Académique Documents
Professionnel Documents
Culture Documents
10
COVER STORY
Machinery
Machinery Lubrications annual Lube Room Challenge showcases exceptional lube rooms submitted by readers who
have transformed their lubricant storage and dispensing methods to best practices.
CERTIFICATION NEWS
Theres a negative bias toward the BandAid solution in engineering, but there
are times when a convenient shortcut is
needed. The trick is being able to recognize when a Band-Aid solution
is appropriate and when it is not.
More
44
HYDRAULICS AT WORK
24
34
AS I SEE IT
OIL ANALYSIS
Lubrication
46
48
LUBE-TIPS
Our readers provide excellent advice on a
host of lubrication-related issues.
While gasoline and diesel engine oils generally have the same anatomy
and are formulated from the blending of base oils and additives, they
actually are quite different when examining the lubricants required
performance for each engine type.
Editorial Features
Departments
20 GET TO KNOW
32 NOW ON MACHINERYLUBRICATION.COM
18 PRODUCT NEWS
22 CROSSWORD PUZZLER
30 BOOKSTORE
40 PRODUCT SUPERMARKET
42 TEST YOUR KNOWLEDGE
Contamination Control
AS I SEE IT
JUSTIFYING the
COST of EXCLUDING
a GRAM of DIRT
escalate the ingress. Air typically enters through vents and breathers,
past shaft seals, unsealed hatches and cleanout covers, and other
unprotected machine openings.
New oil is also a source of contamination, as are invasive inspection and repair activities. Hydraulic systems using linear actuators
receive a high percentage of their particles from ingression past worn
wiper seals and rod seals. Of course, mechanical wear, corrosion,
oil degradation and surface exfoliation are also common sources of
solid particles.
The cost of contaminant exclusion relates to both retrotted
hardware and routine maintenance tactics for blocking contaminant
entry. These costs include such things as transfer cart ltration, proper
breathers on machines and lubricant storage vessels, improved seals
(labyrinth, for instance), tighter system closures, greater awareness
and care during internal
inspections and part
replacement (education
and better procedures/
tools), routine cleaning of
www.MachineryLubrication.com
Machinery
Lubrication
PUBLISHER
Mike Ramsey - mramsey@noria.com
FIVE CLEANEST
MIDDLE SEVEN
FIVE DIRTIEST
Total Particles
980
33,000
Total Nonmetallic
911
20,643
162,632
Total Metallic
69
12,357
Percent Metallic
7%
37%
42%
GROUP PUBLISHER
Brett OKelley - bretto@noria.com
EDITOR-IN-CHIEF
Jason Sowards - jsowards@noria.com
SENIOR EDITOR
Jim Fitch - jtch@noria.com
TECHNICAL WRITER
Jeremy Wright - jwright@noria.com
CREATIVE DIRECTOR
Ryan Kiker - rkiker@noria.com
GRAPHIC ARTISTS
Steve Kolker - skolker@noria.com
Gustavo Cervantes - gcervantes@noria.com
Julia Backus - jbackus@noria.com
ADVERTISING SALES
sales@noria.com
Phone: 800-597-5460
MEDIA PRODUCTION MANAGER
Rhonda Johnson - rjohnson@noria.com
CORRESPONDENCE
You may address articles, case studies,
special requests and other correspondence to:
Editor-in-chief
MACHINERY LUBRICATION
Noria Corporation
1328 E. 43rd Court Tulsa, Oklahoma 74105
Phone: 918-749-1400 Fax: 918-746-0925
E-mail address: jsowards@noria.com
www.MachineryLubrication.com
|3
AS I SEE IT
4|
The Tally
As you can see, many variables and
factors inuence the cost of excluding a
gram of dirt. However, there are many more
costly consequences associated with failing
to exclude. The quote at the beginning of
this article claimed a 10-to-1 difference. On
closer inspection, the actual difference is
arguably more than 100-to-1 when taken
across the life of the machine.
www.MachineryLubrication.com
Hydraulics
HYDRAULICS
AT WORK
BRENDAN CASEY
HOW a BAND-AID
SOLUTION can FIX
your HYDRAULICS
problems
Last year there was a book on the New York Times bestseller list called Have a New Kid by Friday. It was written by
psychologist Kevin Leman and has sold more than 400,000 copies.
To capitalize on this books success, Leman is hurrying out another
titled Have a New Husband by Friday.
Lemans literary success is testimony to the appeal and popularity of the quick (and effortless) x for a problem. Dont get me
wrong, I have no issue with the concept of a quick x where one is
legitimately available, but as a parent I know you cant replace a
childs bad behavior with good in seven days. Most parents cant
even read the book in seven days. As a husband, I also know my bad
habits wont be eliminated in seven days. My wife may well be able
to replace me in seven days but not change me.
Any thinking person knows instant results for anything but the
simplest of problems are an illusion, but this is not to say that the
notion of a quick x or even a Band-Aid solution doesnt have its place.
Last week I had a conversation with a longtime client whos been
having a long-running battle with the manufacturer of a hydraulic
machine he purchased three years ago. The machine has never
6|
91%
81%
HYDRAULICS AT WORK
8|
www.MachineryLubrication.com
10 |
www.MachineryLubrication.com
evidence of how their lubricant storage and dispensing methods have been
transformed. The following entries showcase how designing a proper lube
room is one of the rst steps to achieving lubrication excellence.
Agrium
Tim
m JJohnson at Agriums Conda phosphate operation in Soda Springs, Idaho, was just waiting for a chance to show the improvement that had
bbeen made to his plants lubrication program. The photos below illustrate just how far the company has come in a relatively short period of time.
