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JANUARY/FEBRUARY 2010 • VOL 11, NO. 1 • WWW.LMTinfo.COM
Contents
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
FEATURES CONDITION MONITORING 10
Oil-Analysis Data Evaluation © ALEXEY STIOP—FOTOLIA.COM
Until you understand what you’re looking at and looking for, you’re no better off than before you implemented your oil-analysis program. Ray Thibault, CLS, IMA I & II, Contributing Editor
UTILITIES MANAGER 16 17
■ Big Money Talks ■ Saving Energy With Sealing Systems
THE FUNDAMENTALS
DEPARTMENTS
21
5 6 8 24 34 35 37 38
How To Begin Measuring Maintenance Effectiveness: Part IV Lucky you! There is one KPI that comes close to taking into account almost all variables in a production process. What is it? Raymond L. Atkins, Contributing Editor
LUBE SHOWCASE 31
Food Grade Lubricants What’s it take to move products around and through our food chain safely and efficiently? These leading suppliers have a number of answers. They offer effective solutions for a wide range of food grade needs.
Publisher’s Note My Take From Our Perspective The Green Edge Solution Spotlight Problem Solvers Information Highway Supplier Index
Registration Is Now Open!
APRIL 27-30, 2010 MAINTENANCE M AINTENANCE andd RRELIABILITY ELIABILITY TTECHNOLOGY ECHNOLOGY SSUMMIT UMMIT Case History Presentations Trend-Setting Seminars Practical How-To Workshops Latest Products & Services
JANUARY/FEBRUARY 2010
PLUS! An opportunity to take exams for CMRP and CLS Certification
Hyatt Regency O’Hare • Rosemont (Chicago), IL
Don’t Miss The Capacity Assurance Conference!
www.MARTSconference.com MARTS f www.LMTinfo.com | 3
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
January/February 2010 • Volume 11, No. 1 ARTHUR L. RICE President/CEO arice@atpnetwork.com
BILL KIESEL Executive Vice President/Publisher bkiesel@atpnetwork.com
Making the Difference with Innovative Excellence
JANE ALEXANDER Editor-In-Chief jalexander@atpnetwork.com
RICK CARTER Executive Editor rcarter@atpnetwork.com
High Purity Polyol Esters (POEs) • Extend Machinery Life
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
• Lower Energy Costs
Editorial/Production Assistant gpietras@atpnetwork.com
ELLEN SANDKAM
• Reduce Friction
Direct Mail esandkam@atplists.com
EDWARD KANE
• Severe Temperature and H1 Available
Reprint Manager 800-382-0808, ext. 131 ekane@fostereprints.com
Editorial Office
www.inolex.com lubeinfo@inolex.com
1.800.521.9891 Call for your local distributor For more info, enter 62 at www.LMTfreeinfo.com
Achieving Efficiencies Through Practices & Products Apply for a free, one-year subscription at
www.LMTinfo.com 4|
LUBRICATION MANAGEMENT & TECHNOLOGY
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 2009. 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.
JANUARY/FEBRUARY 2010
PUBLISHER’S NOTE Bill Kiesel, Publisher
Sailing Into 2010 & Beyond
I
recently spent time putting my old wooden sailboat away after a season on Lake Michigan. As I worked, I began to realize how similar sailing is to magazine publishing. Exhilarating, yet challenging. In sailing, preparation is crucial before you set out on any trip. Those of us with a passion for this pastime know that once you’re away from shore, things can change quickly and dramatically— from clear skies and smooth waters to hurricane-like conditions in a matter of minutes. Adequate preparation involves maintaining the right attitude and mindset to plan for whatever adversities might arise. Again, it’s much like publishing. The last few years have been tremendously challenging for most businesses; B2B magazines have been hit especially hard. Successfully navigating the turbulent business climate has required having a sailor-like mentality and understanding that our chosen course, just like winds and waves, may change, regardless of what we want. In talking with executives across numerous industries, I hear plenty of nostalgia for what was—and for the old ways of doing business. Technologies have changed, and so have spending patterns. Most of these executives, however, continue to long for a return to the “simpler” business era of the past. It’s not going to happen. I was born into this business. My father also was an executive in B2B publishing—a very successful one! Tough challenges and rapidly changing conditions have always been part of our lives. My dad’s consistent response? “Attitude is EVERYTHING. Stop complaining and do SOMETHING.” At Lubrication Management & Technology, we’re not complaining. We are constantly doing SOMETHING. It goes without saying that our publications and Websites have been greatly enhanced. Print and online improvements are just part of the story, though. We’re doing new things in other areas, too. For example, check out several things on tap for MARTS 2010 (www.MARTSconference.com):
JANUARY/FEBRUARY 2010
■ Actor, author and manufacturing activist John Ratzenberger, one of this year’s featured keynoters, will speak about his “Nuts, Bolts & Thingamajigs” foundation that brings students and manufacturing together. ■ Futurist and financial professional Bob Chernow will offer predictions for manufacturing, technology, the economy and other key issues. ■ A gala “Reliability Gives Voice to Autism” event will kick off MARTS. This collaboration with the Autism Society will feature dinner and live entertainment, while raising awareness and funds for the cause. MARTS, though, is just one of many exciting information-packed learning venues on the horizon. Stay tuned for updates on other conferences that we co-sponsor/co-produce, including: ■ Energy Summit 2010, promoting solutions for energy efficiency and sustainability across industry (www.energysummitonline.com) ■ IMEC 2010, an International Maintenance Excellence Conference (www.imec.ca) The good news about the current business climate is that it has fueled an explosion of creativity in Media. In our case, we’re merging the best of what we have been doing over the years, while transitioning and embracing the countless opportunities ahead of us. Like my old wood boat, the design and structure are solid and fast, but new technologies make it safer and more fun. Some fight the future and long for the past. Not us! We’re embracing the future and building on past successes as we sail into 2010 and beyond. LMT
www.LMTinfo.com | 5
MY TAKE
Jane Alexander, Editor-In-Chief
Parachute Packing Þrst wrote about this topic in my January 2010 column for LMT’s sister publication, Maintenance Technology (MT). Please indulge me as I go over it again here. I think it fits. As I mentioned in MT, I had spent much of New Year’s Day blubbering over the receipt of one of those “Who’s Packing Your Parachute?” e-mails. The message focuses on what is said to be an actual event in the life of Charles Plumb, a U.S. Navy pilot shot down over Vietnam. He ejected from his plane, parachuted into enemy hands and spent six years in a Communist Vietnamese prison. Having survived the ordeal, Plumb returned home and began lecturing on lessons learned from his experience. Sometime later, as the story goes, he was approached in a restaurant by another diner, who called Plumb by name and said that he knew about his days flying jets from the Kitty Hawk. As it turned out, this guy— a person heretofore unknown to Plumb and someone he might never have come in contact with—had been the individual who packed the parachute that saved the former pilot’s life years before. While I can’t vouch for the veracity of all the details, the story does make great food for thought. In the end, the recipient (that’s YOU) is encouraged to reflect on and thank the people in your life who have worked on packing your “parachute” by sending this inspirational chain-letter type of message on to as many of them as you can. Receiving this e-mail from someone you know can really touch your heart. This time around, though, the experience was especially moving for me. The sender was one of my little brothers— the toughest, sternest, hardest-driving one. Brilliant and decisive, with arguably the best head for business in our entrepreneurial family, he’s always been the sibling that the rest of us (both older and younger) have looked up to. I never could have envisioned this high-flying wing-walker EVER needing a parachute, much less thinking of me as someone who had done any folding and tucking on it. I thank him for that and lots of other things, too, including reminding me that we shouldn’t wait to show our appreciation for the countless, often unknown, parachute packers in our lives, personal and otherwise. That brings me to my point. On behalf of Lubrication Management & Technology, I thank all of you—readers, contributors, advertisers, suppliers and other friends of this magazine—for helping pack OUR parachute. Whoever you are, wherever you are, please know that we are well aware that your loyalty and strong, ongoing support are what give us the ability to get out there and really “fly” in this space! We know that the last couple of down years have been extremely rough on you. We also know that a full economic recovery is not necessarily going to be a done deal this year. No matter. At LMT, we’re committed to serving your critical information needs—and those of future generations of lubrication management professionals and suppliers to the industry—for many years to come. In short, we look forward to helping pack YOUR parachute(s) for a long, long time! Best Wishes for a Happy & Prosperous 2010! LMT jalexander@atpnetwork.com
I
6 | LUBRICATION MANAGEMENT & TECHNOLOGY
JANUARY/FEBRUARY 2010
The future of manufacturing is in the hands of today’s young people. Nuts, Bolts & Thingamajigs, the foundation of the Fabricators & Manufacturers Association International is focused on securing the future of manufacturing, innovation and invention in North America. This happens when young people are introduced to the joy and pride of “tinkering”. When a young person learns they can make something useful and practical with their own hands, they’ve taken the first step to a career. Hundreds of students learn this each year at NBT summer manufacturing camps. When students are ready for career training, there are scholarships from NBT for those who attend technical schools, community colleges and universities to obtain specialized training needed for the highly skilled manufacturing work of the future.
Insure the future of your industry with a gift. Your corporate pledge, personal donation or legacy gift will launch careers for skilled mechanics, electricians, machinists, engineers, laser operators, and so much more.
Donate today at www.nutsandboltsfoundation.org or call 815-381-1338
Don’t Miss Out!
Meet Nuts, Bolts & Thingamajigs founder and spokesperson, actor John Ratzenberger at the MARTS conference. Attend his keynote at 8:00 a.m. April 28, followed by a book signing. Make a $20 donation to NBT and obtain an autographed copy of his book, We’ve Got it Made in America. Visit www.martsconference.com for more information.
For more info, enter 63 at www.LMTfreeinfo.com
FROM OUR PERSPECTIVE
Ken Bannister, Contributing Editor
The Lubrication Challenge!
O
ver the holidays, I had chance to visit with some old friends. They were thrilled to inform me of their teenage son’s recent work promotion to the position of plant lubrication technician, in charge of his facility’s lubrication program. Intrigued that a worldleading robotic manufacturing organization would trust its entire program to a high-schoolprepared, teenaged veteran of its organization— a three-month veteran, that is—I couldn’t wait to hear how the company had prepared him for this important position. When I congratulated the young man on his new job, I was saddened, but not surprised to find out that he and his employer believed that his organizational skills are what gave him the ability to step into his new role. The fact is that he had “shadowed” the position for three days to see if he thought himself suitable, after which he felt confident he knew enough to organize the lubrication program better than his predecessor. In the shadowing process, he had picked up some real pearls of wisdom from the previous “lubricator,” who successfully instilled in him that “oil is oil, and grease is grease; you just got to get plenty in there!” Ironically, when I offered him a seat in a lubrication fundamentals course to help him gain an understanding of lubricants and their application, he politely refused, stating that after several weeks on the job, he already knew enough about lubrication. Besides, he thought he would likely be moving on to another position once his reorganization of the lubrication program was completed! I am dismayed at the pervasiveness of this one-dimensional view of the lubrication management process. Countless management, engineering and maintenance professionals— and non-professionals—share it. It’s one of the greatest paradoxes in today’s maintenance business: Lubrication management continues to be a victim of misunderstanding and ignorance,
8|
LUBRICATION MANAGEMENT & TECHNOLOGY
wherein the act of lubrication is considered an elementary task requiring only the most basic knowledge, simplistic thinking and rudimentary skill sets. With virtually no formal lubrication training offered in yesterday’s or today’s apprenticeship and engineering programs, few individuals entering the lubrication management arena have in-depth knowledge and problem-solving experience in the field to fall back on. Many, though, are rich in opinion based on myths and old wives’ tales perpetuated on a daily basis—lubrication myths and tales that too often go unchallenged. Fortunately, this situation need not continue! The fact that you are reading this magazine today tells me you are a perfect advocate to help raise the profile of lubrication management in your company and your profession. Thus, I challenge all Lubrication Management & Technology readers to assist me in making 2010 the year in which we change the perception of lubrication. Let’s put in place lubrication management programs that deliver increased equipment reliability, increased equipment availability, increased environmental compliance, reduced maintenance and reduced energy consumption—all for minimal corporate cost. Our publication will do its part by continuing to bring to you innovative articles and valueadded technology news to help you inform, sell, implement and monitor your lubrication management initiatives. Good Luck! LMT kbannister@engtechindustries.com EDITOR’S NOTE: Meet and learn from Ken in person at MARTS 2010, where he again will be presenting his highly acclaimed all-day workshop “Lubrication for Industrial Facilities,” on Tuesday, April 27. To register for this invaluable professional-development opportunity, visit www.MARTSconference.com
JANUARY/FEBRUARY 2010
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CONDITION C ONDITION M MONITORING ONITORING
Oil-Analysis Data Evaluation © ALEXY STIOP—FOTOLIA.COM
Until you understand what you’re looking at and looking for, you’re no better off than before you implemented your oil-analysis program. Ray Thibault, CLS, OMA I & II Contributing Editor
M
y last article discussed the importance of implementing an oil-analysis program and some strategies for building one that’s top-notch (“Developing An Effective Oil-Analysis Program,” pgs. 12-16, LMT, Nov./Dec. 2009). Previous articles had covered proper sampling techniques and the relevant tests used in oil analysis. This article focuses on understanding and applying the data generated by an oil-analysis report in order to identify potential problems and be able to take corrective actions before a serious situation develops. Emphasis here will be on industrial applications only, NOT on mobile equipment where oil analysis is also used extensively. Incorporating actual data from a plant, key factors (by equipment type) that need to be considered when evaluating an oil-analysis report will be noted.
