic Oil
Transmission Oil
Turbine Oil
X X X X
X X X X X X
X X X
X X X X
X X X X
X X X
X X
X
X
X
X X
X X X X X
X X X
X
X X
X X X
X X X X X X X X
X
* Note: This table is provided for guideline purposes only! Always consult your lubricant supplier to determine the actual additive in your chosen lubricant. 8. EP (Extreme Pressure) Agents. . . Sulphur, phopherous and chlorine additives are used to cause a chemical reaction that eutectically softens wear surfaces into a sacrificial metal soap that breaks away from the surface under high-load, extreme pressure conditions (thus reducing the frictional impact of metal-to-metal contact). Solids additives such as Molybdenum Disulphide (MoS2), Polytetraflouroethylene (PTFE) and graphite can be added to a lubricant to act as “sliding agents” and allow contact surfaces to move over one another with minimized contact under severe loading conditions with less surface degradation than the chemical additives. 9. Friction Modifiers. . . Long-chain polar additives that have an affinity for metal surfaces are added to crankcase and transmission oils to reduce the surface friction of lubricated parts in an effort to increase fuel economy. 10. Pour-Point Suppressants. . . Additives known as pour-point suppressants are used to prevent the formation of wax crystals in paraffinic mineral oils at low temperatures. This, in turn, allows the oil to pour at lower temperatures. 11. Rust Inhibitors . . Also known as corrosion inhibitors, this type of additive forms a protective shield against water and corrosive acids to 24 | LUBRICATION MANAGEMENT & TECHNOLOGY
stop the formation of corrosion and rust on ferrous, copper, tin and lead-based metals. 12. Viscosity Improvers. . . Viscosity improvers employ long-string polymers that expand as an oil’s temperature increases. This process serves to “thicken” the oil, or increase its viscosity. These additives are used to increase an oil’s serviceability over a wider temperature range in multi-grade form and to bolster lower-quality base oils that have lower viscosity index (VI) ratings. Table II details which additives are used in various oil types. Note: This table is provided for guideline purposes only! Always consult your lubricant supplier to determine which additives are actually used in the lubricant you have chosen to use. LMT Ken Bannister is a certified Maintenance and Lubrication Management Consultant for ENGTECH Industries Inc. Ken is the author of the “Machinery’s Handbook” Lubrication chapters, along with the best selling “Lubrication for Industry” textbook recognized as part of the ICML and ISO’s Domain of Knowledge. Ken also teaches numerous formal certification preparatory training courses for the ICML MLT/MLA certification and the ISO LCAT certifications. For more training information, Ken can reached at 519-469-9173, or by email at kbannister@engtechindustries.com. For more info, enter 02 at www.LMTfreeinfo.com
NOVEMBER/DECEMBER 2013
HOLD THESE DATES
March 18-21, 2014 Hyatt Regency O’Hare, Rosemont, IL
Go to www.MARTSConference.com for further details.
You don’t want to miss MARTS 2014!
Calling All Innovators! Don’t just leave it to ‘the other guy’ to show off his/her innovation. You Could Be Our Next Grand-Prize Winner! Enter Now.
Categories: Innovative Devices, Gizmos & Gadgets Innovative Processes & Procedures Innovative Use of Third-Party Resources Honoring the essence of innovation in maintenance and reliability, entries will be judged on the following elements:
Practicality. . . Can it be adopted across industry? Can it be easily replicated, manufactured or sold?
Simplicity. . . Is the ROI less than 3 months? Is the idea intuitive and easily understood?
Presented By
Applied Technology Publications
Deadline for Entries is Midnight, December 31, 2013. Our Grand-Prize Winner & Runners-Up Will Be Announced Early 2014.
Details & Entry Forms Available At www.reliabilityinnovator.com
Impact. . . Reliability Ergonomics (operator, maintainer) Safety Energy reduction Environmental Maintainability (reduces maintenance)
Sponsored By The Innovators At
PROBLEM SOLVERS
Durable, Easy-To-Install Pail Lid
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Lubrication System For Stamped, Drawn Material
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he PIG 5-Gallon Latching Pail Lid from New Pig is designed to fit both steel and poly 5-gallon pails. The durable, powdercoated steel lid opens easily and closes with a single latching hasp. A reinforced hinge, latching mechanism and nitrile gasket create a tight seal around the lid, helping to keep pail contents pure and decrease vapor emissions. In addition, a fast-latch ring makes installation easy.
ndustrial Innovations’ Spra-Rite Alpha Lubricating System provides a solution for controlling lubricant application to stamped, drawn material or the tooling process, and is suited for smaller pressrooms and vanishing oil applications. The turnkey solution includes a controller, injector manifolds, stainless steel tank, nozzles and tubing. The process control module offers numeric programming for up to six injector valves as well as a “purge or test” feature. Each system comes with a five-gallon stainless steel reservoir with a liquid regulator, air relief valve and strainer.