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One of the companys previous lube rooms used typical barrel racks,
no desiccant breathers or oil filtration. Oil inventory space was
small, forcing some stock to be left outside exposed to the elements.
r
te
Af
The new oil filtration and dispensing room allows oil to be delivered directly to the inside of the room, avoiding hazards and
exposure to the elements. This room is climate-controlled and
large enough to fit all oils that are used in the plants equipment.
r
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Af
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The old-style lube room required all oil drum delivery from
vendors to be done outside and then moved through a narrow
doorway, exposing personnel to hazardous conditions.
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Af
The view from the inside of the new oil filtration and dispensing
room shows oil filter units, dispensers, desiccant breathers and
oil inventory. Instructions for the operating filter system are
available on the bulletin board. The floor is covered with a nonslip epoxy coating, which improves the safety of personnel and is
tough enough for the heavy loads from the oil drums. Desiccant
breathers are installed on all oil barrels when put into service.
When an empty barrel is replaced, the new oil is allowed to
multi-pass in the filter system for two hours before dispensing.
This results in typical ISO-rating improvements from 20/17/14 at
the beginning of multi-pass to 15/14/13 when complete.
This is a close-up of the oil dispenser. Each type of oil has been
tagged on the on/off switch, fill piping and at each drum filter.
The dispenser tray is engineered to hold more than 55 gallons in
the event of an upset. Also, the floor is designed to contain all oil
stocked inside this room in case of accidental spills.
www.MachineryLubrication.com
www
MachineryLubrication com
| 11
COVER STORY
Cargill
Cargills facility in Newark, Calif., follows best practices by filtering and
dispensing in designated containers. Previously, lubricant was dispensed in whatever container was available. Now color-coded containers with like-colored tags are
posted at each piece of equipment.
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enabling all the new oil and uids to be ltered. Hydraulic uids are
ltered to an ISO 4406 cleanliness standard of 17/15/13. Motor oil
and transmission uids are kidney-looped with 10-micron lters for
a period of up to 24 hours. Fluids are then dispensed through Graco
pumps and separate 10-micron lter assemblies. Transfer carts are
also equipped with the same quick couplers, and they receive the
same ltering process before they are used.
To minimize contamination, the vents from the IFH tanks are
independently plumbed to a centralized overow container system,
which is vented with a desiccant lter. Transferring the uids
consists of a sequence that uses different types of pumps specic
for a type of uid being pumped. Hydraulic and specialty uids are
dyed to specied colors for easy identication. EWEB uses a series
of containers that are also color-coded and labeled for the same
specic uids. Spill containment is utilized for all storage tanks and
racks. The lube room also includes spill clean-up materials, spill
dikes and absorbent wipes.
The room has been equipped with an emergency shower and
eye-wash station. The facility is certied in Oregon as an Eco-Biz
facility, meaning that it has reached the highest standards in minimizing its environmental impact. EWEB employees have taken pride
in implementing proper material-storage methods and hazardous
waste-management techniques within the lube room.
12 |
www.MachineryLubrication.com
COVER STORY
MillerCoors
MillerCoors first upgraded its lube room in Golden, Colo., several
M
years ago with some significant changes. Although the more recent upgrades
are minor in comparison, they are still important in the companys journey
to world-class lubrication. The MillerCoors lube room now has an exhaust
ventilation system, fire-protection system and explosion-proof lighting
fixtures. A training room has been created specifically for lubrication with
a 3-hour class offered. A bi-weekly Lube-Tips style e-mail is sent out
to all the packaging teams on best lubrication practices and lubrication
safety issues. The e-mails provide a great way to keep people thinking about
lubrication and its importance to the reliability of the equipment.
re
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te
Af
Oil drum transfer pumps were often left in poor environments (left)
where they could be exposed to contaminants. A storage drum for
the pumps was provided to keep them cleaner and in one place
(right). There are also separate hoses to avoid cross-contamination
of lubricants. Both the pumps and the hoses have identification tags.
te
Af
This old drum pump setup (left) had basic transfer pumps.
Although breathers were later installed on each drum, the oil was
still not being filtered, and the operators had to hook up an air
hose to the pumps. No 5-S visuals were in place. The picture on
the right shows the new pump systems with 10-micron filters and
5-S visuals on the floor with oil identification placards on the wall
behind each drum.
Be
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fo
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te
Af
This old wooden workbench (left) was being used for filling Oil
Safe secondary containers and for cartridge replacement of grease
guns. It was replaced with a stainless-steel table (right) similar to
those used for food preparation in restaurants. It provides a cleaner
setting to do this work.
14 |
SSeptember
b -O
October
b 2011
www.MachineryLubrication.com
M hi
L bi i
Georgia-Pacific
Initially, the oil storage room at the Georgia-Pacic mill in
In
Muskogee, Okla., needed a lot of attention.
When the room was overhauled, an HVAC unit was installed
to maintain room temperature, the entire room was cleaned and
repainted, new lighting was installed, new cabinets for equipment
lters and oil transfer pumps were put in, press lters were added to
clean the oil before it enters storage totes, new oil containers were
purchased and proper labelling was instituted.
The plants next steps toward achieving lubrication excellence will be to change from a 10-micron filter to a 5-micron
filter to improve particle counts, implement monthly preventive
maintenance, train all operations and maintenance staff on the
fundamentals of lubrication, revise the sampling program and
install proper oil sampling ports on the equipment.