10 | LUBRICATION MANAGEMENT & TECHNOLOGY
JANUARY/FEBRUARY 2010
CONDITION MONITORING
Sample Information Site
Equipment Information Your Plant
Area
Area 1
Unit
Unit 1
Equip
Main Air Blower
Descrip
1 MAB Compressor Lube Oil
Sample Pt Key
555-0999
Centrifugal Fan/Blower
Equip Type
y
Cooled
y
Filtered Filter Size
15u
Sump Cap
850 gals Pressurized
Lub Sys
Fld in Use
Your Brand ISOVG 32
Fld Grade
ISOVG 32
Bear Types
05/04/2004
Gear Types
Last Fld Chng
Cooling Tower Water
Cooling Src
OB & IB Sleeve Bearings
Lubed Comp
Sleeve
Fig. 1. Information on a collected sample that the user supplies to the oil analysis lab
Oil analysis can be likened to a blood test during an annual physical. A blood test provides important information on a person’s health; oil analysis supplies vital information on the health of your machinery. None of this information, however, is of any value unless you are able to understand and apply the data contained in the reports generated by these analyses. The following details will help you do so. Report format Although oil-analysis laboratories may use a variety of report styles, there are many similarities in how the data is reported. Oil analysis looks at two primary oil conditions that could cause equipment problems. 1. Chemistry changes can be caused by the oxidation or thermal degradation of the oil. This is usually detected by measuring the acid number and the oil viscosity. Wear Metals
2. Contamination, primarily from particle or water ingression, can dramatically affect equipment life. Addition of the wrong oil is also a form of contamination. Primary tests to measure contamination are particle counts for solid components and Karl Fischer for water. Atomic emission spectroscopy (AES) detects metallic contaminants such as dirt ingression by measuring the silicon level and changes in metallic additive levels, which may indicate lube mixing. The report is broken down into two major components: â– Sample/equipment information is at the top of the report. It includes all pertinent information on the sample and the equipment type. This information is on every report and is developed from details the user provides to the laboratory when filling out the equipment form. Furnishing complete information will aid in identifying problems and making meaningful recommendations.
Additive Metals
Iron Coppe Tin Lead Chrom Nicke Alumi Titan 18 0 0 0 0 0 0 0 12 0 0 0 0 0 0 0 40 0 0 0 0 0 0 0 20 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 10 10 10 10 5 5 10 5 20 20 20 20 10 10 20 10 0 0 0 0 0 0 0 0
Silve 0 0 0 0 0 0 5 10 0
Calci Magne Zinc 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Phosp 0 0 0 0 0 0 0 0 0
Contaminant Metals
Bariu Molyb Antim 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Silic 15 8 4 0 0 0 10 20 0
Sodiu 82 36 18 4 1 1 40 40 0
Boron 0 0 0 0 0 0 10 20 0
Potas 44 24 11 6 2 0 15 30 0
Vanad 0 0 0 0 0 0 10 20 0
Physical and Other Tests TAN 0.24 0.12 0.1 0.09 0.07 0.06 0.15 0.2 0.05
Flash 390 390 395 395 395 395 360 340 395
ISO Code 21/18/16 17/16/14 17/16/13 17/15/11 16/13/08 20/18/16 21/19/17 13/11/07
KF 1220 226 102 93 85 66 100 200 43
Color 2 2 2 2 2 2 2 4 0
4u
6u
14u
21u
38u
68u
16774 1042 998.4 950.7 480
2109.3 462.3 455.1 293 77.3
448.2 162.7 66.1 18.6 2.3
320.1 58.6 43.2 11 1.3
105.2 44.2 22 8.2 0.3
22 18.3 10.6 6.6 0.2
41.6
13.5
1.3
0.5
0
0
Fig. 2. A sample oil analysis report JANUARY/FEBRUARY 2010
www.LMTinfo.com | 11
CONDITION MONITORING
■ Test results are presented in the body of the report. Recommendations, when needed, are either at the top after the equipment section or at the bottom of the report. ◆ Most reports list the data horizontally by date, with the latest on either the top or bottom. (Some labs may list their data vertically, with the latest on the left.) ◆ Emission spectroscopy (usually located right after the sample/equipment section) is separated into three groups: wear metals, additives and contaminants. It’s a crucial part of any oil-analysis report measuring metallic elements in ppm (parts per million), but only particles <10 micron are detected. Thus, additional techniques are needed to measure large wear particles. ■ Physical tests for oil condition and contamination are usually near the bottom of the report. These include tests for viscosity, water, acid number, FTIR (Fourier Transform Infrared), particle counts and ferrous density. Analytical ferrography is on a separate page. ■ The sample report in Fig. 2 also lists the new oil reference sample to compare with the used oil. Many labs don’t report this data, which gives good insight on the condition of used oil. New oil reference samples should be updated yearly. ■ Oil analysis reports include a severity rating. Most companies have a two tier code: abnormal or caution and critical or warning. One laboratory has a four tier severity code from 1-4. The data in the report is color coded to reflect the severity. Most companies use red for critical.
Report evaluation: Information in Table I comes from an actual oil-analysis report. Only pertinent data from the report is presented. Table I. Actual Hydraulic Equipment Oil Analysis Findings
Emission Spectroscopy, ppm Date Sampled Iron Copper Chromium Zinc
Phosphorous Silicon
2/25/08
20
10
1
472
235
23
1/20/08
3
2
0
480
230
4
12/20/07
0
0
0
482
236
0
Physical/Other Tests Date Sampled
Viscosity
Acid #
KF Water, ppm
ISO PC
2/25/08
32.4
0.66
201
23/21/19
1/20/08
31.8
0.41
155
18/15/13
12/20/07
31.8
0.42
59
16/14/12
This report indicates sudden high iron and copper wear for a hydraulic system. The copper could be coming from the pump and the iron/chromium indicates cylinder rod wear. (The particle count increased as a result of abrasive particles being introduced into the system; these particles caused the wear.) Further investigation with analytical ferrography was conducted to identify the wear mode and types of particles present. The results showed the presence of the following: ■ Excessive siliceous, iron oxide and nonmetallic debris
■ The report in Fig. 2 includes the lab’s watch and warning limits. (Most laboratories don’t include this information.) Problem diagnosis As noted here, the following factors, per specific equipment type, reflect how oil-analysis data can be used relative to problem identification. Hydraulic Equipment... ■ Cleanliness is a key component in smooth operation. Thus, particle counts should be closely monitored. ■ Pump wear is not a common problem and is usually exhibited through increased copper levels resulting from wear of slipper shoes, swash plate and pressure plates.
■ Cutting wear particles, indicating severe abrasion wear ■ Excessive amounts of large fibrous masses consisting of cellulous and synthetic glass fibers. Report conclusions: The sudden increase in particles was linked to the sudden increase in wear. Analytical ferrography concluded that the particles came from a sudden filter rupture releasing a large number of abrasive particles into the system. (This was confirmed when the system was checked and the filter rupture was found. Whenever there is a large increase in particle counts, the filter integrity should be checked.) Steam/Gas Turbine Equipment...
■ Aluminum occurs in gear pumps from housing wear. ■ Iron/chrome indicate the presence of cylinder rod wear, usually from abrasive particles. 12 | LUBRICATION MANAGEMENT & TECHNOLOGY
Wear metals are not common and are flagged at very low levels. Many systems have large fluid reservoirs, and even a small amount of metallic wear can indicate a serious problem. JANUARY/FEBRUARY 2010
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CONDITION MONITORING
Don’t depend entirely on your oil-analysis lab for recommendations. You know your equipment and its history better than a lab does. ■ Turbine oils normally contain no metallic additives. Any presence of metallic additives usually indicates lube mixing. For example, if zinc and phosphorous are found in turbine oil it indicates the addition of hydraulic oil. Some turbine oils may contain phosphorous as an antiwear package. Be sure to run a new oil reference on your oil to see what additives are present. ■ Turbine oils are in systems for extended periods (especially steam-turbine oils). Other non-routine tests, such as RPVOT (Rotating Pressure Vessel Oxidation Test), water separability, etc. are conducted periodically to determine their condition. ■ A major problem with steam-turbine oils is water incursion through a steam leak. Water levels should be closely watched in turbine oils—and kept below 200 ppm. ■ Varnishing in gas turbines has become a major issue and many oil-analysis laboratories have developed extensive testing packages to measure the varnish potential of the oil. Discussion of these tests is beyond the scope of this article. Report evaluation: Table II. Actual Steam/Gas Turbine Equipment Oil Analysis Findings
Emission Spectroscopy, ppm Date sampled
Iron
Copper
Tin
Silicon
5/13/09
12
7
38
10
4/12/09
2
0
4
4
3/10/09
2
0
0
0
Physical Tests/Other Tests Date sampled
Viscosity, cSt @40C
Acid #
KF Water, ppm
5/13/09
36.6
0.26
1220
4/12/09
35.0
0.12
99
3/10/09
31.4
0.06
93
■ High level of water ingression at 1220 ppm Additional tests performed with the use of analytical ferrography indicated the following results: ■ Large number of red oxides signifying rust through water incursion ■ Large number of siliceous particles ■ High alloy steel particles indicating shaft wear ■ A few large Babbitt particles and a large number of smaller ones Report conclusions: A serious condition existed due to higher-than-normal wear caused by steam incursion into the bearing housing. The introduction of water and particles resulted in Babbitted bearing wear and corrosion. Find source of steam incursion and repair. Consider changing oil because the high acid number along with viscosity increase signifies oil is becoming highly oxidized. If oil is not changed, remove water through vacuum dehydration. (In this case, the oil was changed and the steam leakage problem resolved. No further problems were experienced.) Stationary Enclosed Gearboxes... ■ High iron wear—usually around 100 ppm—is common in gearboxes and varies by type and manufacturer. Oil-analysis labs are able to establish more accurate condemning limits if they are provided with complete information, such as type, OEM, model number, sump capacity and filtration, if any, on the gearbox being analyzed. ■ DR (Direct Reading Ferrograph) and PQ (Particle Quantifier) tests are typically used to measure ferrous density and should be considered routine for unfiltered gearboxes.
