CONTENTS

March - April 2010

Features

machinerylubrication.com

Features in Detail
4 As I See It
Ban the Can: Sealable, Reusable
Oil Containers are Smarter Option
Use of traditional oil cans serves as a constant reminder
of maintenance neglect and program stagnation.

8 Viewpoint
Answers to Your Questions About Lubrication-
related Varnish and Varnish Removal
Everyone seems to be talking about varnish. But, what is
it? What causes it? And most importantly, how can it be
prevented and eliminated?

10 The Exponent
Human Factors Engineering:
12 Cover Story The Next Frontier in Reliability
All in the Family Human factors account for 75 to 80% of what goes
Toyotas lift truck manufacturing plant in Columbus, Ind., deserves notice for efforts wrong in the factory. We must align our procedures,
to improve its maintenance personnel, preventive maintenance tasks and equipment training and supervision to address that.
lubrication. Editor-in-chief Paul V. Arnold explains it all in this in-depth case study.
24 Hydraulics at Work
4 32 How to Define a Machines
Optimum Operating Viscosity Range
Determining this range and operating within it is the
ultimate goal for hydraulics users.

26 From the Field

The Rights and Wrongs of Greasing:
From Selection to Application
A proper greasing strategy should include fundamental
methods along with some new technologies.
38
38 Contamination Control
Addressing Oil Contamination
in Paper Machine Applications
This article explains methods to prevent and remove
water contamination from oil.

44 Perspective
The Dos and Donts of Oil Sampling
Jason Kopschinsky provides simple rules for this impor-
Editorial Features Departments tant task.
2 Editors column 38 Contamination 22 Product News
4 As I See It Control 30 Product Spotlight 46 Back Page Basics
8 Viewpoint 42 Certification News 32 Lube-Tips An Overview of Oil Level Sensors
10 The Exponent 44 Perspective 34 Product Supermarket and How They Work
24 Hydraulics at Work 46 Back Page Basics 36 Crossword Puzzler Jeremy Wright helps you better understand sensors for
26 From the Field oil applications.