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www.MachineryLubrication.com
After the lube room was modified, the condition of the storage room and its
contents were dramatically improved.
| 15
COVER STORY
Power Partners
Power Partners Inc. in Athens, Ga., never really had a lube storage room, but
company officials thought they were fine until they read a few articles in Machinery
Lubrication and attended a Reliable Plant Conference. They quickly realized they
had a big problem.
The company has come a long way over the last 14 months. While there are a
few more things they want to accomplish, they are extremely proud of their efforts.
With the new lube room and enhanced policies and procedures that go with it,
Power Partners has realized an annual cost savings of more than $28,000. Factor in
the other reliability programs they have implemented in the shop, and the annual
cost savings total more than $46,000.
Rio Tinto transfers oil from 55-gallon barrels into totes, which
are then filtered and fitted with desiccant breathers.
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Temple-Inland
The
Th
h Temple-Inland lube room in Cumberland City, Tenn.,
boasts drums with air-powered pumps and 5-micron lters, sample
ports and quick disconnects on the drums and Oil Safe containers.
Oil is ltered as the Oil Safe containers are lled, and the lids do not
need to be removed to ll. The pumps can also be utilized to polish
the oil before use.
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Rio Tinto
The
Th
h lube room at Rio Tinto Minerals in Boron, Calif., was built
in 2007 and has been maintained thanks to the hard work of the
lube crew and support from upper management. The company
transfers oil from 55-gallon barrels into totes using dedicated lter
carts. The totes are then ltered to achieve the desired ISO standard
and tted with desiccant breathers. Oil samples are taken monthly
to verify continued compliance. All oil is dispensed into color-coded
containers, which are cleaned after being used.
16 |
te
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Af
Af
Cerveceria Bucaramanga
The
Th
h initiative to modify the lube room of Cerveceria Bucaramanga, a SABMiller plant in Colombia, began after company personnel
read an article in Machinery Lubrication on the advances of Clopay
Plastics lube room. They felt encouraged to improve their lube room
and received advice from Noria Latin America as well as a lot of training,
which was important to their success. They also have included several
practices from the Oil Analysis Basics book by Noria Corporation.
With the improvements, Cerveceria Bucaramanga now has an oil
cleanliness level of ISO 4406 (14/12/8) on its oil
storage tanks. The lube tasks also are ergonomic
and easier to perform, having been optimized by
more than 15 percent. The workers feel proud of
this and take great care to maintain this goal and
even improve upon it.
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These photos show the old Cerveceria Bucaramanga lube room before the improvement
project began.
www.MachineryLubrication.com
| 17
PRODUCT NEWS
MOTOR OIL
Valvolines NextGen motor oil features a new formula made from
50-percent recycled oil to deliver 100-percent engine protection.
Developed through years of research, technology and innovation
from scientists coupled with improvements in the oil re-rening
process, NextGen motor oil is good for engines and the environment, exceeding industry specications with reduced environmental
impact compared to non-recycled motor oil.
Valvoline
www.valvoline.com
800-832-6825
FILTER PACK
FOOD-GRADE LUBRICANTS
The new UltraLube food-grade lubricants not
only meet NSF standards but also offer four
times the natural lubricity of petroleum-based
oils. These bio-based oils instantly penetrate
into areas where lubrication is needed most
and create a long-lasting bond to metal and
plastic surfaces. Specically formulated with
EP additives to provide protection under heavy
shock loads, UltraLube H1 Food Machinery
Grease is ideal for lubricating bearings, gears
and machine slides. It also offers superior
adhesion and protects all ferrous metal
components from rust and corrosion.
The new FilterPak from Y2K Fluid Power incorporates a sturdy diamond-plate aluminum frame,
a milled-aluminum grip and a 1-hp Viking pump
with a capacity of 2.5 to 5 gallons per minute. It
also sports a visual indicator with 50 psi bypass,
a 10-foot swivel discharge hose, a 7-foot swivel
suction hose, a 3-foot electrical cord and an on/
off switch.
Y2K Fluid Power
www.y2kfluidpower.com
888-925-8882
UltraLube
www.UltraLube.com
800-545-1689
PORTABLE
LUBRICATION SYSTEM
CRC
www.crcindustries.com
800-556-5074
18
METAL-WORKING FLUID
Developed for use in high-pressure applications, the new Cimperial 1072-HFP uid from Cimcool is recommended for all metals and
heavy-duty machining operations including turning, drilling, tapping,
reaming, gear cutting and broaching. It prevents, controls and reduces
foam even when uids are used in high-pressure delivery systems.
Cimperial 1072-HFP also provides excellent lubricity, extends uid life,
is operator and machine friendly and helps prevent corrosion on parts
and machine components.
Cimcool
www.cimcool.com
888-246-2665
PRESSURE SWITCH
SKFs new DSB1 pressure switch for monitoring centralized lubrication systems is designed to attach directly to the lubricant line.
This position is in contrast to conventional pressure switches that
branch off to a cul-de-sac where grease is never mixed, which can
form a blockage, harden and render the pressure switch ineffective.
The new DSB1 pressure switch is installed before the last distributor,
where the grease consumed by the distributor constantly ows past
the switch, effectively preventing blockage.
SKF
www.skf.com
267-436-6000
FOOD-GRADE
COMPRESSOR LUBRICANTS
Ultrachem has developed a new line of Omnilube food-grade rotary screw and reciprocating air-compressor lubricants with improved
wear, oxidation and lubricity. These fully
synthetic compressor oils are formulated from
high-quality polyalphaolen (PAO) base oils
with a proprietary additive package to achieve
long life. The oils meet all of the requirements
of the USDA and FDA H-1 regulations, and
conform to NSF requirements. They are also
approved for Kosher use.