The report reflected in Table II notes several serious problems: ■ High iron wear
■ High copper levels are common for worm gears because the yellow metal ring gears are sacrificial.
■ High tin wear along with copper wear, indicating the wiping of a Babbitted bearing
■ Analytical ferrography is a valuable test to use for the prevention of major gear failures.
■ Viscosity increase of 15% over new oil reference
■ Typical EP gear oils have 300-350-ppm of phosphorous.
14 | LUBRICATION MANAGEMENT & TECHNOLOGY
JANUARY/FEBRUARY 2010
CONDITION MONITORING
Report evaluation: Table III. Actual Enclosed Stationary Gearbox Oil Analysis Findings
Emission Spectroscopy, ppm Date sampled
Iron
Copper
Nickel
Phosphorus
12/01/06
150
33
5
111
11/05/06
39
16
1
109
10/05/06
22
11
1
116
Physical Tests/Other Tests Date sampled
Viscosity, cSt @40C
Acid #
FDRS
FDRL
KF Water,ppm
12/01/06
226.5
0.49
88.8
142.3
129
11/05/06
219.8
0.40
22.4
66.8
138
10/05/06
221.4
0.43
16.9
38.4
140
This report indicates the onset of severe wear as evidenced by the large jump in FDRL (which measures ferrous particles > 5 microns). Analytical ferrography results indicated the following: ■ Heavy accumulation of carbon steel wear particles ■ Large striated gear wear detected, indicating severe root/ tip sliding wear ■ Large carbon steel particles, which were indicative of heavy pitch-line fatigue ■ Excessive number of copper particles indicating heavy bearing/cage wear Report conclusions: Severe gear and bearing wear is occurring and will lead to an impending failure unless corrected. (It actually turned out that portions of the gearbox had to be replaced, but the problem was identified early enough to order the parts and install with minimal downtime. A sudden failure would have resulted in a minimum of six weeks downtime and much higher repair costs. The problem was identifying the root cause in this large heavily loaded gearbox. No problem was initially identified with the lubricant. Viscosity, acid number and contaminants were all normal. Consequently, it was assumed the problem was mechanical—but this was not found during the repair process. Upon further investigation, it was determined that the OEM recommended the wrong viscosity oil. The initial recommendation of an ISO 220 was too low for the speed and load conditions. The EP package of the oil, with 100 ppm of phosporous, also seemed low. The gearbox was repaired and ISO 320 EP oil was used, resulting in no further problems.) JANUARY/FEBRUARY 2010
In summary The ability to read and understand an oil-analysis report is vital for making decisions on your equipment. Don’t depend entirely on your oil-analysis lab for recommendations. You know your equipment and its history better than a lab does. There can be a great discrepancy among the laboratories when it comes to recommendations. Because of the large number of samples analyzed daily, their recommendations are exception-driven by a computer. Some labs have analysts who look at the exception data and make the recommendations. Many reports will simply recommend that the oil should be changed—which, in many cases, doesn’t address the root cause problem. The more knowledgeable you are in understanding the data in your report as it relates to your equipment, the easier it is to work with an oil-analysis technical expert. You know your equipment and he/she knows testing. Together, you can come up with the right solution to the problem. Here are several key points to keep in mind: ■ Most reports will not show any exceptions. Review reports based on the criticality assigned to the report by the laboratory. Study all reports that show some abnormality. Call your laboratory for clarification of critical warnings you receive. ■ When an action step is recommended relative to a problem, rectify that problem as soon as possible. Many a catastrophic situation has developed as a result of the corrective action step(s) recommended by a laboratory not being taken in a timely manner. ■ If a critical situation develops with no warning, resend the sample for testing. Don’t base a major equipment decision on one sample point. ■ Lube mixing is a common problem. You need to send in a new oil reference yearly to get meaningful comparisons on the condition of the used oil. Look at the viscosity and metallic additives to identify lube mixing. ■ Finally, work closely with other condition-monitoring specialists (i.e., vibration analysts) in your plant to confirm potential problems. LMT
Contributing Editor Ray Thibault is based in Cypress (Houston), TX. An STLE-Certified Lubrication Specialist and Oil Monitoring Analyst, he conducts extensive training in a number of industries. Telephone: (281) 257-1526; e-mail: rlthibault@msn.com www.LMTinfo.com | 15
UM BIG MONEY TALKS William C. Livoti
Proposed Legislation: The Economic Impact
I
f I were a bettin’ man, I would put money on Congress getting SOME type(s) of energy-efficiency/climate-change legislation into law in the not-too-distant future. While I’m not about to offer an opinion on the possible cause of possible climate change, I do want to discuss the economic impact of proposed bills that are attempting to deal with it. Upon passage, in whatever form, what would these types of measures mean for U.S. industries? Think higher energy costs passed on to customers by the utilities. Just what we need! Where will additional costs come from? Scrubbers…The cost for a new-technology scrubber system for the typical pulverized coal plant is roughly $550M—and it wouldn’t lead to one penny in revenue for the utility. In fact, a scrubber will draw an additional 2% to 5% in auxiliary power. Replacement of obsolete plants…If a climate bill were to pass in its latest form (at the time of this writing in mid-December 2009), a number of older (pre-1970s) coal-fired plants will be unable to meet the new emission standards or find it too costly to get into compliance. We could build new plants, but what kind? Fossil, nuclear, renewable? How long will it take to add enough capacity to replace the old units? And, let’s not forget the need for even more future capacity… Carbon capture and sequestration…This technological advancement has captured the interest of both the DOE and the EPA as a possible solution to environmental problems with fossil-fired power plants. Although actual implementation costs are yet to be determined, they’re bound to be high. As with new scrubbers, additional auxiliary power will be required, thus reducing a plant’s output—and the utility’s profit margin as well. (At the recent PowerGen 2009 event, engineers involved with the development of this new technology noted that capturing and sequestering 90% of the CO2 from a power plant would add 2¢/kWhr to the bus bar costs.)
UM1 | UTILITIES MANAGER
What are our options? The legislation that’s under debate has me very concerned—for industry’s economic future and my own. However, rather than try living off the grid, I suggest that we make every effort to run our plants as efficiently as possible and take the time to fully understand the content of impending energyefficiency/climate-change-related bills. Remember, too, that we can control the impact of whatever may come out of Washington by being proactive—don’t wait until the “horse is out of the barn!” Among other things, implement energyefficiency programs NOW. Seek out suppliers that promote/provide energy-efficiency studies NOW. Optimize and/or replace your existing energy-hog equipment and systems to increase the efficiency of your operations NOW.
Remember that we can control the impact of whatever may come out of Washington by being proactive. For more information on current and proposed energy-efficiency/climate-change legislation and standards that will definitely change the industrial landscape, please join noted energy expert Bill Adams (of Flowserve and the Pump Systems Matter [PSM] initiative) and me at MARTS 2010. Our joint presentation, “The Two New Legs of Lean: Energy Efficiency & Reduction of Greenhouse-Gas Emissions,” will show you what you’ll need to comply with if you want to stay in business, as well as some successful strategies for doing so. (Please go to www.MARTSconference.com for the complete conference schedule.) UM Bill Livoti is a fluid power and power industry engineer with Baldor Electric Company. He also is vice chair of the Pump Systems Matter (PSM) initiative. Telephone: (864) 281-2118; e-mail: wclivoti@baldor.com
VOLUME 5 / NO.1
SEALING SYSTEMS UM
Saving Energy With Sealing Systems © NEDIM—FOTOLIA.COM
The numbers don’t lie. Choosing the wrong sealing system can be a real drain on an operation’s process efficiency, not to mention its reliability, environmental compliance and, ultimately, its overall profitability.
I
n the world of process equipment economics and reliability, the energy efficiency of sealing systems is frequently regarded as being unimportant and insignificant. A careful look, however, reveals that sealing systems are often key factors in establishing system efficiency, reliability and emission-control improvements. Upgrading these systems can greatly help a process plant in these types of improvement initiatives, as well as in its carbon-footprint and total life-cycle-costreduction efforts. Take, for example, mechanical seal and compression packing applications.
Special To Utilities Manager From The Fluid Sealing Association (FSA)
VOLUME 5 / NO. 1
UTILITIES MANAGER | UM2
UM SEALING SYSTEMS
Why Consider Sealing Systems In Energy Efficiency? It’s simple: they are seldom analyzed or evaluated. The area where a shaft penetrates the casing of a fluid handling device, such as a pump, is a potential leak path. Either a seal chamber or stuffing box with a mechanical seal or compression packing is adjacent to this area. Both are central components in a sealing system that ensures containment of this leak path. The type of system will determine energy consumption, among other things.
Mechanical seals… Mechanical seals are found in the majority of centrifugal pumps today—particularly in those handling volatile, hazardous or valuable fluids. Available in a wide variety of types, arrangements and materials, mechanical seals create an extremely restrictive leak path perpendicular to the axis of the shaft between two rubbing seal faces. Leakage is normally not visible and frictional heat is carried away by the pumped fluid surrounding the seal. When conditions around the seal are too severe, support systems are applied to create an artificial environment for the seal. These conditions often include abrasiveness or poor lubricity of the pumped fluid and high temperatures. (Recent design and material technology developments have focused on development of seals that perform in applications without the need for additional support systems to achieve environmental control.) Seals are energy-efficient devices, but some of the basic, more popular seal support systems in use today can consume large amounts of energy—in some cases exceeding the power output of the pump driver. Sealing system energy losses should, therefore, be carefully considered in any pump system assessment. Compression packing… Packing creates an adjustable, close-clearance leak path parallel to the axis of the shaft. Some leakage must be maintained to lubricate and cool the packing material, but frictional heat is always present due to the large surface area in contact with the shaft. When the pumped product is abrasive or the packing needs additional cooling, a clean external flush is typically piped into the stuffing box. This flush is part of the sealing system and can indirectly consume large amounts of energy—that’s why it should be considered in any energy assessment. UM3 | UTILITIES MANAGER
Sealing system efficiency To take advantage of energy-reduction opportunities, we must first determine the energy consumption of the sealing systems used in process equipment. While the focus is typically on pumps, process equipment that incorporates these systems includes compressors, mixers, dryers and all equipment with a rotating or reciprocating shaft that passes through the wall of a pressurized vessel or housing. One approach is to analyze the overall sealing system’s Life Cycle Costs (LCC) (i.e. all cost contributors, including energy consumption). A useful tool in such an analysis is available on the FSA website (www.fluidsealing.com). This free “Seal Life Cycle Cost Estimator” software enables simplified comparative analysis as to what sealing system is more cost effective. The contribution of energy is an integral component of any analysis. The “Seal Life Cycle Cost Estimator” tool can be used to analyze sealing systems as simple as a packed pump with no environmental controls, to those that incorporate complex double, tandem and multi-stage mechanical seal arrangements with their own separate lubrication systems, auxiliary pumps, motors and heat exchangers. Users can make total-cost comparisons, as well as comparisons for energy consumption and cost. Methodology To compare sealing system energy consumption and operating costs, three steps should be taken: 1. Identify the points where energy is consumed and label them on a schematic diagram. 2. Prepare a spreadsheet showing the sources, forms and amount of energy consumption. 3. Define current costs for various sources of energy consumed by the sealing systems. These will be primarily electrical in nature, from prime movers such as motors, and thermal, from a variety of sources. Examples include the cost of cooling water and various forms of energy needed to power the sealing system and replace heat energy consumed in the process system. Sealing system schematic… The sealing system schematic helps to determine the source of the energy consumed. The most apparent source is electrical energy from the drive motor, the most common prime mover. When just this source is examined, large differences in the electrical energy consumption between various mechanical seal types can be seen as shown in Figure 1. Differences in frictional characteristics of the four types of mechanical seals cited produce significant differences in the power consumption of the motor. While these are relatively large differences VOLUME 5 / NO. 1
SEALING SYSTEMS UM
Fig. 1. Frictional power consumption of mechanical seals ( @1750 RPM @100 psig ) 4
3 2
2 1
1 0
0 1.000
2.000
3.000
4.000
Shaft Size (inches) Single Unbalanced
Dual Balanced
Single Balanced
they do not include the energy consumption of the auxiliary components of the entire sealing system. When all these sources of energy consumption are included a quite different perspective develops. Example mechanical seal system analysis… Figure 2 shows one of the more popular, but least efficient, sealing systems for environmental control and protection of mechanical seals. This type of system is used in hot oil pumping service. Typical application specifics include: ■ Single stage, end suction centrifugal pump (API 610 Compliant) ■ Provides heat to various area of the plant ■ Process fluid — Hydrocarbon @ 315 C (600 F) ❍ Specific
gravity 0.8
❍ Specific
heat 1.67kj/kg-ºC (0.4BTU/lb-ºF)
Dual Dry Gas Seal
kW
HP
3
Sources: Mechanical Seals for Pumps: Application Guidelines, pgs. 154-156, published by Hydraulic Institute, 2006; and FSA “Seal Life Cycle Cost Estimator” tool, www.fluidsealing.com
Origin of energy consumption… The initial perception from Fig. 1 may be that most of the sealing-system energy consumed is by the drive motor in overcoming the frictional heat created by rubbing contact between the stationary and rotating faces of the seal. As shown in the schematic, that portion represents less than 1% of the total power consumed by this sealing system, reflecting the relative efficiency of the mechanical seal itself.