Machinery Lubrication www.machinerylubrication.com March - April 2010 1

EDITOR
Customer Service: What Are
People Saying About You?
PAUL V. ARNOLD
NORIA CORPORATION
A mericans are lousy at customer service.
That is a generalization, but it is a trait
that is substantiated in survey after survey.
We are used to bad service, but that
doesnt make instances of it any less memo-
rable. I find it difficult to recall what I had for
dinner two nights ago, but I can tell you that I
ordered a cheeseburger with no ketchup and
no mustard from a fast food joint two weeks
ago and received a cheeseburger with double
ketchup and double mustard. Or that in
January the cable guy who was supposed to
show up between 10 a.m. and noon showed
up at 3 p.m. Or that a few months back I
called to change the address on a magazine to
which I subscribe; I later found out they
changed it ... to an address I held six years
ago. Or that after buying an iPod last fall, the
store clerk dropped it five feet from a shelf to
the concrete floor and then rolled his eyes and
muttered when I asked for a different one.
Good service also is memorable, and
instances carry with them the hope of how
things could be or should be. Last year,
when picking up a rental car from National,
the employee behind the counter greeted
me with a handshake; the first words out of
his mouth were, Thank you. Wow. And in
January, when checking into a Disney prop-
erty hotel for a conference, the front desk
attendant noticed that I was wearing a
running jacket. While the topic of being a
runner never came up in conversation,
when I got to my room 10 minutes later, a
map of area running trails, a bottle of water
and an energy bar were waiting for me.
Everyone has a customer service story to
tell. And chances are strong that there is a
customer service story about you. You dont
have to wear a headset or stand behind a
counter to be in the customer service busi-
ness. We all serve somebody.
So, what are they saying about you?
And, why are they saying it?
2 March - April 2010
Most people at Energizers battery
manufacturing plant in Missouri speak
highly of predictive maintenance steward
Rick Staley. It may be because this lubrica-
tion expert embodies a philosophy that
Walt Disney lived by: Do what you do so
well that they will want to see it again and
bring their friends. Rick isnt shy about
inviting operations personnel to stick
around when hes working on a piece of
their machinery. He wants them to see what
hes doing and welcomes them to ask ques-
tions about the work, the machine and
about the lubricants in that machine. Its
not uncommon now for other operations
friends to join in. Staley and the Energizer
maintenance crew get extra props for
sharing their success with customers. After
winning the ICMLs Gill Award for oil
analysis and lubricant condition moni-
toring in 2009, they brought the trophy
through each department as if it were the
Stanley Cup. Everyone got to hold it and
have their photo taken with it. Staley
reasoned that the award wasnt about
work that we did for them. It was about
work that we did with them.
Quality guru W. Edwards Deming wrote
that our customers should take joy in our
products and services. Not a passing
interest. Joy! How do you do that? I met an
operations team leader who recounted an
experience he had with an hourly mainte-
nance technician who serves as the sites
lubrication specialist. The team leader
wanted to know more about the new filtra-
tion system that had been installed in the
plants lubrication storage room. The tech-
nician was heading for lunch, but wound up
cancelling those plans. Instead, he took the
team leader to the lube room and spent a
half-hour explaining the entire system and
what cleaner oil would mean for the team
leader and the operations department.
www.machinerylubrication.com
Whos the biggest fan of filtration now out
in the production area?
Additional ideas to improve customer
service are out there. Steal them. Use them.
Maintenance leaders at Toyota and
other companies that Ive visited employ a
neat concept which works especially well for
large plants with big departmental work-
forces and/or those that use shift/task
rotation. It ties into a customer service
creed of Yahoo! co-founder Jerry Yang: It
helps a ton when you learn and know
peoples names. At these plants, mainte-
nance posts laminated, magnetic cards on
the side of production machinery. On a
card is the name of the maintenance tech
responsible for that equipment or area of
the plant, along with a photo of the tech
and various ways to get in touch with him
or her when questions, comments, needs or
emergencies arise. This helps get everyone
on a first-name basis, puts a face to a name
and decreases response time.
Maintenance pros at several plants
create newsletters that are sent to
members of the production team and plant
management. They include case studies of
saves and explain reliability-enhancing
projects taking place throughout the
facility. The best newsletters Ive seen go
out of their way to acknowledge produc-
tions role in the work. Saying thanks is a
recurring theme.
Ill leave you with this quote from British
author Nelson Boswell. You may not have
heard of him (hes no Disney or Deming),
but the words are appropriate: Here is a
simple but powerful rule always give
people more than what they expect to get.
Thank you for reading this column and
for your support of our products. If I can be
of service to you or your organization from
an information or resource perspective, just
let me know. Thats my job.
Machinery Lubrication
AS I SEE IT
Ban the Can: Sealable,
Reusable Oil Containers
JIM FITCH
NORIA CORPORATION are Smarter Option
T he oil can was in need of a major redo years ago. It was grossly
outdated in terms of modern views and needs relating to lubri-
cation and machinery reliability. Fortunately, new products
sporting highly advanced features have emerged on the market. For
clarification, Ill refer to the historic products as oil cans and
their modern replacements as S&R containers. S&R is short for
sealable and reusable.
Despite the obsolescence, the oil can still seems to prevail unde-
terred in many user organizations like a bad rash. You think its
finally gone and then it just comes right back. Either these compa-
nies that use such archaic products are Neanderthals or they simply
do not understand the business case for ditching the old in favor of
the new. This column was written to provide a gentle nudge to
those who seem to have trouble getting or understanding this
important message. In the world of machine reliability, this
message is not trivial but rather a foundational underpinning of a
well-engineered reliability program.
Law of the Critical Few
Why do machines fail? The reasons are many, but Vilfredo
Pareto (from the Pareto Principle) taught us that we need to focus
our time and resources on the so-called critical few. It is these few
Figure 1. By their design and generic nature, traditional oil cans
contribute to contamination and misapplication issues. Some models
are also hard to clean.
4 March - April 2010 www.machinerylubrication.com
causes that contribute to the vast majority of failure occurrences.
Precision maintenance depends on targeting the critical few. One
such cause is the vital need to control the ingress of contamination
that too often enters our machines. Contamination is a silent but
terminal disease in machinery that doesnt get needed attention in
most organizations. Another such cause is the importance of