Ultrachem
www.ultracheminc.com
302-325-9880
www.MachineryLubrication.com
19
ML
GET TO KNOW
Christensen
Directs Lube
Crew at
Kennecott
Utah Copper
ML
CROSSWORD PUZZLER
Get a Printable Version
of This Puzzle Online at:
MachineryLubrication.com/puzzle
4
5
6
7
8
9
10
11
12
13
14
15
16
17
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ACROSS
1 A process for treating raw extracted base stocks with
hydrogen to saturate them for improved stability.
DOWN
2 A measure of the total acidity or basicity of an oil.
3 An engine design in which oil is not retained in a pan beneath
the crankshaft.
22 |
www.MachineryLubrication.com
OIL ANALYSIS
BY: BEATRIZ GRAA, INEGI; JORGE SEABRA, FEUP; AND PINTO SOUSA, PORTUCEL
Lubricant
Analysis
in
Steam
Turbines
T
Oil Degradation
I
up
Gro
s
Oil
Time
24
Ferrography Analysis
Ferrography is a technique that provides valuable information
about wear evolution in machinery through analysis of a representative lubricant sample. Developed by Vernon Westcott at
www.MachineryLubrication.com
OIL ANALYSIS
the U.S. Navy in the 1970s as a conditionmonitoring technique, it has been applied
by hundreds of worldwide users to all
kinds of lubricated systems.
The potential of ferrography is not
only limited to predictive maintenance
strategies. Its important contribution to
tribology studies, by assisting in a better
understanding of the wear mechanisms
and of the lubricant effects on the contact
surfaces, turns this versatile technology
into one of the most powerful diagnostic
tools to assess machine health, providing
valuable information about the past,
present and future condition of the
machines lubricated components.
The test procedure is lengthy and
requires the skill of a well-trained analyst.
As such, there are signicant costs in
performing analytical ferrography not
present in other oil analysis tests. However,
if time is taken to fully understand what
analytical ferrography uncovers, most
agree that the benets signicantly
outweigh the costs and elect to automatically incorporate it when abnormal wear
is encountered.
Oil Flow
Slide
Magnet
Large particles deposit at
entry point where the
magnetic pull is the weakest.
Jan-10
Oct-09
Jul-09
May-09
Jan-09
45.9
0.14
606
3.2
400/0
242
45.8
0.08
442
4.4
50/0
238
44.3
0.12
368
4.2
300/0
229
45.9
0.1
305
8.4
190/0
232
46.6
0.06
>1200
2.4
470/0
210
<0.05
7
23/21/17
147
3.7
22/19/16
65
5.8
22/19/16
179
9.5
23/23/22
<0.05
7.5
23/21/18
95
<10
62.2
19.7
67
4
70
-
REFERENCE
PHYSICAL PROPERTIES
Viscosity@ 40C [cSt]
41.4-50.6
Acid Number [mgKOH/g]
0.3
Demulsibility [s]
300
Air Release [min.]
5
Foam, seq. I [ml/ml]
450/0
Flash Point [C]
>185
CONTAMINATION
Water Content [ppm]
100
Insolubles [mg/100ml]
10
ISO CODE
18/16/12
VARNISH POTENTIAL
Amine %
>25
RULER
Phenolic %
>25
Analytical results from standard oil tests show the oil viscosity and acid number are within
the range over the time period.
27
OIL ANALYSIS
Used Oil
phenol
inhibitors
(depletion)
New Oil
oxidation and
thermal
degradation
28
Filter Analysis
Static-generated sparks are very
common incidents in the ltering systems
of turbo-generators. This is a phenomenon of molecular friction occurring as
oil ows through small clearances, such
as the lter media. Since oil and lter
media are both dielectric, this electrical
energy builds until a limit is reached,
and then sparks are released in the
lubrication system in the direction of the
ground. These electrical arcs can have
an extremely high, localized temperature
(about 20,000 degrees C), instantly
cracking the hydrocarbon molecule.
Since spark discharges generated
on lters and other locations are a key
root cause of varnish, and some of the
previous oil analysis results conrmed
that (through additive depletion and
high particle counts), one of the duplextype lters was dismantled and analyzed
through an optical microscope.
Evidence of electric discharge can be
easily seen through microscopic inspection of the lter media, lter core, lter
meshes and from debris carried away from
the lter.
Figure 5 shows one of the plugged
lters changed in a periodic maintenance
action due to a plugged lter alarm, with a
microscopic view of the lter mesh. As can
be seen, black and brown shiny deposits
(sludge and varnish) are present in high
concentrations, clogging the lter mesh.
The solvent used for cleaning the lter
mesh was collected and used to prepare
a ferrogram where signicant amounts
of ferrous spherical wear particles were
identied (Figures 6 and 7). One source of
spherical ferrous debris is the erosion wear
activated by electrical discharges. The high
temperatures attained by the sparks on
the steel surface thermally liquefy the steel
debris, which acquires a spherical shape
due to rapid cooling under the action of
surface tension.
The microscopic analysis of the lter
core surface showed several small, circular
burned holes left by the high-temperature
spark discharges on the metal surfaces.