ENGTECH Industries Inc.
■ System pressure — 345 kPa (50 psi) in seal chamber ■ Pump shaft — 3600 rpm, 50 mm (2.0”) diameter in seal area ■ Pump driver — 50 hp (typical) ■ Sealing devices ❍ Mechanical
seal or
❍ Compression
packing
■ Heat lost at the pump must be replaced at the system boiler/heat exchanger For more info, enter 66 at www.LMTfreeinfo.com
VOLUME 5 / NO. 1
UTILITIES MANAGER | UM4
UM SEALING SYSTEMS
Low Temperature Seal with API Plan 32 – Cool External Flush 7.6lpm (2 gpm) kerosene flush @ 38 C (100 F)
Q3= 47 kW (160,000 BTU/hr) power required to replace heat lost through dilution of the pumped fluid
Q1= 351 W (1,200 BTU/hr) frictional power consumed by seal
Sealing System Power Consumption = 47.4 kW Fig. 2 Least energy-efficient mechanical seal system (Source: Mechanical Seals for Pumps: Application Guidelines, pgs. 250-251, published by Hydraulic Institute, 2006)
It is also notable that the total power consumed by this least-energy-efficient system, 47.4 kW (63.5 hp), exceeds that of the drive motor itself. Virtually all of that is due to the power required to replace heat lost through dilution of the pumped fluid. Based on an FSA study of over 28,000 seal applications where pumping temperature exceeds 200 C (400 F) this is a realistic case. Over 20% of the mechanical seal applications surveyed employed this API Piping Plan 32. To show that sealing systems represent an opportunity for significant improvements in energy efficiency, we can look at more-current types of energy-efficient systems. The power consumption of many of these proven—but much less frequently applied—systems is less than 50% of this least efficient example. Dry gas seals, one of the latest technologies and most efficient sealing systems, consume 0.5 kw (0.7 hp)—about 1% of this least-efficient system. They also effectively provide a zero emission seal. Conclusion Sealing system energy assessments should be an important part of any plant energy assessment. Selection of an energyoptimized sealing system can lead to significant overall plant energy savings that go right to the bottom line. While not covered here, systems with much greater energy-efficiency than the example illustrated are available. Consultation with your mechanical seal or compression packing manufacturer will enable selection of the most energy efficient system for your application. UM
About FSA. . . Customized, Targeted Lists For Your Marketing Needs
ATP List Services Ellen Sandkam www.atplists.com 1300 S. Grove Ave., Suite 105, Barrington, IL 60010 847-382-8100 x110 / 800-223-3423 x110 info@atplists.com / esandkam@atplists.com
The Fluid Sealing Association (FSA) is an international trade association whose membership represents over 85% of the manufacturing capacity for fluid sealing devices in North America. Its Mission Statement notes that the association seeks to promote a safe, clean environment for society and be recognized as the primary source of technical information; influence and support development of related standards; and provide education in the fluid sealing area. The FSA Web site (www.fluidsealing.com) provides an ideal place for seal users to find technical articles, obtain publications and learn out about upcoming seal training opportunities. There, too, is where you can download the “Seal Life Cycle Cost Estimator,” discussed in this article. (The FSA will be offering 2 full-day workshops at MARTS 2010, one on mechanical seals, the other on compression packing and gasketing. Please visit www.MARTS conference.com for details.)
For more info, enter 67 at www.LMTfreeinfo.com For more info, enter 251 at www.LMTfreeinfo.com
UM5 | UTILITIES MANAGER
VOLUME 5 / NO. 1
A SPECIAL SUPPLEMENT TO LUBRICATION MANAGEMENT & TECHNOLOGY
Recapping Parts I – III
How To Begin Measuring Maintenance Effectiveness Part IV Lucky you! There is one KPI that comes close to taking into account almost all variables in a production process. What is it? Read on.
Raymond L. Atkins Contributing Editor
JANUARY/FEBRUARY 2010
PHOTO © SLEEPYDRAGON – FOTOLIA.COM
As we’ve noted throughout this series, key performance indicators (KPIs) are the metrics that an organization chooses to use as their measures of process performance. They can vary among industries and among individual processes. To begin managing by metrics, an organization must first collect meaningful and pertinent data—information that is important to the operation of the business—which is then converted into one or more KPIs. These tools can be used to immediately evaluate the performance of a process variable, as well as provide a means for tracking that variable over time.
W
e have discussed several KPIs over the course of this series, each of which has measured one or more components in the overall production process. These various metrics have been presented as the tools management can use in measuring the health of portions of the process. Still, the question arises: Is there a single metric that takes into account all of the variables in a given production process? There is one that comes close. It’s known as “TEEP,” which stands for Total Effective Equipment Productivity. TEEP is an ideal or best-case benchmark against which a production process is measured. It is the comparison between the theoretical capacity of a machine versus that machine’s actual performance. TEEP uses as its litmus test the hypothetical output of a machine if it ran perfectly, all the time. As an example, suppose you have a machine in your process that is rated to produce one part per hour. TEEP assumes that if it were to run continuously at the capacity determined by the machine manufacturer’s OEM specifications, this equipment would produce 24 parts per day, 365 days per year—and that this benchmark is the number against which your actual performance should be measured. Consider the number to be an absolute (whether it can actually be obtained), like absolute zero or the speed of light. The formula for this calculation is Actual Parts per Unit of Time X Total Time/Theoretical Parts per Unit of Time = TEEP. www.LMTinfo.com | 21
TEEP is not for everyone. It’s a strategic measure that is used in, among other things, determining the need for capital outlay. Now, don’t throw the magazine away and reach for the television remote. It’s not as difficult as it sounds. I’ll say it in English this time: TEEP is the number of good widgets you are making in a given time period compared to the total number of widgets the machine is capable of making if it ran perfectly at its rated capacity during that same period of time. Let’s look at the machine we just referenced. You have a process that produces widgets, and your primary machine is an old, but well-maintained widget-maker that is rated at one unit per hour. Your plant works two eight-hour shifts each day over a five-day work week, with the weekend being devoted to maintenance efforts. Your process continually achieves uptimes above 90%, and you seldom have any quality issues. Last week, the plant produced a total of 77 widgets at this machine center during your 80 planned production hours. The TEEP percentage for this rather rosy scenario would be as follows: 77 actual widgets produced X 168 total hours in the week/168 possible widgets = 77%. What does this number tell us? Basically, a TEEP percentage of 77% indicates that 23% of this particular process capacity was unrealized—even though this same process is running exceptionally well when evaluated by less stringent measures. (FYI: a handy TEEP calculator is available to you at http://www.downtimecentral.com/oee.shtml.) By the way, if your particular process is achieving a TEEP percentage above 75%, that is an excellent number, and you may take a moment to congratulate yourself. “But wait,” you say. “I don’t want to run three shifts, seven days a week. I’m producing between 70 and 80 widgets per week. That’s world-class output within my particular industry, especially considering the equipment I have, and that’s all the widgets I can sell, anyway. So why would I want to compare myself to a standard that makes no sense for me?” Why, indeed? TEEP is not for everyone. It’s a strategic measure that is used in, among other things, determining the need for capital outlay. Suppose that the giant widget plant down the road—your main competition, perhaps—has a big fire or some other issue that causes a serious curtailment in its ability to turn out product. This leads to a widget shortage, and the price per unit skyrockets. At last, you can sell as many of the things as you can produce—and pretty much get your own price. Your unfortunate competitor will be limping along for at least a year, and as you look for ways 22 | LUBRICATION MANAGEMENT & TECHNOLOGY
to take advantage of what could be an extremely profitable time for your business, your eyes might drift to and linger upon the 23% of your unrealized capacity (as determined by your 77% TEEP). There are several options open to you at this point. You can weed out the few rejects and breakdowns you have and push your TEEP to 80%. You can add a third shift and increase your TEEP or add an extra production day to do the same. You can go to a seven-day/24-hour schedule if you have high confidence in your maintenance program’s ability to work around the extra demands you are placing upon the process. You can even attempt to speed up your widget-maker—if such an action can be undertaken economically, and provided you keep in mind that there are often unforeseen consequences to running a process in excess of its rated capacity. Regardless of what you do, the TEEP measure is the benchmark that lets you know how much additional production is available without additional capital expenditure (such as adding more machines, replacing older equipment, etc.). Benchmarking against what? Since we are on the subject, we should spend a few moments discussing the concept of benchmarks, which are those standards—sometimes theoretical—against which we measure and track our own performances. What should these numbers be? What is “world-class?” Who decides? There is a consensus among maintenance consultants and scholars alike that benchmarks should be challenging but achievable—and I agree with that guideline. As for the actual numbers, however, there is little agreement. Benchmarks differ across industries, across plants and across machine centers. Take uptime as an example. For years, a production uptime percentage above 80% was considered to be a good effort, and 85% was thought to be outstanding. As maintenance practices and machine technology have improved, the best of the best have continued to ease their uptimes in the direction of 88%, then 90% and finally to 95% or higher. The issue for each plant and for every manager is to benchmark their own processes against achievable goals— and to encourage small but steady increments of improvement in their own unique process. Aspiring to a challenging benchmark should be a positive experience for the entire organization. To illustrate this point, let’s go back to the widget industry for a moment. JANUARY/FEBRUARY 2010
A SPECIAL SUPPLEMENT TO LUBRICATION MANAGEMENT & TECHNOLOGY
Suppose you are the production manager for the original widget plant in your organization (the old workhorse), and you have the task of operating technologically obsolete machinery that has been poorly maintained for much of its history. The factory runs uptimes in the mid-70s and makes a small profit. Further assume that upper management has determined that large capital outlays are not in your facility’s future. Times are hard, and they’ll continue to run the plant as long as it pays to do so. But, if you drop into the red, that may be all she wrote. Under conditions such as these, it is probably not wise to benchmark yourself against the leading plant in your industry—a brand-new, technological marvel that consistently posts uptime percentages in the mid- to high-90s. It’s not a case of never being able to get there from here. If you establish a proper PM (preventive maintenance regimen), initiate PdM (predictive maintenance) as budgets allow, do realistic, honest root-cause analyses (RCAs) for every process failure, work safely and begin a conscientious training program, you can wash away most sins over time. There is, however, another component you must consider. If you are consistently running uptime percentages in the mid-70s and are benchmarking against a goal of 95%, you may find that your rate of improvement drops over time. Specifically, your organization may develop a morale problem, because the goal is perceived as being out of reach. If your process has consistently run uptimes in the 75th percentile and through world-class techniques you are
Reliability GivesVoice To
Autism at MARTS 2010
For more details, including information on sponsorship opportunities, visit:
www.MARTSconference.com w
able to raise this average to 80%, you have achieved a huge gain in effectiveness. Conversely, if the new and improved 80% uptime is compared to a 95% goal, it still seems as if the organization has an impossibly long way to go. If, though, the benchmark were 85%, then your people have moved halfway toward their goal—a goal they perceive as being reasonable and achievable. Remember, as goals are reached, new, higher ones can be set. Thus, by making each new goal plateau achievable, you are not limiting the longterm potential of the company, particularly if you reward the attainment of these plateaus as they are reached. Use your metrics effectively To manage by metrics, you must first make the conscious decision to gather accurate data that is meaningful to your organization. The accuracy of your data is the critical component of the process. You must then convert the data into KPIs that your organization is capable of maintaining. Put simply, the gathering and manipulation of data into a useable form is an important job that must be performed by personnel who realize this fact and who are capable of performing the task. Finally, your KPIs should be benchmarked against realistic numbers. You must learn to walk before you can begin to run. LMT Ray Atkins is based in Rome, GA. E-mail: raymondlatkins@ aol.com; visit his Website: www.raymondlatkins.com; or hear him speak at MARTS 2010 (www.MARTSconference.com)
Applied Technology Publications, SUCCESS by DESIGN and the Autism Society of Illinois are joining together in an effort to give voice to autism during MARTS 2010. Originally planned as a publishing awards event, we have expanded the scope of this occasion to raise awareness and funds for autism, a growing disorder that has already touched the hearts and lives of countless professionals in the industrial engineering, reliability, maintenance, energy and environmental sectors. Collaboration with the Autism Society was specific in that this organization is out on the front line 24/7, providing immediate support and services to families affected by autism. It’s a type of challenging endeavor with which MARTS attendees can well identify as they, themselves are on the front line keeping critical infrastructure and industrial operations up and running no matter what. Kicking Off MARTS 2010 With A Worthy Cause These “Reliability Gives Voice To Autism” activities will take place at the Hyatt Regency O’Hare on the evening of April, 27, 2010, starting with a cocktail reception at 5 p.m, followed by a gala charity dinner, live entertainment and door prizes. You won’t want to miss this exciting and worthy event, which also helps kick off MARTS 2010!