ensuring that the correct grade and quality of lubricant goes into
the machine. It sounds like common sense, but sadly, it is fraught
with human error. Fortunately, S&R containers address both of
these causes. (More on that later.)
Further, a surprisingly high percentage of lubricant consumption
is disposed of unnecessarily. Oil cans often have residual oil in them
from the previous use. They are then placed on the ground in the lube
storage room or near a machine. Because (A) these oil cans arent
labeled correctly (causing identification confusion of the residual
lubricant), (B) there is a need to use the container for a different
grade of oil, and/or (C) the residual oil has not been protected from
environmental contamination, this remaining lubricant is normally
discarded. As much as 20 percent of total oil consumption in many
organizations is wasted unnecessarily in this manner.
There are many more benefits to lube programs by using S&R
containers. These include ergonomics (ease and convenience of
use), safety, avoiding human error and general good housekeeping.
The following is an overview of how modern S&R containers
achieve these important goals.
Contamination Control:
The Silent Disease
Particles and moisture enter lubricants from a variety of sources
and entry points. Many of these contaminants arrive in stages through
the chain of custody as lubricants are handled and transported from
blend plant to ultimate point of use. For small machines, a surpris-
ingly large amount of contamination is introduced at the last stage,
between intermediate storage (e.g., drum or tote) and the machine.
This is where the S&R container plays a vital role in controlling
contaminant ingression during routine oil changes and top-ups (the
introduction of makeup oil). Here is how that is achieved:
Cleanable: Oil cans with narrow openings are hard to clean (see
Figure 1). Ever tried to clean one of these guys? Conversely, wide-
mouth bottles such as the S&R containers in Figure 2 and 3 offer
Machinery Lubrication
welcomed convenience when it comes to routine
cleaning, typically done in a parts cleaning station
or industrial washing machine. Most importantly,
they present little opportunity for invasion of
contamination and, hence, there is less need for
such periodic cleaning.
Sealable: Unlike teapot type oil cans, S&R
containers are tightly sealed to control air
exchange and contaminant ingression. The air
vent, nozzle and other openings are all snug tight
when not in use. You dont have to filter or clean
what doesnt become dirty.
Vent valve or breather: Yes, air does need to enter
during oil dispensing, but S&R containers restrict
the exchange of ambient air when not in use.
Traditional oil cans, on the other hand, act more
like dirt magnets by constantly collecting dust on
the oil-wet internal surfaces. Some users have
enhanced their S&R containers by installing small
breathers (air filters) at the vent opening to remove
particles from incoming air during oil dispensing
good, better, best! Some of the hand pumps avail-
able from S&R container manufacturers have
integrated these breathers into the design.
Dispensing filtration: Some S&R containers are
conveniently sold with hand pumps and hoses. An
oil filter can be installed between the pump and PUBLISHER
the hose to serve as a final trap for particles Mike Ramsey - mramsey@noria.com
before the oil enters the machines sump. This
GROUP PUBLISHER
works especially well with low-viscosity fluids Brett OKelley - bretto@noria.com
(turbine oils, for instance).
Quick-connects: Another advantage of using EDITOR-IN-CHIEF
an S&R container with a hand pump is the ability Paul V. Arnold - parnold@noria.com
to install a female quick-connect (QC) on the
hose end and the male coupling on the machine SENIOR EDITORS
Jim Fitch - jfitch@noria.com
(both fitted with dust caps). This eliminates the
Drew Troyer - dtroyer@noria.com
need to open fill ports to add oil (causing the Mark Barnes - mbarnes@noria.com
introduction of contaminants) and also helps
ensure that the oil is being filtered during TECHNICAL WRITERS
dispensing. Most importantly, there is no need to Jason Kopschinsky - jkopschinsky@noria.com
use dirt-laden funnels. Finally, if the male QC is Jeremy Wright - jwright@noria.com
Stephen Sumerlin - ssumerlin@noria.com
properly located in an active area of the sump
(and below the fill level), this port can double as
SENIOR DESIGNER
an oil sampling port (avoiding the undesirable Ryan Kiker - rkiker@noria.com
practice of using a drop-tube when vacuum
sampling). GRAPHIC ARTIST
Properly sized spout tips: Where a QC is not a Kam Stinnett - kstinnett@noria.com
practical option, S&R containers can be fitted
with spout tips narrow enough to dispense oil ADVERTISING SALES
Brett OKelley - bretto@noria.com
into even the smallest fill ports (see Figure 2). Phone: 800-597-5460, ext. 112
Again, this conveniently avoids the need to use
funnels. PRODUCTION MANAGER
Rhonda Johnson - rjohnson@noria.com
CORRESPONDENCE
You may address articles, case studies,
special requests and other correspondence to:
Paul V. Arnold - Editor-in-chief
MACHINERY LUBRICATION
Noria Corporation
P.O. Box 87 Fort Atkinson, WI 53538
Phone: 920-568-9768 Fax: 920-568-9769
E-mail address: parnold@noria.com
SUBSCRIBER SERVICES: The publisher reserves the right to accept or reject any
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Copyright 2010 Noria Corporation. Noria, Machinery Lubrication and asso-
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Reproduction in whole or in part in any form or medium without express written
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 AS I SEE IT
Figure 2. Small fill port? With the right container and spout
tip, it is no big deal.
Liner option: Some users have discussed the application of thin
plastic liners with the S&R containers. These clean liners, similar to
trash bags, are secured in the threads between the base and the lid
of the container. The wide-mouth feature of these containers
enables this option when the ability to clean the container is not a
practical alternative.
The Human Interface
Todays S&R containers are clearly the product of human
engineering and industrial design. They offer needed convenience
Figure 3. This S&R container features four handles, allowing the technician to
choose the grips that are right for the application.
6 March - April 2010 www.machinerylubrication.com
and ease of use in addition to safety features. Here are a few
examples:
Get a grip: For a simple oil container, youd think one handle
would do the trick. Not true. These guys have as many as four
handles (see Figure 3)! Handles are positioned for transport,
tipping during dispensing and gripping the base container.
Graduation markings: Some of these S&R containers have level
markings for easy measurement of oil volume during fill and
dispensing.
Label mania: I mentioned common human errors from intro-
ducing the wrong lubricant into the machine. Much of this can be
avoided by taking away the guesswork and enhancing communica-
tion. The S&R containers have this figured out. They are equipped
with an assortment of labeling options including colors, adhesive
labels and plastic data pouches for detailed product information
(including MSDS sheets). Perhaps youve also heard that OSHA
doesnt like lubricants and chemicals sitting around in unmarked
containers.
Tips to Best Use Containers
Besides the obvious, what follows are additional tips to optimize