In conclusion, turbine oils must be
well-maintained to extend their service life
www.MachineryLubrication.com
Figure 5. Plugged filter from the turbogenerator and filter mesh with black and
brown shiny residue (200x magnification)
H Y D R O F I N
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29
BOOK STORE
Format: DVD
Fo
Publisher: Noria
Corporation
Anyone responsible
for the maintenance,
operation and reliability of electric motors
w
will benet from this
training video. It provides
plant personnel with an overview of the best practices for lubricating electric motor bearings. You can use the video to train
operators, lubrication technicians, mechanics, electricians and
maintenance personnel for years to come.
Authors: D. M. Pirro
and A. A. Wessol
This newly revised and expanded
reference book emphasizes the
need for lubrication and careful
lubricant selection. Thoroughly
updated and rewritten, the
Second Edition of Lubrication
Fundamentals discusses product
basics, machine elements that
require lubrication, methods
of application, lubrication, lubricant storage and handling,
lubricant conservation and much more.
Card
www.MachineryLubrication.com
ML
NOW ON
MachineryLubrication.com
Every day, thousands of industrial professionals from around the United States
and around the world visit the Noria Corporation Web sites. See what makes these sites so
popular and informative. Visit us today and every
day at www.machinerylubrication.com.
Automated Lubrication
Benefits and Design Options
While grease guns and manual lubrication seem
to get the job done for many maintenance operations, their benets often cannot compare to those
provided by an automated lubrication system in
terms of productivity, environmental issues and
worker safety. An automated lubrication system
helps to prevent bearing failure by providing the
right amount of the right lubricant at the right time
to the right place. Find this article in the Bearing
Lubrication section on the ML site.
32 |
www.MachineryLubrication.com
| 33
ML
CERTIFICATION NEWS
Ten years ago, ICML held its very rst examination session
in Biloxi, Miss., changing the course of the machinery
lubrication industry. In the small pioneering group of only six
practitioners stood Rendela Wenzel, who took it upon herself to
be part of the very rst group of ICML candidates. By successfully completing that rst ICML exam, she not only became one of
the rst ICML-certied professionals but also the very rst ICMLcertied female practitioner.
In celebration of ICMLs 10th anniversary, we wanted to tell
Wenzels remarkable story.
Wenzel remains one of a still few female reliability engineers and
machinery lubrication practitioners. Although part of an ICMLaward-winning team, she was one of the people ICML recognized
at the 2011 Reliable Plant Conference in Columbus, Ohio, as
embodying the spirit of ICML in the area of certication.
Wenzel is currently the corporate lubrication technical team
leader for Eli Lilly. She has 14 years of experience in maintenance
and operations, troubleshooting maintenance issues, implementing
Rendela Wenzel (center) and her team from Eli Lilly were the recipients of the 2008
John R. Battle Award.
34 |
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| 35
CERTIFICATION NEWS
Along with Kurt Bittner of PSEG Nuclear and Scotty Lippert of Clopay
Plastics, Wenzel was honored at the 2011 Reliable Plant Conference in
Columbus, Ohio, as representing the spirit of ICML.
which was later replicated at Melrose Park and also the Huntsville,
Ala., facility. She was able to transform the culture of reactive maintenance into a proactive environment that valued reliability activities
and wanted them integrated into their PMs and daily operator tasks.
I took the structure of the existing vibration program as a
model and integrated an oil and thermography program into the
PM tasks and jobs of the craftsmen, Wenzel notes. This was a
daunting task in a union environment. Oil analysis was an extra
task for the machine repairmen, and thermography was an extra
task for the electricians.
Oil analysis became something that Wenzel and her team did
routinely over the next three years to diagnose many potential failures, which resulted in greater uptime.
I implemented the changes in very small increments, including
oil leak-detection devices such as a UV light and dye that could
nd oil leaks, she says. One leak in our facility equated to more
than $42,000 per year in savings. I decreased oil consumption by
25 percent and eliminated time-based oil changes. I added proper
sampling ports, revamped our lube room and instituted an operator machine-cleaning program. The production on our bottleneck
step increased by 10 percent, which eliminated one shift per week
of overtime.
36 |
www.MachineryLubrication.com
www.MachineryLubrication.com
| 37
CERTIFICATION NEWS
38 |
Energy Northwest
Jeff Scott, MLA II
Entergy, Inc.
James R. Fraser, MLA II
Exelon Corporation
Steven Wood, MLA I
Filtramax
Francois Lepine, MLA I
First Energy Corp.
James E. Black Jr., MLA II
Scott K. Graton, MLA II
Florida Power & Light
David LaGuardia, MLA II
Chevron
Hilary A. Fernando, MLT II
Aimee Hawkins, MLT II
Sorasak Saengwanit, MLT II
Alexander William Stephenson, MLT II
Georgia-Pacic
Greg Van Camp, MLT I
Shawn M. Day, MLT I
Dennis R. Leach, MLT I
Alex Moses, MLT I
William R. Nichols, MLT I
Wayne Noakes, MLT I
William Paul Terrell, MLT II
Jason Vance, MLA I & MLT II
GenOn Energy
Ryan Bailey, MLT I
DuPont
Erica R. Cross, MLT I
Larry E. Kunze, MLA II
Richard Lipscomb, MLT I
Aaron P. Moore, MLT I
John Edward Nesselroad, MLT I
Brian Thompson, MLT I
IPM
David Williams, MLT I
Eastman Chemical
Earl F. Edens, MLA III
Emirantes Aluminium
Mohammed Yousef Abusheikha,
MLA I
ITW Polymex
Ricardo Joel Duarte Loperena, MLT I
Aldo Guatemala, MLT II
Edgar Guzman Lopez, MLT I
JM Huber
Dana Rowan, MLT I
Oil-Dri
Donald K. Everett, MLT I
Kim Robert Jaynes, MLT I
Mitchell Jon Schalk, MLT I
Jim Warden, MLT I
Luminant Power
Jeremy Layne Swanson, MLA III
Overlake Oil
Paul Hawkes, MLT I
Machine Evaluation
Michael E. Thornton, MLT I
Owens Corning
Andrisa Jefferson, MLT I
Petrobras
Julio Cesar L. Alves, MLT I
Solange Virilo Borbily, MLT I
www.MachineryLubrication.com
Rio Tinto
Morgan Hall, MLA I
Brendan Moffat, MLA I
Brian Wagstaff, MLA I
Southern Company
Neal Mac Namara, MLA II
Taylor Enterprises
Thomas J. Loar, MLA II
Teck Highland Valley Copper
Mark Baker, MLA II
Shane Kozoriz, MLA II
Mark Mulroy, MLA II
Temple-Inland Forest Products
William Scott Davis, MLA II
ICML Certifications
LLA I = Laboratory Lubricant Analyst Level I
MLA I = Machine Lubricant Analyst Level I
MLA II = Machine Lubricant Analyst Level II
MLA III = Machine Lubricant Analyst Level III
MLT I = Machine Lubrication Technician Level I
MLT II = Machine Lubrication Technician Level II
www.MachineryLubrication.com
Need to take
an exam?