New Pig Corp. Tipton, PA
Industrial Innovations, Inc. Wyoming, MI
For more info, enter 30 at www.LMTfreeinfo.com
For more info, enter 31 at www.LMTfreeinfo.com
Dramatically extends equipment life!
HOLD THESE DATES
March 18-21, 2014 Hyatt Regency O’Hare, Rosemont, IL
Krytox® Fluorinated Greases and Oils are: Chemically Inert. Insoluble in common solvents. Thermally stable. Temperature range (-103˚F to 800˚F). Nonflammable. Nontoxic. Oxygen Compatible – safe for oxygen service. Low Vapor Pressure. Low Outgassing. No Migration – no silicones or hydrocarbons. Krytox® offers Extreme Pressure, Anticorrosion and Anti-wear properties. Mil-spec, Aerospace and Food Grades (H-1 and H-2) available! Useful in Vacuum Systems.
Go to www.MARTSConference.com for further details.
For technical information, call: 203.743.4447 / 800.992.2424 (8 AM – 4 PM ET)
Authorized Dupont™Krytox® Distributor Since 1991 Over 100 grades in stock! No minimum quantities.
m
s
m
s
m
s
You don’t want to miss MARTS 2014!
California - Illinois - Connecticut - Canada e-mail: support@miller-stephenson.com www.miller-stephenson.com m
s
For more info, enter 66 at www.MT-freeinfo.com
NOVEMBER/DECEMBER 2013
www.LMTinfo.com | 27
PROBLEM SOLVERS
Grease For Lift-Truck Wheel Bearings
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ayLube’s highperformance nano-ceramic grease is suited for use on lift truck wheel bearings for frozen food processing and handling facilities. According to the company, the grease maintains its original viscosity and adhesion even after daily pressure washing. It operates in temperature ranges from -40 to 800 F, and the nano-ceramic particles remain intact to 2500 F. The NSF-H1 Food Grade Certified grease has high load-bearing properties, a low dielectric constant, does not contain metal or silicone and is resistant to steam, acids and most chemical products. Dayton Progress Corp. A MISUMI Group Co. Dayton, OH For more info, enter 32 at www.LMTfreeinfo.com
Single-Point Automatic Lubricator
P
ower Lube Industrial’s Greasomatic® is a programmable, single-use, single-point automatic lubricator built to perform in a variety of applications. The lubricator offers capacity for seven time settings and a blocked line indicator, programmable up to 12 months. It also features a sophisticated dial without the inconvenience of separate parts. A translucent window in the body allows monitoring of the lubricant level, eliminating potential waste. Greasomatic is corrosion-proof and suitable for EX environments. PLI, LLC Racine, WI For more info, enter 33 at www.LMTfreeinfo.com
Easy Locking Of Sprockets, Gears, Pulleys, Timing Cams And Rollers
A
ccording to U.S. Tsubaki, its extensive POWER-LOCK portfolio offers a simple and cost-effective solution to problems associated with keyed or machined drive shafts. Incorporating POWER-LOCK technology into existing and new designs provides increased shaft strength while reducing machining and maintenance costs. The company notes that POWER-LOCK eliminates backlash damage to keyways and specialty machined bores in applications that experience reversing loads or high torque. In addition, machining expenses associated with keyways, spline bores, steps and snap ring grooves can be removed from the equation. The easy-to-install device is suitable for locking large or small sprockets, gears, pulleys, timing cams and rollers.
U.S. Tsubaki Wheeling, IL
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28 | LUBRICATION MANAGEMENT & TECHNOLOGY
NOVEMBER/DECEMBER 2013
PROBLEM SOLVERS
Versatile Ultrasonic Data Collector
T
Efficient, Easy-To-Maintain Compressor
he SDT270DU ultrasound data collector from SDT Ultrasound Solutions finds leaks, inspects electrical systems, predicts lubrication cycles for rolling element bearings, analyzes gearboxes and other slow-speed rotating assets, tests steam traps, assesses valve performance, reveals faults in reciprocating compressors, and more. Onboard memory stores data to a userdefined survey, and all stored measurements can be viewed on the LCD and transferred to UAS for trending, alarming, reporting and action.
ngersoll Rand says its new Centac C800 centrifugal air compressor is built on the latest-generation centrifugal-compressor platform. An extension of the company’s Centac C1000 product line, the C800 is certified as ISO 8573-1Class 0. Designed to minimize downtime and lower total cost of ownership, it features tapered polygon attachments to create a precision fit and evenly distribute torque, as well as a simplified oil-piping system with an integrated oil filter. According to the company, C800’s optimized components and systems reduce energy use by up to 6% at full load.