the use of S&R containers:
1) Buy enough containers such that they are dedicated to work
areas and lubricant types. Dont share containers and risk
cross-contamination of lubricants.
2) Store S&R containers near the point of use in lockers to keep
them clean and safe. This also enhances convenience (top-ups
are more timely) and minimizes the risk of cross-contamination.
3) On the container labeling, mark the date when it was last
cleaned and when it needs to be cleaned next.
4) Always take note of any sediment, sludge or water. If this is
found, troubleshoot the source to avoid future introduction of
these contaminants into your machine.
5) Keep the outside of these containers wiped clean, especially the
nozzle and handle areas.
6) Train all operators and lube technicians on the proper use of
S&R containers.
Dont Be Caught Napping
S&R containers serve as a visual sign of maintenance excellence.
Conversely, use of fossilized oil cans serves as a constant reminder
of maintenance neglect and program stagnation. S&R containers
are not high science, but rather a strong statement of a job well
done. Its time to act.
About the Author
Jim Fitch has a wealth of in the trenches experience in lubrication, oil
analysis, tribology and machinery failure investigations. Over the past two
decades, he has presented hundreds of lectures on these subjects. Jim has
published more than 200 technical articles, papers and publications. He
serves as a U.S. delegate to the ISO tribology and oil analysis working group.
Since 2002, he has been director and board member of the International
Council for Machinery Lubrication. He is the CEO and a co-founder of Noria
Corporation. Contact Jim at jfitch@noria.com.
Machinery Lubrication
VIEWPOINT
Answers to Your Questions
About Lubrication-Related
MARK BARNES
NORIA CORPORATION
Varnish and Varnish Removal
I n the world of lubrication, hot topics come and go. Whether its
synthetic oil, electric motor lubrication or ultrasonic-assisted
regreasing, certain themes take on a greater profile from time to
time. Lately, the hot topic that Ive seen and have been asked more
questions about than any other is varnish. From compressors to gas
turbines, hydraulics to gearboxes, everyone seems to be talking
about varnish. But, what is varnish? What causes it? And most
importantly, how can it be prevented or eliminated?
In the past few years, significant efforts have been made to try
to understand this ubiquitous material. Youll find numerous arti-
cles, case studies and other information on the subject in
Machinery Lubrication magazine and Norias own Lubrication
Excellence conference proceedings. Some of the brightest and most
competent lubrication chemists and engineers have studied the
issue and done a tremendous job helping to explain the cause,
effect and techniques for varnish mitigation.
Usually when were talking about varnish
and lubricant degradation, were talking
about by-products of base oil degradation,
but not always.
But in talking to the layperson the maintenance manager or
reliability engineer who really doesnt care about free radicals,
carbon and oxide insolubles or peroxides, but rather how to control
the problems associated with varnish I still see a great deal of
confusion and lack of understanding.
Unfortunately, the situation is not helped by a certain amount of
information put out by well-intentioned but misinformed people or
organizations. So in the interests of setting the record straight, Ill
attempt to shed some light on the topic of varnish and, in partic-
ular, try to provide some pointers to those dealing with this issue to
help them wade through the plethora of fact and fiction.
What is Varnish?
First, let me state that theres no such thing as varnish! By that,
I dont mean that varnish-like deposits in our machines are a
8 March - April 2010 www.machinerylubrication.com
figment of our imagination. Rather, varnish is a rather generic term
used to describe the deposits formed by lubricant degradation.
Usually when were talking about varnish and lubricant degrada-
tion, were talking about by-products of base oil degradation, but
not always; in some cases, deposits can be caused by additive
depletion or a chemical incompatibility between the additives and
other foreign materials (chemicals, dissolved gases, water, etc.)
that may be present in the lubricant.
When it comes to base oil degradation, there are four main ways
in which base oils degrade: oxidation, thermal stress from hot
machine (or other) surfaces, compressive heating due to air
entrainment and electric arcing from stray currents. Since each of
these mechanisms is different both physically and chemically, it
stands to reason that the end result the by-products of fluid
degradation also will be different. This is important to under-
stand because the method by which we control and eliminate the
deposits formed will depend on the method of formation.
Oxidation vs. Thermal Stress
A common mistake when talking about lubricant degradation is
to state that the oil has oxidized; this is not always the case. In
terms of lubricant degradation, oxidation has a very real meaning,
representing the chemical reaction between oxygen present in the
air with base oil molecules. Think of taking a bite out of an apple
and watching the exposed flesh slowly turn brown over time. The
brown coloration is a result of the oxygen in the air reacting with
(oxidizing) the flesh of the apple.
Typically, oxidation builds up over a prolonged period of time
and is not usually a result of an instantaneous event. While
prolonged oxidation can lead to very tough deposits, by-products
of oxidation usually can be dissolved in fairly mild solvents such as
toluene or removed through mild abrasive cleaning.
Contrast this to thermal stress, which is caused by a high, local-
ized heat source (machine surface, compressed gas bubble,
electrical arc, etc.). Thermal stress usually occurs over a much
shorter timeframe and results in deposits that are much harder to
remove either through mechanical or chemical means. To under-
stand the differences, consider cleaning a fry pan. If the food has
Machinery Lubrication
been cooked slowly and properly, cleanup is fairly straightforward
with warm water and dish detergent. But if the food has been
burned, it will take much more scraping and maybe even cleaning
solvents to remove all of the deposits. The same is true for oxida-
tion vs. thermal lubricant failure.
Testing for Degradation
One of the tools we can use to detect the onset of lubricant dete-
rioration is, of course, oil analysis. While later-term changes such as
viscosity will occur with either thermal or oxidative failure, the
fingerprint of early term oxidation is very different than that of
incipient thermal failure. While with oxidation, acid number and
Fourier transform infrared (FTIR) oxidation numbers typically rise,
with thermal stress, acid number and FTIR oxidation will often
remain low, appearing to be normal while other telltale tests such
as FTIR nitration may prove a better indicator.
Color also is a good indicator of lubricant degradation. While a
simple visual check is a good screen, other more sophisticated spec-
trophotometric tests such as quantitative spectrophotometric
analysis (QSA) provide an excellent early warning of lubricant
degradation. But with color changes, you should apply caution.
While its true to say that an oils color will change when an oil
oxidizes, the reverse is not always true. A change in color doesnt