ICML regularly holds
exam sessions throughout
the United States and the
world. Upcoming dates
and locations for ICML
exams can be found at
www.lubecouncil.org
September - October 2011
| 39
PRODUCT SUPERMARKET
Meltric Corporation
www.royal-purple-industrial.com
888-382-6300
mcrosby@royalpurple.com
www.meltric.com 800-433-7642
mail@meltric.com
www.cannoninstrument.com
800-676-6232
sales@cannoninstrument.com
Analysts, Inc.
Miller-Stephenson Chemical
Company, Inc.
www.analystsinc.com 800-655-4473
orders@analystsinc.com
www.miller-stephenson.com
203-743-4447
UE Systems, Inc.
Summit Varnasolv will alleviate problems from varnish and carbon in your
rotary screw or rotary vane compressor. Clean your compressor while it
is running, no need to disassemble.
Use Varnasolv to clean heat transfer
systems, high temperature chains
and gearboxes.
www.uesystems.com
800-223-1325
info@uesystems.com
www.klsummit.com/varnasolv.pdf
800-749-5823 info@klsummit.com
Castrol Industrial
North America Inc.
877-641-1600
40
www.ifhgroup.com
800-435-7003
info@ifhgroup.com
www.MachineryLubrication.com
www.ccisupply.com/BellUltra
352-291-2300
pwr@c.rr.com
Checkfluid, Inc.
Hornche Corporation
www.checkuid.com 866-652-8728
info@checkuid.com
www.easylube.com
service@easylube.com
One Eye Industries for all your magnetic and industrial ltration needs.
Our ltration solutions have applications in all industries. We manufacture
an extensive product line utilizing new
magnet technology.
PLI LLC
www.oneeyeindustries.com
877-888-8727
info@oneeyeindustries.com
www.memolub.com
800-635-8170
sales@memolub.com
FLUIDALL Solutions
www.FLUIDALL.com
800-849-0591
sales@FLUIDALL.com
www.inolex.com
800-521-9891
lubeinfo@inolex.com
www.MachineryLubrication.com
Harvard Corporation
www.harvardcorp.com 800-523-1327
store.noria.com 800-597-5460
September - October 2011
41
PRODUCT SUPERMARKET
ML
This month, Machinery Lubrication continues its Test Your Knowledge section in which we
focus on a group of questions from Norias Practice Exam for Level I Machine Lubrication Technician and Machine Lubricant Analyst. The answers are located at the bottom of this page.
A)
B)
C)
D)
E)
GARZO, Inc.
www.garzoproducts.com/108.html
713-466-8679
tmpafford@garzoproducts.com
A)
B)
C)
D)
E)
Proactive
Predictive
Preventive
Percussive
Reactive
FLUIDALL Solutions
www.FLUIDALL.com 800-849-0591
sales@FLUIDALL.com
A)
B)
C)
D)
E)
High-pressure hydraulics
Gears
Engines
Turbines
Journal bearings
Noria Corporation
store.noria.com
800-597-5460
Answers: 1-A; 2-B; 3-C; 4-E; 5-A
42
www.MachineryLubrication.com
Lubrication Programs
FROM THE
FIELD
STEPHEN SUMERLIN
6 STEPS
to UPDATE your
LUBRICATION
program
Benchmarking
Lubricant Consolidation
Many times, as a byproduct of the design and engineering phase, lubricant consolidation occurs. This is
important on many levels, as it allows for a clearer picture
of what products need to be purchased, which reduces
purchasing costs, eliminates unnecessary or unused products from
inventory, decreases the likelihood of lubricant cross-contamination
and helps the lubrication team understand which products they
need and why. As the specialized procedures are created during the
design and engineering phase, each lubrication activity should have
the correct lubricant specied. This will help ensure that the technician is using the right product in the right place.
Implementation
Re-benchmarking and
Continuous Improvement
| 45
ML
LUBE TIPS
Readers
Supply Super Solutions
and Sound Suggestions
The Lube Tips section of Machinery Lubrication magazine
features innovative ideas submitted by our readers. Additional tips can be found in our Lube-Tips e-mail newsletter. If you
have a tip to share, e-mail it to us at editor@noria.com. To sign up
for the Lube-Tips newsletter, visit www.machinerylubrication.com
and click on the Newsletters link at the top.
same time degrade another. When specied concentrations of additives become unbalanced, overall oil quality can be affected.