Or contact:
Bill Kiesel, Publisher of Maintenance Technology and Lubrication Management & Technology magazines at: bkiesel@atpnetwork.com; or: 847.382.8100 x116
We look forward to having you join us and others across the Reliability Community in giving “Voice To Autism” at MARTS 2010!
For more info, enter 68 at www.LMTfreeinfo.com JANUARY/FEBRUARY 2010
www.LMTinfo.com | 23
THE GREEN EDGE
Little Things Add Up For Green-Minded Companies © PKAZMERCYK—FOTOLIA.COM; © KMIT—FOTOLIA.COM
Thinking small is not always bad.
G
reen workspace alterations come in all stripes, from big ones that can help produce significant savings i after a payback period to smaller ones that generate savings immediately—and cost little or nothing upfront. The U.S. General Services Administration (GSA) recently explored and tracked a number of facility and workspace green alterations to determine their effectiveness and savings. While the GSA study focused on federal office space, the strategies it followed are effective in nearly any work environment, including industrial space. Tiny tweaks capture big benefits The first suggestion by the study’s
authors—which involves turning up the thermostat in summer—is something that any business can easily do. By adjusting summer HVAC output from 74 to 78 F, average energy costs for cooling were cut by 4%, or 10.6 cents per sq. ft. annually in the GSA sample. A side benefit was that the change also increased employee satisfaction: More than 60% of employees said they were uncomfortable working in the colder temperature. Another easy, cost-saving measure involved replacing HVAC-system filters on schedule, and with highperformance filters. The GSA study estimates that 30% of the facilities examined inspected their filters too infrequently. By checking maintenance records to ensure proper replacement,
and using filters with a Minimum Efficiency Reporting Value rating of 13 or above, the GSA study predicts these facilities would cut overall HVAC energy expenditures by 2%. Finally, by replacing bulky CRT monitors with LCD units, businesses can quickly cut their energy use. CRT monitors draw nearly three times the energy of LCDs: 75 watts compared with 20-25 watts of peak energy. LCD screens were also found to produce appropriate brightness levels more consistently—something that current research suggests might improve performance of visual tasks. For additional information about the study and other energy-saving alterations for the workplace, visit www.gsa.gov LMT
DOES YOUR COMPANY HAVE A GREEN EDGE? E-mail your product and service news to: gpietras@atpnetwork.com For information on advertising in the Green Edge section, contact KATHY JAROS at: Phone: (847) 382-8100 ext. 117 / Fax: (847) 304-8603 / E-mail: kjaros@atpnetwork.com
24 |
LUBRICATION MANAGEMENT & TECHNOLOGY
JANUARY/FEBRUARY 2010
TTHE HE G GREEN REEN EEDGE DGE
New Onsite Wind-Turbine Service Partnership
T
he North American Wind Service Alliance (NAWSA) has joined with Wind Drives, a wind-turbine gearbox repair and remanufacturing company, to provide gearbox-oil changeouts, onsite service, PdM services and commissioning of rebuilt gearboxes
to extend wind-turbine life. As the only integrated wind-turbine service network in North America, NAWSA offers a Web-based, single point of contact for all wind-generator concerns, from emergency response to diagnostics and repairs. More than 50 tower-rescue-
trained technicians and support technicians throughout the country provide on-site evaluation, removal, installation and support. NAWSA and Wind Drives Wharton, NJ and Milwaukee, WI For more info, enter 31 at www.LMTfreeinfo.com
Fuel-Cell Industry Could Generate More Than 1M New Green Jobs
T
he global fuel-cell industry could create 700,000 green manufacturing jobs over the next decade, according to “Fuel Cells: Sustainability,” an Industry Review from Fuel Cell Today (FCT), an organization that gathers market-based intelligence on the fuel-cell industry. The group further predicts that more than a million total new jobs could be created during this period to accommodate fuel-cell installation, servicing and maintenance. FCT projects that Asia will dominate in terms of manufacturing over the next decade, while key adopter regions, including Europe and North America, will be the prime locations for installation and maintenance jobs. The study also raises a number of issues for the fuel-cell industry itself, which, if not addressed, could be a barrier to fuel-cell adoption, including education, skills and training and supply-chain development. Fuel Cell Today Hertfordshire, United Kingdom
For more info, enter 32 at www.LMTfreeinfo.com
Patented
• Removes scale from pipe work • Removes scale from heat exchangers and steam boilers • Saves energy by keeping heating elements scale free • Increases life of capital equipment • Reduces cleaning costs, chemicals & labor • Saves 50% on cooling tower make up water • Saves irrigation water • Provides short term payback Applications: Residential • Commercial • Industrial
Dealer territories available. Scalewatcher North America Inc., Oxford PA Call Toll Free (800) 504-8577 or by email: sales@scalewatcher.com
www.scalewatcher.com For more info, enter 69 at www.LMTfreeinfo.com
JANUARY/FEBRUARY 2010
www.LMTinfo.com | 25
TTHE HE GREEN GREEN EEDGE DGE
Safer, Spill-Proof Transfer Of Flammable Liquids
Ludeca Opens Wind Energy Diagnostics & Monitoring Division
he newest GoatThroat Pumps for environmentally safe transfer of flammable liquids are in production now. Featuring a lug with a grounding wire on their fronts, SCP-6500 models will be available March 1, 2010. The lug will allow users to ground the pumps, making them safe for use with class 1 and class 2 flammables. All components that come in contact with the pumped fluid are created with conductive plastic. Available in four models, GoatThroat Pumps fit containers and drums from 5 to 55-gallons; typically have a service life of 10 to 15 years; and provide for spill-proof, safe transfer of over 850 fluids and solvents. RoHS compliant, these food grade products are designed to drain containers dry, making them Resource Conservation and Recovery Act (RCRA) empty. They also meet UN safety standards, helping customers meet compliance and environmental requirements.
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udeca has opened its LUDECAwind Division to provide system support services for wind turbines. Services include installation and start-up of condition-monitoring systems, telediagnosis services with remote monitoring, laser alignment and geometric measurement systems, continuous alignment monitoring and consulting. The Germanishe Lloyd (GL) Wind certified VIBROWEB XP Wind online monitoring system supplied by Ludeca was developed exclusively for windturbine condition monitoring. According to the company, it is an easy-to-install, intelligent and compact unit that operates autonomously without a PC.
Westcott Distribution Inc. New York, NY
New Environmentally Friendly Lubricating And Cleaning Items
For more info, enter 33 at www.LMTfreeinfo.com
Patented-Formula “Green” Spray Lubricant
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iQuifix, a patented “green” spray lubricant is an effective, easy-touse, non-aerosol, non-toxic and odorless formula with low VOCs. Its manufacturers note that the product is the only spray lubricant that meets California standards for indoor air pollution. It contains no PCBs, trichloroethlylenes, dioxins or metals, and has a high flash point of 275 F. LiQuifix complies with new EPA regulations that identify methane and five other greenhouse gases as dangerous to humans and also meets FDA Regulation 21 CFR for incidental food contact. LiQuifix Stamford, CT For more info, enter 35 at www.LMTfreeinfo.com
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MAINTENANCE LUBRICATION MANAGEMENT TECHNOLOGY& TECHNOLOGY
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Ludeca, Inc. Doral, FL For more info, enter 34 at www.LMTfreeinfo.com
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utek has launched a SmartGreen™ offering of lubricating and cleaning items. The line features extra-large, biodegradable wipes or towelettes that have soy-based lubricants and environmentally friendly cleaners. Unlike tube packages, the company says these wipes can be kept anywhere and not dry out. Simply Soy wipes can be used to clean and lubricate tools and other metal surfaces to prevent rust build-up, and are certified for safe use in food areas. Extra-large, heavy-duty Gas Off wipes remove, suspend and absorb gas smells from hands and surfaces. Grime Off removes drips and smears from non-porous surfaces like tools and equipment. Nutek Chagrin Falls, OH For more info, enter 36 at www.LMTfreeinfo.com JANUARY/FEBRUARY FEBRUARY 2009 2010
MAINTENANCE and RELIABILITY TECHNOLOGY SUMMIT
Don’t Miss The Capacity Assurance Conference! New Speakers!
Critical Topics!
Powerful Presentations!
The premier educational event for maintenance professionals, MARTS 2010 covers the widest range of topics in its history. With 30 one-hour Conferences and 17 full-day Workshops, MARTS offers valuable, job-critical information for:
MARTS 2010 Highlights: * Keynote Speaker John Ratzenberger – the actor, author and manufacturing activist will speak about Nuts, Bolts & Thingamajigs, his foundation that brings students and manufacturing together.
Plant and Facility Managers Maintenance Engineers and Managers Maintenance Team Leaders and Members Plant Operators and Engineers Reliability Engineers and Managers ... at the comfortable Hyatt Regency O’Hare hotel, 10 minutes from O’Hare Airport in Rosemont, IL.
* Futurist and financial professional Bob Chernow, who will offer predictions for manufacturing, technology, the economy and other key issues. * A special “Reliability Gives Voice to Autism” event that kicks off MARTS 2010 with a worthy cause. It will feature dinner and live entertainment while raising awareness and funds for autism. * Solid representation from industry experts such as Christer Idhammar, Bob Williamson, Doc Palmer and many others, including Enrique Mora, who will present a Spanish-only Workshop on TPM.