always mean oxidation; it could equally be thermal stress.
Varnishs Presence:
Mineral Oil vs. Synthetic Oil
How do we prevent varnish? The answer to this question will
depend on the reason the deposits are there.
For example, you will hear people tell you that synthetic oils or
highly refined mineral oils will resist oxidation better than conventional
oils. This is a true statement, but any oil (mineral or synthetic) ther-
mally stressed by adiabatic compression (compressive heating due to
gas entrainment) to 1,500 degrees Fahrenheit will thermally degrade.
Likewise, theres the question of solvency. While highly refined
mineral oils or synthetic hydrocarbons certainly resist oxidation
better than most minerals oils, their lack of natural solvency means
that once a problem starts, the deposit formation may occur much
faster in a more highly refined oil. Conversely, the solvent action of
conventional mineral oils is fairly mild. Just like dish detergent alone
Machinery Lubrication
wont remove burned-on food residue from a fry pan, conventional
mineral oils will not solubilize stubborn lubricant deposits.
Techniques for Removing
Degradation By-products
Once deposits form within a system, at some point, were going to
want to remove them. There are a number of techniques for removing
lubricant degradation by-products including the use of electrostatic
separators, balanced charge agglomeration and cellulose media.
Numerous case studies have proved the efficacy of these tech-
niques at controlling and removing deposits; but again, caution
must be applied. While a certain technology may indeed prove
useful in controlling varnish caused by oxidation, it may not do
so well with varnish from thermal stress.
Root Cause Before Solution
Whats the answer to varnish mitigation? Just like a doctor
should never prescribe a remedy until he or she has diagnosed the
illness, we should resist the urge to jump to a solution thats proven
to remove varnish unless we know the symptom(s). Taking antibi-
otics to cure a viral infection wont work. Likewise, using a
technique to remove oxidative by-products may not work if thermal
stress is the causative factor.
Therefore, before you jump headlong into a solution, try to
determine the underlying root cause of varnish formation so you
can be better informed to make the right choice of how to prevent
and eliminate varnish from your machines.
As always, this is my opinion; Im interested in yours.
About the Author
As a skilled educator and consultant in the areas of oil analysis and
machinery lubrication, Mark Barnes has helped numerous clients develop
effective machinery lubrication programs and troubleshoot complex lubri-
cation problems through precision lubrication and oil analysis. As vice
president of Noria Reliability Solutions, Mark and his group work on proj-
ects in the areas of: plant audits and gap analysis, machinery lubrication
and oil analysis program design, lube PM rationalization and redesign,
lubricant storage and handling, contamination control system design and
lubrication, and mechanical failure investigations. Contact Mark at
mbarnes@noria.com.
www.machinerylubrication.com March - April 2010 9
 THE EXPONENT
Human Factors Engineering:
The Next Frontier in
DREW TROYER
NORIA CORPORATION Reliability
O ver the 20 years that Ive been in the reliability engineering
field, most of our effort to improve the dependability of
manufacturing processes has been equipment focused. Ive been no
exception. On the surface, it seems to make sense. Its the equip-
ment that breaks down, isnt it? Yes and no.
A few years ago, I asked our readers to tell me what goes wrong
in the factory based upon the general failure cause categories
outline in the U.S. Department of Energys root cause analysis stan-
dard (DOE-NE-1004-92). You replied that the equipment is to
blame in less than 20 percent of the occurrences. Nearly 80 percent
of what goes wrong can be attributed to people issues. Problems
with procedures and training (combined) are responsible for nearly
40 percent. Personnel/human error constituted a little more than
22 percent of the vote. Management oversight represented about 9
percent. Also, design problems totaled roughly 9 percent.
Really, though, wouldnt you agree that if we had good proce-
dures, training and supervision that wed go a long way toward
minimizing personnel/human error? The bottom line is that human
factors are responsible for 75 to 80 percent of what goes wrong in
the factory. Its time for us to align our efforts accordingly.
Analysis and Classification
In 2003, the U.S. Secretary of Defense proclaimed in a memo-
randum that world-class organizations do not tolerate
preventable accidents. This led to an edict to reduce preventable
errors by 50 percent and resulted in the formation of the
Department of Defense Safety and Oversight Committee and the
relatively new branch of reliability management called Human
1.30%
8.73%
23.78% Procedural Problem
8.98%
Personnel/Human Error
Equipment/Material Problem
Training Deficiency
15.05%
Management Oversight
22.54%
Design Problem
19.63% External Phenomenon
Figure 1. Reader Data on the Causes of Failures in the Factory
10 March - April 2010 www.machinerylubrication.com
Factors Engineering (HFE). The intent was to develop and stan-
dardize a human performance coding, analysis and management
system throughout the DoD; it is called the Human Factors
Analysis and Classification System (HFACS). While it was devel-
oped to improve aviation safety, it is fully applicable to any
reliability-critical application or industry (including manufacturing)
where people are highly integrated in the business processes.
DoD statistics suggest that human error is a causal factor in 80
to 90 percent of all mishaps. As previously discussed, my research
into the manufacturing industries similarly suggests that human
error accounts for around 80 percent of what goes wrong in plants
and factories. Since human error is the dominant failure mecha-
nism in most systems (healthcare being no exception), it should be
the focal point of our reliability management system.
The human factors classification system is broadly organized
into the three latent failure and one active failure categories.
1) Organization Influences (Latent Failures/Conditions): This
category includes the failure to provide adequate resources, an
appropriate organizational climate and/or sufficient organiza-
tional processes, such as procedures.
2) Unsafe Supervision (Latent Failures/Conditions): This cate-
gory includes inadequate supervision, planned operations that are
known to be inappropriate, failure to correct known problems and
violations made by supervisors.
3) Preconditions for Unsafe Acts (Latent Failures/Conditions):
These include:
environmental factors, such as the physical and technological
environment;
condition of the individuals, including cognitive and psycho-
behavioral factors;
condition of the individuals, including physiological state, phys-
ical/mental limitations and perceptual errors; and,
personnel factors, including coordination, communication and
planning errors, and self-imposed stress such as fitness,
alcohol/drug use, nutrition, etc.
4) Unsafe Acts (Active Failures/Adverse Events): These include
errors caused by lack of skill and/or clear instruction, errors in judg-
ment, and errors in perceptions. They also include violations.
Machinery Lubrication
Applicable to Manufacturing Organizational
Latent Failures/Conditions