Automotive Lubrication
BACK PAGE
BASICS
Comparing GASOLINE
and DIESEL
ENGINE Oils
Ive been instructing the Fundamentals of Machinery Lubrication course for a few years now, and many times the
course has been the birthplace of the articles Ive written. The questions and discussions in the course are very representative of what
the average maintenance professional is curious about. Most tend
to like the discussions about passenger car and truck oils because
they not only affect them at work but also at home. In fact, I use
this curiosity to my advantage. If I ever notice a subject is starting to
bore an audience, Ill nd a way to incorporate an automotive twist
to it. Soon all the ears seem to perk up. This article is no different. I
plan to explore the similarities and differences between gasoline and
diesel engine oils to appease your curiosity.
Viscosity
Viscosity is the single most important property of a lubricant. When
I am working as a consultant and designing a lubrication program,
one of the rst steps I take is to calculate required viscosities. Getting
the right viscosity is of the utmost importance. The selected viscosity
needs to be pumpable at the lowest start-up temperature while still
protecting the components at in-service temperatures.
Typically, diesel engine oil will have a higher viscosity. If we were
to put this higher viscosity in a gasoline engine, several problems
might arise. The rst is heat generation from internal uid friction.
Ive covered before how this heat affects the life of an oil. A good rule
of thumb is that for every 10 degrees C you increase the temperature,
you cut the life in half. The second problem is the low-temperature
pumpability of this higher viscosity. During cold starts, the oil may
be very thick and difcult for the oil pump to deliver to the vital
engine components in the lifter valley. This most certainly will lead to
premature wear, as the components will be interacting without the
benet of lubrication.
Additive Levels
Diesel engine oil has more additives per volume. The most prevalent are overbase detergent additives. This additive has several jobs,
but the main ones are to neutralize acids and clean. Diesel engines
create a great deal more soot and combustion byproducts. Through
blow-by, these nd their way into the crankcase, forcing the oil to
deal with them. When you put this extra additive load in a gasoline
engine, the effects can be devastating to performance. The detergent
will work as it is designed and try to clean the cylinder walls. This
can have an adverse effect on the seal between the rings and liner,
resulting in lost compression and efciency.
So how do you know if an oil has been designed for gasoline or
diesel engines? When reading a label, look for the API (American
Petroleum Institute) doughnut. In the top
section of this doughnut will be a service
designation. This designation will either
start with an S (service or spark ignition) for gasoline engines or a C
(commercial or compression ignition)
for diesel engines.
www.MachineryLubrication.com
Fundamentals of
MACHINERY
LUBRICATION
Learn Precision Lubrication Skills
For Maximizing Machine Reliability
Heres a Sample
of What Youll Learn:
How to build a safe and effective
lubricant storage and handling program
How to rate filters and select the right
filtration for the job
Lubricant labeling and coding systems -what works and what doesnt
Industrys best procedures for greasing
electric motor bearings
How to get the right lubricant in the
right place at the right time and in
the right amount
Presented by
Noria Corporation
What Industries
Will Benefit?
Aerospace
Automotive Manufacturing
Earthmoving
Food and Beverage
General Manufacturing
Lumber and Wood
Municipal Utilities
Petrochemical
Pharmaceuticals
Power Generation
Primary Metals
Process Manufacturing
Pulp and Paper
Rubber and Plastic
Textile
Transportation
Electric Motors
Compressors
Diesel Engines
Final Drives
Gas Turbines
Gearboxes
Hydraulic Systems
Hydrostatic Transmissions
Paper Machines
Process Pumps
Rolling Mills
Steam Turbines
Blowers/Fans
Extend
Machine Life
By Up To
10X
Improve Health
And Workplace
Safety
A More Effective
Oil Analysis Program
Effectively Troubleshoot
Lubricant-related Machine
Failures
Stop Costly
Bearing
Failures
Compare And Select The
Best Lubricants For The Job
Reduce Energy
And Fuel Costs
Create More Effective
Lubrication PMs
Solve
Annoying
Hydraulic System Problems
Improve Equipment
Meantime Between Failures
Learn how to get data-rich oil samples, exactly where to install oil
sampling ports, and what sampling
equipment should and shouldnt
be used.
Checklists
Look-up Charts
Vendor-neutral
Makes A Difference!
Alfredo Romaro,
Maintenance Technician,
Kawneer Company
Course Outline
Join This List Of World-class
Companies That Have
Benefited From Noria Training
3M
Alabama Power
Alcoa
Alumax
Ameren
American Electric Power
ArcelorMittal
Archer Daniels Midland
Barrick Goldstrike
BHP
Boeing
Boise Cascade
BP
Cargill
Castrol
Caterpillar
Centralia Mining
Chevron
Citgo
Clopay
ConAgra Foods
ConocoPhillips
Constellation Energy
Dow Chemical
Dow Corning
DTE Energy
DuPont
Dynegy
Eli Lilly
Entergy
ExxonMobil
First Energy
Florida Power
Ford Motor Co.