APRIL 27-30, 2010 Hyatt Regency O’Hare, Rosemont (Chicago), IL
www.MARTSconference.com Or Call Tom Madding: 847.382.8100 x108 JANUARY/FEBRUARY 2010
PRESENTED BY: ®
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APRIL 27-30, 2010 MAINTENANCE M AINTENANCE aand nd RRELIABILITY ELIABILITY TTECHNOLOGY ECHNOLOGY SSUMMIT UMMIT
What is MARTS? The Maintenance & Reliability Technology Summit is a four-day educational experience and professional development opportunity for maintenance and reliability professionals working in industry. Components include two days of full-day Workshops, two days of one-hour Conferences, two Professional Development Courses and Certification Examination opportunities. All sessions are presented by practitioners and other industry experts who have signed on to share their knowledge about industrial skills, not to sell products or services.
MARTS 2010 Workshops
Attendees interested in learning about products and services have ample opportunity to meet with MARTS exhibitors, located in common areas. For exhibition opportunities, contact Tom Madding: 847.382.8100 x108
Lean Equipment Management: The Prescription for Rapid and Sustainable Gains /
MARTS 2010 Basics Location: Hyatt Regency O’Hare, Rosemont, IL www.ohare.hyatt.com Dates: Tuesday through Friday, April 27-30, 2010 Workshop Days: Tuesday and Friday (17 full-day Workshops offered) Conference Days: Wednesday and Thursday (30 one-hour Conferences offered; see schedule on next page) Professional Development Course 1: Certified Lubrication Specialist (CLS) Review, Tuesday through Thursday Professional Development Course 2: Taking Command of Your Maintenance Process: Is to provide a comprehensive from Certifieducational cation to Implementation, training, and professional Tuesday and Wednesday development opportunity for Certifi cation Exam Day (for technicians, CLS and CMRP): maintenance and reliability Friday engineers, supervisors and managers Note: interested in takingfacilities. an exam must in allIndividuals industries and major register directly with STLE (CLS) and SMRP (CMRP). Link to these sites at www.MARTSconference.com
28 28|| LUBRICATION 28 L LUBR UBRICA UBR BR RICA CATIO CATIO CA TION T IIONMANAGEMENT MANA M ANA ANA AG GEMENT GEM GE EM EMENT EN & TECHNO T TEC ECHNOLOG ECHNO LOGY O Y LUBRICATION MANAGEMENT &TECHNOLOGY TECHNOLOGY
Workshops are full-day, intense explorations of a given topic. Most run from 8:00 a.m. to 3:00 p.m., with an hour for lunch (included in price). See www.MARTSconference.com for addition details and to register.
Pre-Conference Workshops: Tuesday, April 27, 2010 Robert M. Williamson, Founder, Strategic Work Systems, Inc. Lubrication for Industrial Facilities / Ken Bannister, Principal Consultant, Eng Tech Industries, Inc. Fundamentals of Mechanical Seals / Mechanical Seal Division of the Fluid Sealing Association (FSA) Best Practices in Compression Packing & Gasketing / Compression Packing and Gasket Divisions of the Fluid Sealing Association (FSA) Leading Organizational Change / Scott Franklin, Principal Consultant, Life Cycle Engineering Getting Started with Predictive Maintenance / Mike Gilley and Mike Dixon, Principals, Fox River Systems Reliability Centered Maintenance / Anthony “Mac” Smith, Senior Consultant, AMS Associates 4 Lean Tools to Revolutionize Your Maintenance System (Part I) / Ed Stanek, President, LAI Reliability Special Spanish-Language Workshop: How to Prevent or Revert Failure in Your TPM Implementation / Enrique Mora, President, LeanExpertise.com
Post-Conference Workshops: Friday, April 30, 2010 Lubrication for Profit: Best Practices for Lube Selection and Application on Process Machinery / Ray Thibault, CLS, OMA I & II; Lubrication Training & Consulting Motor System Maintenance and Management / Howard Penrose, Ph.D., CMRP; Vice President, Engineering and Reliability, Dreisilker Electric Motors, Inc. Contractor Management Strategy / John Elliott, Senior Consultant and Jerry Wanichko, Manager, T.A. Cook Consultants, Inc. Ensuring Reliability Through Systematic Work Control / Dave Krings, CMRP, BSME; President, Nobreakdowns.com Using SMED to Transform Your Lean Enterprise / Enrique Mora, President, LeanExpertise.com Maintenance Planning and Scheduling / R. D. (Doc) Palmer, PE, CMRP; Partner, People and Processes, Inc. IR Thermography for Electrical and Mechanical Systems / R. James Seffrin, Director of Infraspection Institute 4 Lean Tools to Revolutionize Your Maintenance System (Part II) / Ed Stanek, President, LAI Reliability
JANUARY/FEBRUARY JAN ANUAR UAR ARY/F Y/FEBR EBRUAR EBR BR B RUAR UARY2010 UARY 2010 10 0 JANUARY/FEBRUARY 2010
The Capacity Assurance Conference! MARTS 2010 Conferences
Conferences are one-hour presentations, given by an expert in the field. Accompanied by a PowerPoint presentation, they include ample time for Q&A, and are divided into six categories: Data Management Lubrication Strategy Green Maintenance & Reliability Technology
See the schedule below for Conference offerings and other Conference-Day activities:
WEDNESDAY APRIL 28 (15 Conferences) 7:00 a.m. to 8:00 a.m. Continental Breakfast 8:00 a.m. to 8:45 a.m. Keynote Address John Ratzenberger, actor, director, author and spokesperson for the Nuts, Bolts & Thingamajigs Foundation 8:45 a.m. to 9:30 a.m. Break / Exhibits 9:30 a.m. to 10:30 a.m. Data Management Interoperability Between Plant Design and Other Systems for Reduced OPEX and Improved Maintenance, Turnarounds and Reliability Adrian Park, Intergraph Process, Power & Marine Green The Two New Legs of Lean Bill Adams, Flowserve, and Bill Livoti, Baldor Electric Co. Strategy Reliability and Maintenance Management: From Good to Great Christer Idhammar, IDCON, Inc. 10:40 a.m. to 11:40 a.m. Technology Understanding Torque Measurements and Torsional Analysis Trent Martz, IVC Technologies Maintenance & Reliability Where’s Your Reliability Policy? Robert M. Williamson, Strategic Work Systems, Inc. Strategy Forward to the Basics! (Designed for the Rocket Scientists and Over-Achievers Among Us!) Jeff Shiver, People and Processes 11:40 a.m. to 1:00 p.m. Lunch / Exhibits
JANUARY/FEBRUARY JANUARY/FEBRUARY J JAN AN ANUAR UAR UA ARY/F Y//FEBR Y/ EBR EB RUAR UA U UARY A AR RY2010 2010 2 20 010 01 010 0
THURSDAY APRIL 29 1:00 p.m. to 2:00 p.m. Lubrication How to Kill a Bearing / Ken Bannister, Engtech Industries, Inc.
(15 Conferences)
1:00 p.m. to 2:00 p.m.
7:00 a.m. to 8:00 a.m.
Green World-Class Companies Need World-Class Motor Management and Maintenance / Noah Bethel, PdMA Corp.
8:00 a.m. to 8:45 a.m. Keynote Address Bob Chernow, futurist/ financial expert
Maintenance & Reliability Plant Floor Reliability: A Four Senses Approach / David Rosenthal, MEMC Electronic Materials
Strategy 20 Sure-Fire Ways to Shoot Your Maintenance Effort in the Foot / Ray Atkins, contributing editor
Break / Exhibits
2:10 p.m. to 3:10 p.m. Technology Ultrasound for Condition-Based Monitoring and Energy-Efficiency Improvement / Mike Gilley and Mike Dixon, Fox River Systems Maintenance & Reliability How to Make Your TPM Implementation a Total Success Enrique Mora, Leanexpertise.com Strategy Planning Maintenance With Production Support / John Crossan and Randy Quick, Manufacturing Solutions, Intl. 3:10 p.m. to 3:40 p.m. Break / Exhibits 3:40 p.m. to 4:40 p.m. Maintenance & Reliability RCM Lessons Learned: An Update Mac Smith, AMS Associates, and Joe Saba, JMS Software Green How to Reduce the Payback Period for Energy Efficiency Projects / Ralph Semyck, Siemens Industry, Inc. Strategy Change Behavior to Achieve Results: High Impact Learning Tara Denton, Life Cycle Engineering (LCE) 4:40 p.m. to 6:00 p.m. Reception / Exhibits
Continental Breakfast
8:45 a.m. to 9:30 a.m. 9:30 a.m. to 10:30 a.m. Strategy Using Web 2.0 Technologies and Social Media to Continuously Improve Maintenance and Reliability Jeff Shiver, People and Processes Maintenance & Reliability The Development of Condition-Based Maintenance in a Service Company Howard Penrose, Dreisilker Electric Motors Strategy Life Cycle Costing Management Ali Zuashkiani, University of Toronto Strategy The Right Part at the Right Time at Cost-effective Prices Richard R. Rosales, ABB 10:40 a.m. to 11:40 a.m. Maintenance & Reliability Prospering in a Lean Maintenance Environment Ed Stanek, LAI Reliability Systems Green An Easy Approach for Applying Today’s AC Drives / James Mullinix, Vacon Strategy O&M Peer Networking Bob Gibson, Scientech
Strategy Maximizing Human Resources Performance within the Maintenance Organization / Michael Gehloff, General Physics Corp. Lubrication Benchmark Your Lube Program Through Oil Analysis Stacy Heston, POLARIS Laboratories Open Discussion Group Topic TBA / Bob Williamson 2:10 p.m. to 3:10 p.m. Data Management How to Make Your CMMS Interoperate With the Real-Time Enterprise C.C. (Cliff ) Pedersen, Pedersen Enterprises Inc. Technology Infrared Thermography: What’s Hot in PdM / Jim Seffrin, Infraspection Institute Strategy Applying Disruptive Learning Techniques in a Manufacturing Environment Mitch Stansloski, Pioneer Engineering Maintenance & Reliability Title TBA / T.A.Cook Consulting, Inc. 3:10 p.m. to 4:00 p.m. Break / Exhibits 4:00 p.m. to 5:00 p.m. Plenary Session / Closing Remarks
Maintenance & Reliability Classical RCM: Try It, You Are Bound to Like It / Tim Allen, AMS Associates 11:40 a.m. to 1:00 p.m. Lunch / Exhibits
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The Capacity Assurance Conference! APRIL 27-30, 2010
MAINTENANCE andd RELIABILITYTECHNOLOGY RELIABILITY TECHNOLOGY SUMMIT MARTS 2010 Professional Development Opportunities Two professional development courses are offered at MARTS 2010. These are designed for managers looking for in-depth, focused reviews, and technicians who want to build their skill sets. Courses are held Tuesday through Thursday. Professional exams for Certified Lubrication Specialist (CLS) and Certified Maintenance Professional (CMRP) are offered on Friday. Individuals interested in taking an exam must register directly with STLE (CLS) and SMRP (CMRP). Link to these sites at www.MARTSconference.com, or see below. 3-Day Review Course: Certified Lubrication Specialist (CLS) Review Instructor: Ray Thibault, Lubrication Training & Consulting Dates: Tues., April 27 through Thurs., April 29 Times: 9:00 a.m. to 4:00 p.m. (except Tues., April 27: 8:00 a.m. to 3:00 p.m.) Cost: $1,195 Attendees of this course learn how to evaluate and select lubricants, recommend changes, consolidate inventories, conduct a lube survey, and create and manage a used-lubricant analysis program. Technologies covered include bearings and gears, pneumatics and fluid power, fluid conditioning and analysis, and seals. The course was developed specifically to prepare candidates for the Certified Lubrication Specialist exam. (Course enrollment does not ensure certification.)