The human error coding and management system developed by Influences

the DoD is quite comprehensive. In total, theyve identified 131 Latent Failures/Conditions
Unsafe
latent and 16 active errors that lead to a failure or adverse event. Supervision
Likewise, because the failure classification system includes latent Latent Failures/Conditions
Preconditions
and active failures, it is fully applicable to the classification of near- for Unsafe Acts
misses as well as actual failure events. By and large, the Active Failures/
management system can be adopted in its entirety for use in the Hazards Unsafe Acts Adverse Events

manufacturing sector. There are a few that dont apply and prob-
ably a few that are missing, but with minor revisions, the
DoD-HFACS can and should be immediately employed to analyze Failure /
Adverse Event
and prevent human error in facilities.

The Need to Execute
Kurt Vonnegut said in one of his novels if it werent for the people
... always getting tangled up with the machinery; if it werent for
them, Earth would be an engineers paradise. The bottom line is
that people are and in all likelihood will always be in the mix. Since
thats where most of our problems occur, wed better get busy to
start mitigating human factors risks. To do so, our Failure Reporting,
Analysis and Corrective Action System (FRACAS) must contain a
Human Factors Analysis and Classification System (HFACS).
The DoD has done the heavy lifting by creating this system. We
simply need to execute. If you dont have a FRACAS for collecting
failure data, call or e-mail me. You cant manage reliability without it.
Figure 2. How Latent and Active Human Acts Lead to Adverse Events
Remember my axiom for reliability management: Data is the differ-
ence between deciding and guessing!
About the Author
Drew D. Troyer is a champion of effective reliability management and
passionate about helping companies find hidden profits inside their plants. As
a highly sought consultant to Fortune 500 manufacturing firms, award-
winning columnist and teacher, he understands both management
expectations and plant-floor realities. Troyer is a Certified Reliability Engineer
(CRE), a Certified Maintenance and Reliability Professional (CMRP), and
chairs the standards committee of the Society for Maintenance and Reliability
Professionals (SMRP). Contact Drew at dtroyer@noria.com.

Machinery Lubrication www.machinerylubrication.com March - April 2010 11

COVER STORY

All in the Family

Toyota Lift Truck Manufacturing Plant Deserves Notice
for Efforts to Improve Maintenance Personnel, PM Tasks
and Equipment Lubrication
12 March - April 2010 www.machinerylubrication.com Machinery Lubrication
 BY PAUL V. ARNOLD

G eorgetown, Ky., is synonymous with Toyota. Each year, manufacturing leaders from across the
country and across industry sectors make a pilgrimage to this 21,000-resident town to tour the
car plant and learn lean principles, efficiency and asset care from the masters.
Considerably fewer plant professionals know that an equally educational Toyota experience exists in
the southern Indiana city of Columbus (population 36,000). Toyota Industrial Equipment
Manufacturing, or TIEM, may be the best-kept secret in Columbus ... and perhaps all of industry.
Were still kind of unknown, even in our own town, says Fred Williams, the companys customer
center and service training manager. My vision of a small town is that everyone knows what everyone
else is doing. Its a small community and we are all neighbors.
However, while wearing his Toyota work shirt around town, Williams says the conversation normally
goes something like this:
Hey, you work for Toyota? Excellent! I have a Camry. I love that car.
Thats great. However, I dont work for the car side. I work for the material handling equipment
side. I work for Toyota forklift.
Toyota makes forklifts?
Yeah, we make forklifts. Were the No. 1 lift truck manufacturer in the world.
(Long pause. Blank stare.)
... We make them in our town. ... Weve been here since 1990. ... We employ more than 600 people.
... The plant is right off of the highway. ... Big place 890,000 square feet. ... You cant miss it.
I sure do love my Camry.
The TIEM plant may produce different vehicles than its car-making cousin, and it may fly a different
corporate color (orange vs. red), but thats where the deviation stops.
You are at Toyota, says Williams. The same principles that drive our engineering, production,
and maintenance and reliability performance at Georgetown and other Toyota auto sites ... well, we
utilize those, too. This is a close-knit family of companies. We benchmark each other to make sure that
we are all at the same level of Toyota quality and performance.
Like the car plants, the TIEM factory in Indiana is noteworthy for several reasons, including:
its never-ending efforts to continuously improve its processes and people;
its all-hands-on-deck approach to maintenance; and,
its pursuit to efficiently and effectively use every bit of its time and resources.
The examples and comments in this cover story may well change your game plan for preventive
maintenance and machinery lubrication. Who knows? It may change the way you look at forklift
manufacturing.
People dont realize that the forklift industry is pretty cool, says Williams. This is a cool industry,
and we are a big part of it.

The Kaizen Mentality

Its a cold Monday morning in late December. The skies are gray and snow is in the forecast. But
that cant put a damper on Williams day.
Were making lift trucks this morning, so its a beautiful day, he says.
His outlook is straight out of the old Mac Davis song, Oh, Lord, Its Hard to Be Humble:
I cant wait to look in the mirror cause I get better looking each day.
In Williams case, his excitement is that TIEM will be a better lift truck maker today than it was
yesterday, and opportunities exist to make it even better tomorrow and the next day and the next.
Our kaizen mentality tells us that we need to continuously improve our products and processes,
he says. If we keep the focus on continuous improvement, good things will happen for us and our
associates.
This kaizen mind-set is rooted in a couple of Toyota-isms:
1) If you sit back, complacency sets in. At that point, nothing is good.