Formosa Plastics
General Electric
General Motors
Geneva Steel
Georgia Pacific
Georgia Power
Goodyear
Great Lakes Chemical
Harley-Davidson
Holcim
Honeywell
Intel
Heinz
Houston Metro Transit
International Paper
Invista
John Deere
Kinder Morgan
Koch Industries
Lockheed Martin
Lukens Steel
M&M Mars
MillerCoors
Michelin
Mosaic
Noranda Aluminum
Nova Chemicals
Owens Corning
OxyChem
Pacific Gas & Electric
Peabody Energy
Pfizer
Powder River Coal
PPG Industries
Procter & Gamble
Progress Energy
Reliant Energy
Rio Tinto
Seattle Times
Seminole Electric
Shell Oil
Southern Company
Temple-Inland
Texaco
Texas Instruments
Toyota
TXU Energy
Unilever
U.S. Army
U.S. Navy
U.S. Postal Service
USG Corporation
Verso Paper
Via Rail Canada
Westinghouse
Weyerhaeuser
Whirlpool
Willamette Industries
Take This
Course Online!
Get Started Now
Visit LubeIQ.com
Trainers
Get Certified!
Level I certification
testing will be held on
the Friday following the
training by the International
Council for Machinery Lubrication.
How To Certify
There are two ways to register for a
certification exam.
Online:www.LubeCouncil.org
Phone: 918-259-2950
Which Certifications?
This course is designed to help you
prepare for the following ICML certification
exams:
Level I Machine Lubricant Analyst
(MLA)
Level I Machine Lubrication
Technician (MLT)
Find out more about these ICML
certification exams at the ICML web site:
www.LubeCouncil.org
What Is ICML?
The International Council for Machinery
Lubrication (ICML) is a vendor-neutral,
not-for-profit organization founded to
facilitate growth and development of
machine lubrication as a technical field of
endeavor. Among its various activities, ICML
offers skill certification testing for individuals in the fields of machine condition
monitoring, lubrication and oil analysis.
Jim Fitch
Jim Fitch, a founder and president of Noria Corporation, is a highly
sought-after consultant and trainer described by his clients as insightful,
dynamic and thorough. He has advised hundreds of companies on
developing their lubrication and oil analysis programs and has taught
more than 400 training courses in more than 20 countries.
Jeremy Wright
Jeremy Wright, a Noria senior instructor, provides a lively interactive
forum for learning at his courses. As a consultant, Jeremy has helped
numerous Fortune 500 companies develop lubrication procedures,
benchmark to best practices and implement world-class lubrication
programs.
Bob Scott
Bob Scott brings to his courses a wealth of in the trenches experience.
His practical how to advice and engaging teaching style consistently
receive top scores from audiences. Youll reap the benefits from his
25+ years of experience with lubricants, lubrication and oil analysis
and come away from the training with solid, practical skills.
How To Take A Multiple-Choice Exam Includes advice from professionals who have
passed ICML certification exams as well as helpful hints for the night prior to the exam, steps to take
before entering the exam room, techniques to manage your time during the exam and advice for
handling different types of questions.
On-Site Training
Lubrication Fundamentals Discusses lubricant basics, machine elements that require lubrication,
methods of application, lubrication, lubricant storage and handling, and lubricant conservation.
We can customize
Fundamentals of Machinery
Lubrication or any of our other courses
to meet your unique needs. Well
provide expert instruction at a time and
place most convenient for your group.
Want to know more? Call 800-597-5460.
Whether you have 5 or 500 people to
train, Noria is the answer.
Oil Analysis Basics Presents the fundamentals of oil analysis for machinery condition monitoring
in an easy-to-understand format. Youll learn everything from how to take a proper oil sample to
how to select a test slate for your applications.
The Practical Handbook Of Machinery Lubrication Once you start reading this book,
you probably wont stop until you finish it. It is that easy to read. Youll find understandable
explanations of how lubricants work, what theyre made of and how they break down.
Topics ranging from engine lubricants to industrial oils and hydraulic fluids are covered.
4 Ways To Register
Online
www.noria.com
Call toll-free!
800-597-5460 Or 918-749-1400
Mail the
registration form!
Training Course
The phone numbers below are for booking hotel reservations only.
To register for the course call 800-597-5460 ext. 143.
Seattle, WA
Branson, MO
Nashville, TN
Las Vegas, NV
September 20-22, 2011
Rio All-Suites Hotel & Casino
3700 West Flamingo Road
Las Vegas, NV 89103
888-746-6955
Company Information
Organization: __________________________________________________________
New Orleans, LA
San Diego, CA
December 6-8, 2011
Courtyard by Marriott
595 Hotel Circle South
San Diego, CA 92018
619-481-5720
Address: ______________________________________________________________
Mail Stop: ____________________________________________________________
City:________________________________ State/Province: ____________________
Registration Information
_________________________________________________
Industry Information
Agricultural
Automotive Manufacturing
Aviation, Rail, Maritime, Trucking
Chemicals & Allied Products
Construction & Allied Products
Consulting/Services/Training
Food Process Manufacturing
Other
Whats Included
Quantity
______
Method Of Payment
Payment is due before
the course
Noria Corporation
ATTN: Training
1328 East 43rd Court
Tulsa, OK 74105
Charge to:
You may cancel your registration prior to the course date or send a
substitute. If you cancel prior to the course date, we will refund
your entire payment, cancel your invoice or, if you prefer, apply
your payment to another Noria program of your choice scheduled
within 12 months of your original event. Please note that if you do
not cancel and do not attend, you are still responsible for payment.
Note: If youve already registered by phone, fax or online, please do not return this form.
Certification Exams
Certification testing is offered by the ICML the morning following
this training course at the same hotel. Please contact the ICML to
register for the certification exam or register online at their web site:
International Council for Machinery Lubrication
Phone: 918-259-2950 Fax: 918-259-0177
E-mail: info@lubecouncil.org Online: lubecouncil.org