2-Day Review Course: Taking Command of Your Maintenance Process: from Certification to Implementation Instructor: Dave Krings, CMRP, BSME; President, Nobreakdowns.com Dates: Wed., April 28 and Thurs., April 29, Times: 9:00 a.m. to 4:00 p.m. Cost: $995 This comprehensive review of the latest maintenance best practices is designed for busy maintenance professionals looking to either prepare for certification exams or integrate these concepts into their maintenance programs. An expanded version of the popular “5 Pillars: Maintenance & Reliability Professional Review Course,” this new session offers more examples of real-life application and provides a general review for various maintenance-industry certifications. (Course enrollment does not ensure certification.)
Exam: Certified Lubrication Specialist (CLS) Administered by the Society of Tribologists and Lubrication Engineers (STLE). Date: Friday, April 30 Time: 9:00 a.m. Cost: Varies Note: You must register separately with STLE to take this exam at MARTS 2010. Register online at www.stle.org or call 847.825.5536.
Exam: Certified Maintenance & Reliability Professional Administered by the Society for Maintenance & Reliability Professionals (SMRP) Date: Friday, April 30 Time: 9:00 a.m. Cost: Varies Note: You must register separately with SMRP to take this exam at MARTS 2010. Register online at www.smrp.org or call 800.950.7354.
MARTS 2010 Fees And Packages Special FSA Package - $ 1,995.00
FSA Workshop Package - $ 695.00
Includes 1 FSA Pre-Conference Workshop, MARTS Conference and 1 Post-Conference Workshop
Includes 1 Pre-Conference FSA Workshop
Special Summit Package - $ 1,550.00
Lubrication for Profit Workshop - $ 545.00
Includes 1 Pre-Conference Workshop, MARTS Conference and special Post-Conference Workshop “Lubrication for Profit”
Includes “Lubrication for Profit” Post-Conference Workshop only
FSA/Conference Package - $ 1,590.00
Includes 3 days intense training based on STLE’s CLS program
Includes 1 FSA Pre-Conference Workshop and MARTS Conference
2-Day Workshop: Taking Command of Your Maintenance Process: from Certification to Implementation- $ 995.00
Summit Package - $ 1,450.00 Includes 1 Pre-Conference Workshop, MARTS Conference and 1 Post-Conference Workshop
3-Day Certified Lubrication Specialist Workshop - $ 1,195.00
Includes 1 Pre or Post-Conference Workshop and MARTS Conference
2-day review of the latest maintenance best practices is designed for busy Maintenance professionals looking to prepare for certification exams or integrate these concepts into their own maintenance optimization programs
Conference Package - $ 895.00
Certification Exams - Costs Vary
Combo Package - $ 1,190.00
Includes MARTS Conference.
Two Workshop Package - $ 890.00 Includes 1 Pre-Conference and 1 Post-Conference Workshop only
One Workshop Package - $ 495.00 Includes 1 Pre or Post-Conference Post Conference Workshopp
Individuals interested in taking the CLS exam or the CMRP exam must register directly with STLE (CLS) and SMRP (CMRP). Links are available at www.martsconference.com and are also listed on page 28 All packages include continental breakfast, lunch and Wednesday night’s MARTS Reception. For Group Rates, call 847.382.8100 x108.
APRIL 27-30, 2010 www.MARTSconference.com Or Call Tom Madding: 847.382.8100 x108 For more info, enter 70 at www.LMTfreeinfo.com
30 || LUBRICATION LUBRICATION MANAGEMENT MANAGEMENT & &TECHNOLOGY TECHNOLOGY 30
JANUARY/FEBRUARY 2010 2010 JANUARY/FEBRUARY
LUBE SHOWCASE
Our Editors Select
Food Grade Lubricants What’s it take to move products around and through our food chain safely and efficiently? These leading suppliers have a number of answers. They offer effective solutions for a wide range of food grade needs.
Chesterton’s 690 FG Lubricant…
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art of Chesterton’s line of primary chain lubricants, this clear, non-staining chain formula for use in food processing, beverage, and pharmaceutical plants is NSF registered for direct food contact. It’s suitable for applications with temperatures from -9 C to 120 C (15 F to 250 F). Chain “stretch” is a result of wear on the pin and bushing, requiring costly chain adjustments or replacement. According to the company, conventional lubricants do not penetrate tight tolerances and, therefore, provide minimum benefit. These Chesterton products, though, are formulated to penetrate pin and bushings. This can lead to a doubling of chain life, reduced energy and lubricant consumption and increased load-carrying capability. A.W. Chesterton Woburn, MA For more info, enter 37 at www.LMTfreeinfo.com
JANUARY/FEBRUARY 2010
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LUBE SHOWCASE
Castrol Molub-Alloy® Foodproof 823 FM™ Greases. . .
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eveloped for general lubrication of food machinery, these greases have been approved by LGA Bayern as physiologically safe, and by the USDA (NSF) as “H1” lubricants, even if incidental contact with food products is possible. A select base oil blend with an FDA approved thickener provides good adhesion, film strength and wash-down resistance, even at elevated temperatures. Drip-free characteristics and an off-white color complement housekeeping efforts. A high-performance combination of food grade additives provides excellent anti-wear protection and, in conjunction with blending techniques, leads to effective rust protection and long grease service life. Castrol will launch these products in the U.S. in April 2010. Castrol Wayne, NJ
For more info, enter 38 at www.LMTfreeinfo.com
Royal Purple’s Ultra-Performance® Clear FDA Food Service Grease. . .
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his colorless, non-staining, non-drying, biodegradable, aluminum complex H-1 formulation is approved by the USDA for applications in federally inspected meat and poultry plants. Meeting or exceeding the FDA’s CFR Title 21 Section 178.3750 purity regulation, it is specifically designed for use in food processing. It features a bacteriostatic agent to retard bacterial and fungus growth, and is extremely water resistant, even after frequent wash-downs. Polymer additives provide superior adhesive/cohesive strength to lower friction and protect against high shock loads. According to the manufacturer, the synthetic ingredients and anti-wear additives of this multi-temperature service product can increase equipment life.
Royal Purple, Inc. Porter, TX
Blue Works Industrial Grade Silicone from WD-40. . .
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his product quickly lubricates, waterproofs and protects without attracting dirt or other harmful contaminants, and can be used to eliminate sticking and binding and to stop squeaks. The formula withstands high pressure and is NSF H1 food grade certified, yet doesn’t sacrifice all the power and strength of an H2 formula. According to the manufacturer, this fluid is ideal for releasing molded parts and for use on belts, linkages, pulleys, valves, slide conveyors, guide rails, tools, locks, doors, hinges and more. It is safe to use on all metal and non-metal surfaces, including rubber. WD-40 Company San Diego, CA
For more info, enter 40 at www.LMTfreeinfo.com
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32 | LUBRICATION MANAGEMENT & TECHNOLOGY
JANUARY/FEBRUARY 2010
LUBE SHOWCASE
Clarion Food Machinery A/W Oils. . . Mobil SHC Cibus Series Oils For Food Machinery. . .
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deal for the full spectrum of hydraulic, gear and air-compressor applications, Mobil SHC Cibus lubricants are designed to provide food and beverage processors with high performance and long service life, even in extreme operating conditions such as freezers and cookers. In addition to being manufactured in equipment where crosscontamination is minimized, Mobil SHC Cibus Series lubricants are formulated to be nut-, wheat- and gluten-free and suitable under Kosher and Halal dietary law. Engineered with advanced synthetic base stocks, these oils, according to the manufacturer, have outstanding load-carrying properties and low internal friction, which helps cut energy costs. Mobil Industrial Lubricants Fairfax. VA
For more info, enter 41 at www.LMTfreeinfo.com
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lean and clear, pure and simple, these food machinery oils are available in four ISO viscosity grades, and use an additive system designed specifically for lubricants for food-processing equipment. Formulated with a high-purity white mineral oil and additive system, these lubricants are colorless, odorless, tasteless, non-staining and provide excellent wear, rust- and oxidationprotection. Clarion Food Machinery A/W Oils are NSF H1 approved and recommended for medium-pressure hydraulic systems in food processing, canning, bottling and airline lubrication. Clarion Lubricants Houston, TX
For more info, enter 42 at www.LMTfreeinfo.com
Inolex’s Lexolube® FG-350 H1 OCL…
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his polyol ester oven chain lubricant, one of many Inolex food grade offerings, is ideal for baking-chain temperatures up to 500 F. According to the manufacturer, the consistent lubricity and film strength of the Lexolube® line is remarkable and requires less re-application than many other lubricants available. When exposed to high temperatures over time, most lubricants gum up, smoke or leave stains on the machinery. Lexolube chain lubricants, on the other hand, provide clean lubrication and show minimal evaporation, which translates into enhanced performance. These non-toxic products do not require stirring before application. The FG line leads to less maintenance and downtime, and lower energy consumption.
Inolex Chemical Company Philadelphia, PA A
For more info, enter 43 at www.LMTfreeinfo.com
JANUARY/FEBRUARY 2010
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SOLUTION SPOTLIGHT
Economical And Ecological Solution For Used Oil
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mployees at the 25 Five Rivers MetroParkss facilities in the greater Dayton, OH H area feel as though they’ve struck gold —black gold, that hat is. The reason? They’ve been recycling used motor oil from service i vehicles hi l that h maintain i i the h system’s ’ nearly l 15,000 acres to generate heat for their offices and workshop. According to Dave Spitler, assistant park manager, he was seeking a better way than wood-burning stoves to heat the operation’s buildings. “There was a big cost factor in man hours to have staff members cut and split wood for the stoves,” he says. The Clean Burn system has changed all that. These days Used oil storage tanks now collect hundreds of gallons of recycled motor oil from the park’s 99 fleet vehicles and 98 small motorized vehicles (including Gators and lawn mowers), as well as community contributions. After being refined, the oil is pushed through a filter and pre-heated. It’s then injected into the Clean Burn furnace and burned at 1800 F. The high temperatures create low emissions (less than 1% allowable by EPA standards) and generate enough heat to warm the park’s 2400-sq.-ft. office and workshop facilities. “I’ve sent oil recycle barrels to all MetroParks facilities to collect their used oil,” reports Spitler. “Each park saves money since they no longer have to pay anyone to properly dispose of the oil. We bring the full barrels to the central furnace area and replace them with empty barrels. This is a sensible solution that would be viable for other parks nationwide to adapt in order to save money and close the loop on recycling efforts.” 34 | LUBRICATION MANAGEMENT & TECHNOLOGY
Before Clean Burn Prior to installing the Clean Burn system, the Five Rivers Metroparks Ri M k operation i had h d hired hi d contractors to haul away and dispose of used oil. This process not only posed considerable risk for spills and/or contamination of the environment, it also required significant amounts of fossil fuels for transporting the waste oil.
About Clean Burn According to the manufacturer, there are 80,000 Clean Burn functional furnaces and boilers located across the globe. They burn millions of gallons of used oil each year on-site, at the point of generation. Clean Burn is an ENERGY STAR® partner. The company holds numerous industry certifications and works with the U.S. government, the Environmental Protection Agency and various associations to help coordinate the establishment of standards and regulations related to heat recovery and recycling efforts involving used motor oils. Clean Burn, Inc. Leola, PA
For more info, enter 44 at www.LMTfreeinfo.com JANUARY/FEBRUARY 2010
PROBLEM SOLVERS
Near-Laboratory-Quality Viscosity Measurements Made Easy
New Synthetic To Protect Wire Rope
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ubrication Engineers’ new Wirelife™ Almasol® Syn Coating Lubricant is an extremely tacky, nonasphaltic synthetic with exceptionally high film strength. Suitable for extreme environments and conditions, it provides robust outer-surface protection for wire rope and cable used in mining, construction and marine operations. It reduces wear by minimizing wire-to-wire contact with the rope. Typical applications for this product include standing and running lines, draglines, cranes, derricks, hoists and drilling rigs.
he SimpleVIS™ system from Cannon Instrument is a specialized semi-automated viscometer that provides quick, reliable kinematic viscosity results with a touch of a finger. According to the company, this portable unit is ideal for any site that needs near-laboratoryquality viscosity measurements. Everything to get started is included; the user provides only sample and solvent. Capable of delivering direct kinematic viscosity measurement, with no need to correlate dynamic viscosity data, the product incorporates a modified cross-arm style tube that works with both transparent and opaque oils.