Machinery Lubrication www.machinerylubrication.com March - April 2010 13

 COVER STORY
Fred Williams (shown in the side-view mirror of a Toyota lift
truck) is the customer center and service training manager.
Time for TIEM
Company: Toyota Industrial Equipment
Manufacturing Inc., the lift truck manufacturing
division of Toyota Material Handling USA.
Plant: TIEM in Columbus, Ind., a town of
36,000 located in southern Indiana. Site
development began in 1988 and production
began in 1990. The facility has undergone 11
expansions since 1990.
Plant size: 890,000 square feet.
Plant employment: The site employs 620
workers, including 26 in maintenance.
Products: The plant currently makes 63 lift
truck products, including diesel tow tractors,
sit-down electric forklifts, sit-down internal
combustion tire units and sit-down internal
combustion pneumatic tire units. This product
line spans units with lifting capabilities of
2,000 pounds to 17,500 pounds. An average of
100 lift trucks are produced on a daily basis;
nearly 30,000 are produced annually. TIEM
also makes the DC/AC inverter assembly for
Toyota Tacoma pickup trucks.
FYI: Toyota is the worlds No. 1 supplier of
lift trucks. ... Most of the Toyota lift trucks
sold in the U.S. are manufactured at TIEM.
... The plant produced its 350,000th lift
truck in November 2009. ... The site has
been a zero-landfill facility since 2004.
14 March - April 2010
Nearly 30,000 lift trucks come off the assembly line each
year at the Columbus, Ind., factory.
2) All good is not good.
The latter is a favorite quote of Toyota
managers. If your indexes are showing
that you are meeting your goals, perhaps
your goals arent high enough. It ties in
with the two things that are said to occur
when a Toyota manager reaches a stretch
goal. He or she receives a pat on the back
from the boss. The manager then is
expected to apologize for not setting the
bar high enough.
Hows Your Process?
At Columbus, this isnt hype. Its HYP,
an acronym for Hows Your Process?
Every morning at 6:30, each associate
(Toyotas term for an employee) fills out
a form that asks if issues exist within his
or her sphere of influence. If issues exist,
the associate provides details. That
persons designated team leader has
until 10 a.m. to look into the issue and
either install a countermeasure or
outline the next step toward a solution.
The associate has just as much respon-
sibility and accountability. Each month,
he or she is expected to turn in at least
www.machinerylubrication.com
two formal continuous improvement
ideas (which include full implementation
and resolution plans). For December
2009, a total of 449 associates delivered
1,089 ideas.
The adage is that many voices
generate new and better ideas, says
Wendell Crouch, the plants maintenance
and production engineering manager.
This is about problem-solving. We
want our associates to be quality-minded
and continuous improvement-minded
individuals.
The Meaning in
Maintenance
What does all of this have to do with
maintenance and machinery lubrication?
Issues and ideas can and do relate to
oil, grease, coolant, hydraulic fluid, etc.
But, bring it back a level. Continuous
improvement starts with the employee.
TIEMs maintenance structure is built
around generalists. No one is hired as an
electrician or a mechanic or a lubrication
technician. Every associate is brought
into the maintenance department at the
Machinery Lubrication
 COVER STORY
same pay grade and base skill level. Each person goes through a
rigorous training program to develop skills and knowledge.
There is no continuous improvement without training, without
learning, says Williams.
It takes approximately three years to complete the four
education modules. Lubrication concepts are covered in each of
them. Classes are four hours long, once per week, and are held
during non-shift time. The modules and course components are
as follows:
Electric (basic electricity, electrical wiring fundamentals, elec-
trical circuits, and motors and controls), 26 weeks, 104 hours
Hydraulic/Pneumatic (hydraulics and pneumatics), 24 weeks,
96 hours
Skill I (machining fundamentals levels 1 and 2, industrial
plumbing, and welding), 28 weeks, 112 hours
Skill II (PLCs, machine rigging and installation, mechan-
ical/electrical troubleshooting, and CNC and robotics
programming), 26 weeks, 104 hours
Associates also receive training in Toyota-based lean concepts
from the well-known Total Productive Maintenance and five-whys
to the lesser-known genchi genbutsu and yokoten (see terms in
sidebar found below).
Genchi genbutsu embraces the notion that rather than to simply
hear or read about a problem and make a suggestion for improve-
ment, one should actually go to its direct location and experience
the situation first hand. Yokoten involves applying lessons learned
to similar situations. If downtime occurs on a conveyor as the result
of a particular lubrication issue (under-lubrication, over-lubrica-
tion, wrong lubricant, etc.), details of the issue and the
countermeasure are communicated plant wide (and to Toyota fork-
lift plants in Japan, France and China). That way, follow-up work
can determine if like conditions exist elsewhere. If so, the counter-
measure can be implemented.
Armed with this knowledge and the Toyota/lean mentality of
seeing things differently, associates are able to amass meaningful
continuous improvement ideas.
One recent idea addressed lubrication issues with a turntable.
A guard previously had been retrofitted and installed so that
the operator could run a part into it, says Crouch. However, the
Toyota Production System Concepts of Particular Use to Maintenance Organizations
Here is how Toyota defines some of the maintenance-pertinent
concepts of its Toyota Production System. TPS is the basis of
operation at the companys plants around the world, including
the TIEM plant in Columbus, Ind.
Kaizen: Continuous improvement. Muda (waste) exists every-
where. Kaizen refers to the series of activities whereby instances
of muda are eliminated one by one at minimal cost by workers
pooling their wisdom and increasing eff iciency in a timely
manner.
Jishuken: Management-driven kaizen activity where manage-
ment members identify areas in need of continuous improvement
16 March - April 2010 www.machinerylubrication.com
Oil Analysis Points Out Necessary
Work During Shutdowns
The Toyota Industrial Equipment Manufacturing plant in
Columbus, Ind., has been doing oil analysis since 1998,
working primarily with Mobils Signum program.