SDT North America Cobourg, ON, Canada
Ingersoll Rand Davidson, NC
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INFORMATION HIGHWAY
U.S. Tsubaki is a leading manufacturer and supplier of Roller Chains, Engineering Class Chains, Power Transmission Products and KabelSchlepp Cable & Hose Carrier Systems. The Tsubaki name is synonymous with excellence in quality, dependability and customer service and support. An intense focus on research and development, along with continuously modernized production facilities and highly trained engineers allows Tsubaki to provide you with the right solutions for all of your application needs. For more info, enter 68 at www.LMTfreeinfo.com www.kabelschlepp.com
Air Sentry® is a leading developer of contamination control products that keep particulate matter and excess moisture from the headspace inside gearboxes, drums, reservoirs, oil tanks, etc. that hold oils, greases, hydraulic fluids, and fuels. Air Sentry breathers and adapters ensure longer fluid life, better lubrication and lower maintenance costs. For more info, enter 69 at www.LMTfreeinfo.com www.airsentry.com
NOVEMBER/DECEMBER 2013
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Index ADVERTISER
NOVEMBER/DECEMBER 2013 Volume 14, No. 6
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
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WEBSITE
CIRCLE #
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Air Sentry ................................................ www.airsentry.com .............................. 260,69,71 .... 14,29,IBC Des-Case Corporation ........................... www.descase.com................................. 65,265 ................. 19,27 Meltric ..................................................... www.meltric.com ................................. 70.............................. 29 Miller-Stephenson Chemical Co. .......... www.miller-stephenson.com .............. 66.............................. 27 NSK Corporation ................................... www.nskamericas.com ........................ 64,266 ................. 11,19 OILSAFE by Fluid Defense .................... www.oilsafe.com/improve ................... 61............................IFC OILSAFE by Fluid Defense .................... www.oilsafe.com .................................. 261............................ 15 Royal Purple ............................................ www.royalpurpleindustrial.com ......... 262 ,72 ...............16,BC Scalewatcher............................................ www.scalewatcher.com ........................ 63,263 ................... 7,17
1300 South Grove Avenue, Suite 105 Barrington, IL 60010 PH 847-382-8100 FX 847-304-8603
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SALES STAFF CT, KY, ME, MA, NH, NY, OH, RI, TN, VT, ON, QC 18 Oxford Lane Middletown, NJ 07748 Office 732-275-1167; Cell 908-415-3719 RUSSELL BRODY rbrody@atpnetwork.com
U.S. Tsubaki Power Transmission, LLC ... www.longlifelambda.com.................... 62................................ 5 U.S. Tsubaki Power Transmission, LLC ... www.ustsubaki.com/whats-new.html .. 68.............................. 29 U.S. Tsubaki Power Transmission, LLC ... www.longlifelambda.com.................... 264............................ 18
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LUBRICATION MANAGEMENT AND TECHNOLOGY
NOVEMBER/DECEMBER 2013
LASTS LONGER.
DITTO.
Reducing maintenance costs and unplanned downtime for your operation is essential to maintaining your competitive edge. High quality desiccant breathers greatly reduce particulate and moisture contamination in vital lubricating fluids. Clean, dry lubricants work better and last longer, which increases the life expectancy of your capital intensive equipment. Air Sentry® has been setting the bar for longer breather life since we started. Our GUARDIAN® breathers incorporate technology that significantly extends desiccant life. To reduce costs, maintenance intervals, and increase the lifespan of your fluids and critical equipment, contact us to see what GUARDIAN can do for you. It’ll have you breathing a whole lot easier.
More desiccant for the money – more desiccant equals longer life
Modular cartridge design greatly reduces replacement costs
Check valve technology isolates desiccant from ambient conditions
airsentry.com 1-855-242-2792 The gold standard in contamination control A DIVISION OF WHITMORE
930 Whitmore Drive, Rockwall, TX 75087 An ISO 9001 and ISO 14001 registered company
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