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Lubrication Engineers Fort Worth, TX
Cannon Instrument Co. State College, PA
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Mobile Monitoring Of Aging-Oil Conditions
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he Oil Condition Monitor(orOCM01) from Internormen is a mobile diagnostic system for determining the aging condition of oil in hydraulic and lubrication systems by measuring solid contamination, water saturation, temperature, viscosity and relative dielectricity. The system is applicable for both pressure and suction lines and can also be employed when working with foamed oils in gears. Internormen Altlussheim, Germany For more info, enter 46 at www.LMTfreeinfo.com
JANUARY/FEBRUARY 2010
Upgraded Electronic Lubrication Meters
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incoln’s Model 980, 981 and 982 Electronic Lube Meters for vehicle maintenance, lube-truck and other industrial applications feature large, easy-to-read, six-digit digital displays with two-decimal-point precision. The pressure rating has been increased from older models to 1500 psi, and flow capability has been improved to 8 gpm. The meters have a resettable and non-resettable totalizer that displays dispense quantities in pints, quarts, gallons or liters. Each unit has a long-life, field-replaceable, top-load battery, a ½”- ball-bearing swivel and a locking trigger with built-in trigger guard. Lincoln St. Louis, MO For more info, enter 48 at www.LMTfreeinfo.com www.LMTinfo.com | 35
PROBLEM SOLVERS
Reduced-Odor, Multi-Tasking, Semi-Synthetic Metalworking Fluid
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aster Chemical is offering TRIM® SC520, a semi-synthetic metalworking fluid that incorporates a proven EP-additive package to control built-up edge and improve tool life. The manufacturer notes that it performs well in multimetal, multi-operational job shops, and has the wetting and cooling characteristics necessary for excellent machining high-speed i results l on hi h d milling and turning operations. It controls chip welding on soft, gummy materials like aluminum, and rejects tramp oils rapidly. This fluid is compatible with a wide range of materials, including aluminum alloys, cast iron, steels and copper, as well as most plastics and composites.
B i IIsolator Bearing l BBrandd Under New Ownership
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aukesha Bearings, an operating company of Dover Corporation, has acquired Inpro/Seal Company, the leading designer and manufacturer of bearing isolator technologies, effective December 30, 2009. The acquisition adds adjacent product lines to Waukesha’s already strong bearing solutions for oil & gas and power generation markets. To date, nearly 4 million Inpro/Seal Bearing Isolators have been installed in rotating equipment throughout the world. Waukesha Bearing Corp. Pewaukee, WI For more info, enter 51 at www.LMTfreeinfo.com
Master Chemical Corp. Perrysburg, OH For more info, enter 49 at www.LMTfreeinfo.com
Extended-Life Cordless Grease Guns he M12TM Cordless Grease Gun from Milwaukee Electric Tool is part of the company’s LITHIUMION system. Capable f of delivering 8000 psi max operating pressure for heavy-duty applications, it dispenses up to seven grease cartridges per battery charge. The unit comes standard with a high-capacity LITHIUM-ION battery that, the manufacturer notes, can double the performance of the user’s other M12TM tools. Additional features include a lightweight, ergonomic handle design, onboard hose storage and shoulder strap loop.
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Milwaukee Electric Tool Corp. Brookfield, WI
Self-Lubricating Composite Reduces Blow-Mold Maintenance
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ohlox™, a selflubricating thermo composite material designed for blow-mold parts, was created to reduce weekly maintenance on the molds. The material’s low coefficient of friction helps blow-mold parts move freely without the use of lubrication, eliminating the need for mold re-greasing. New greasefree parts include wear rings for mold bottoms and female studs. Patented by Sidel, this technology is available as an option for most new molds and can be adapted to several existing molds for all types of the manufacturer’s blow molders. Sidel Norcross, GA
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36 | LUBRICATION MANAGEMENT & TECHNOLOGY
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INFORMATION HIGHWAY For rate information on advertising in the Information Highway Section Contact your Sales Rep or KATHY JAROS at: Phone: (847) 382-8100 x117 / Fax: (847) 304-8603 / e-mail: kjaros@atpnetwork.com
Web Spotlight: LUBRICATION MANAGEMENT & TECHNOLOGY
NSK Corporation offers over 100,000 different types of bearings, linear motion and automotive component products and ensures maximum uptime with industry-specific solutions and comprehensive services that ensure bearings are being installed and maintained properly. Learn more about NSK’s Asset Improvement Program and world-class components at www.us.nsk.com. For more info, enter 76 at www.LMTfreeinfo.com www.us.nsk.com
NEW LOOK! LMTinfo.com, the newly redesigned Website of LUBRICATION MANAGEMENT & TECHNOLOGY, serves the business and technical information needs of engineers, managers, and technicians who design, troubleshoot, and maintain lubrication and fluid power systems and buy and specify lubricants and fluids. It features information on best practices for managing these systems and the industrial machinery and mobile equipment that utilize them. LMTinfo.com is the one-stop shop for all real-world lubrication professionals, now offering full article archives, enhanced training pages, a comprehensive events calendar and business directory, and more! For more info, enter 71 at www.LMTfreeinfo.com www.LMTinfo.com
The goal of MT-online.com is quite simple: to help plants and facilities leverage their increasingly precious time and resources and achieve world-class status via state-of-the-art asset management strategies, technologies and methodologies.. For more info, enter 72 at www.LMTfreeinfo.com www.MT-online.com
Baker Instrument Co. manufactures high-voltage test equipment for the safeguard of electric motors. Its surge and hipot testers verify insulation integrity by finding weaknesses in turn-to-turn, phase-tophase and coil-to-coil insulation systems within the motor. For more info, enter 74 at www.LMTfreeinfo.com www.bakerinst.com
REGISTRATION NOW OPEN!
LUDECA, INC. - Preventive, Predictive and Corrective Maintenance Solutions including laser shaft alignment, pulley alignment, bore alignment, straightness and flatness measurement, monitoring of thermal growth, online condition monitoring, vibration analysis and balancing equipment as well as software, services and training. For more info, enter 73 at www.LMTfreeinfo.com www.ludeca.com
JANUARY/FEBRUARY 2010
The Maintenance & Reliability Technology Summit is the #1 learning venue and source of practical solutions for anyone concerned with the reliability, maintenance and the overall capacity assurance of critical equipment systems in a plant or facility. Mark your calendars! MARTS 2010 is taking place April 27-30, 2010 at the Hyatt Regency O’Hare in Rosemont, IL. For more info, enter 75 at www.LMTfreeinfo.com www.MARTSConference.com
Hy-Pro Filtration is a total solutions provider for hydraulic and lubrication fluid contamination challenges. The range of products includes DFE rated filter elements, filter assemblies, mobile filter carts, vacuum dehydration units, breathers, coalesce skids and fluid analysis equipment. For more info, enter 77 at www.LMTfreeinfo.com www.filterelement.com
IMI Sensors manufactures ICP®, 4-20 mA and high temperature vibration sensors and transmitters, smart vibration switches, bearing fault detectors, reciprocating machinery protectors, signal conditioning and accessories for predictive maintenance, equipment protection, condition monitoring and machinery vibration analysis. Sensors monitor bearings, gears, motors, spindles, reciprocating compressors and other rotating machinery in harsh environments. For more info, enter 78 at www.LMTfreeinfo.com www.imi-sensors.com
Alignment Supplies, Inc. offers a variety of laser alignment and measurement systems. With EasyLaser measurement products we can offer a solution for your application and alignment needs. For more info, enter 79 at www.LMTfreeinfo.com www.alignmentsupplies.com/
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Index ADVERTISER
JANUARY/FEBRUARY 2010 Volume 11, No. 1
WEBSITE
•
CIRCLE #
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
PAGE #
1300 South Grove Avenue, Suite 105 Barrington, IL 60010 PH 847-382-8100 FX 847-304-8603
ATP Lists ....................................... www.atplists.com ......................................... 67..............UM5
www.LMTinfo.com
Engtech Industries Inc................. www.engtechindustries.com....................... 66..............UM4
SALES STAFF
Hy-Pro Filtration ......................... www.hyprofiltration.com............................ 65................... 13
OH, KY, TN 135 N. Rocky River Road Berea, OH 44017 440-463-0907; Fax 440-891-1254 JOHN DAVIS jdavis@atpnetwork.com
Inolex Chemical Company ......... www.inolex.com........................................... 62..................... 4 Inpro/Seal Co................................ www.inpro-seal.com/cdr ............................. 81..................BC MARTS ......................................... www.MARTSconference.com .................... 23,27 ........68,70 NSK Corporation ........................ www.thinknsk.com ...................................... 61..................... 2 Nuts, Bolts and Thingamajigs..... www.nutsandboltsfoundation.org ............. 63..................... 7 Royal Purple ................................. www.royal-purple-industrial.com ............. 80................... 39 Scalewatcher ................................. www.scalewatcher.com................................ 69................... 25 WD-40 .......................................... www.wd40.com ............................................ 64......... Insert, 9
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AL, CA, CO, DE, FL, GA, MD, MS, NC, NJ, SC, PA, VA, WV, DC 1750 Holmes Drive West Chester, PA 19382 610-793-3093; Fax 610-793-3094 JIM HANLEY jhanley@atpnetwork.com
AR, AZ, NV, NM, OK, UT 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 847-382-8100 x116; Fax 847-304-8603 BILL KIESEL bkiesel@atpnetwork.com
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.
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, KS, LA, MI, MN, MO, OR, TX, WA,WI, BC 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 847-382-8100 x108; Fax 847-304-8603 TOM MADDING tmadding@atpnetwork.com IA, MT, NE, ND, SD, WY, AB, MB, SK 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 847-382-8100 x106; Fax 847-304-8603 ARTHUR L. RICE arice@atpnetwork.com
Classified Advertising/Electronic Sales: 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 847-382-8100 x117; Fax 847-304-8603 KATHY JAROS kjaros@atpnetwork.com
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LUBRICATION MANAGEMENT & TECHNOLOGY
JANUARY/FEBRUARY 2010
“...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.
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Inpro/Seal Company has been in the business of bearing protection for rotating equipment for 32 years and counting. We have been supplying bearing protection for the IEEE-841 motors since they were first introduced. It is only logical that we would expand into the field of motor shaft current mitigation to protect motor bearings. The CDR is:
ROBUST Machined entirely out of solid corrosion resistant
and highly conductive bronze, the CDR/MGS is capable of carrying 12+ continuous amps. They are made exclusively by the Inpro/Seal Company in Rock Island, IL, to ensure consistent quality and same-day shipments when required.
RELIABLE The CDR and MGS (Motor Grounding Seal)
products were developed in our own Research and Experimentation Laboratory and then extensively tested and evaluated by professional motor manufacturing personnel. Our standard guarantee of unconditional customer satisfaction of product performance applies. We stand behind our products.
REALISTIC When you order a CDR or MGS from Inpro/Seal, you are assured of the complete responsibility for technology and performance from a single source. We want to earn the right to be your first choice for complete bearing protection.
For more information visit www.inpro-seal.com/CDR or contact 800-447-0524 for your Inpro/Seal Representative.
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