Oil analysis is performed every six months on major pieces
of equipment. Sampling takes place four to six weeks prior to
a plant shutdown.
Maintenance associates take samples under the supervision
of the plants third-shift maintenance team leader, Brian
Napier. All involved have undergone proper training from
Mobil technical representatives.
Napier receives the results from Signum. After conferring
with maintenance supervisor Brian Weber and maintenance
and production engineering manager Wendell Crouch (and
perhaps Mobil representatives), necessary actions are sched-
uled for the upcoming shutdown.
Oil analysis results are a key component of the depart-
ments shift to a more condition-based strategy.
An example would be a PM (preventive maintenance task)
for a 500-ton press, says Crouch. When it comes to
changing the hydraulic fluid, the PM will spell out, Only do
this if the analysis from Mobil recommends changing.
guard covered up the grease zerk. If a zerk is unseen or inaccessible,
the machine isnt going to get the grease it needs. An idea led to a
modification of the guard. Theres now access to the grease zerk
and the operator can still run a part into it.
Another idea led to greater accessibility to lubricant sumps
and streamlined procedures for draining them.
No kaizen is too small, says Williams. We would rather have
100 small, incremental kaizens than one big home run. All of
those individual kaizens create a stable platform for our products
and procedures.
Improvement ideas are not static creatures. They can be regu-
larly revisited, refined and revamped.
We may find that another plant at a different company has a
better solution than our solution, says Crouch. We arent
against taking the best practices from other places and painting
them TIEM orange.
and spread information through the organization to stimulate
kaizen activity.
Nemawashi: Preliminary work to involve other departments in
discussions to seek input, information and/or support for a
proposal or change (process, policy, etc.) that would affect them.
Monozukuri: Having the spirit to produce excellent products and
the ability to constantly improve a production system and process.
Mu-Jun: Try everything first in kaizen activities. As Taiichi
Ohno (the father of the Toyota Production System) stated,
Making sense is important, but in kaizen, its better to try first
and think later.
Machinery Lubrication
 COVER STORY
Maintenance supervisor Brian Weber (left) goes
over metrics with maintenance and production
TPM specialist Bill Mings checks out
preventive maintenance work orders on
his Motorola Pocket PC handheld device.
TIEM president Kazue Sasaki (second
from left) is a big proponent of the main-
tenance work that has taken place.
Team-Based Method for PMs
TIEM considers its approach to preventive
maintenance to be a best practice ... and the
focus of continuous improvement efforts.
Manufacturing and maintenance personnel
jointly perform approximately 4,500 preventive
maintenance (PM) tasks for the plants 2,900
pieces of equipment. Manufacturing associates
actually perform the lions share of the PMs.
Since the maintenance department has just 19
associates, it comes down to necessity and simple
mathematics.
There are a host of surveys that show 85
percent of all equipment downtime is due to
cleaning, lubricating and tightening, says
Crouch. There are a whole lot more manufac-
turing associates than maintenance associates.
Therefore, I gear my daily operator tasks and
autonomous maintenance tasks toward these
three activities. This way, you can make detailed,
more complex preventive and predictive mainte-
nance activities to cover the other 15 percent of
the downtime, thus allowing 19 maintenance
associates to cover almost 3,000 assets.
Operators perform their PM tasks at the start
and completion of the first shift (the days only
production shift). Since machine stoppages are
rare and to be avoided at all costs, maintenance
handles its PM tasks during the third shift.
18 March - April 2010 www.machinerylubrication.com
engineering manager Wendell Crouch.
The dividing line for coverage is generally that
machine operators handle PMs that take 10
minutes or less to complete and are less than
monthly in frequency. There are other caveats.
If it takes equipment (a ladder, a lift, etc.) to get
to what needs to be greased or lubricated, then that
would be a maintenance task, says Crouch. What
is the potential for doing it wrong? The higher the
risk, the more that it is going to go to maintenance.
If electrical is involved, that goes to maintenance.
Some of the supervisors and team leaders are
authorized lockout/tagout users out there, but most
of the operators are not.
Operators and manufacturing team leaders
have received training on proper lubricating and
greasing practices from the maintenance group
and the plants production engineer.
While the plant is set on this joint approach to
completing PMs, it is continually tinkering. The
maintenance organization is currently working to
change the frequency of PM tasks from a calendar
basis to an hourly or run time basis. It also consis-
tently explores PM effectiveness.
We look at the success of the PM, says main-
tenance supervisor Brian Weber. Is the PM
adding value? Is it preventing downtime? Based
on several factors and metrics (downtime, cost,
etc.), is it being done too frequently, not enough
or just right?
Machinery Lubrication
 Lubrication PMs are always under review. A task may call for the
oil on a machine to be changed every six months. However, oil
analysis and an examination of machine performance and run
hours may alter the policy to a much less frequent change-out
schedule. Needless to say, TIEMs Infor 7i computerized mainte-
nance management system gets a workout. Since 2006, more than
5,000 PM changes have been submitted. This can involve anything
from changing frequency, adding steps to a task, adding part
numbers, changing lubricant type or creating a whole new PM.
Very often, you can find the root cause of a breakdown in
something you did or didnt do when you bought the equipment,
says Crouch. We want to address everything before that piece of
equipment is brought to the plant floor, installed and put into
production.
The strategy consists of three elements:
Design for quality assurance
Design for maintainability
Life cycle costing

Going Paperless for PMs

Another more recent change is in how PMs are
delivered. Starting in June 2009, maintenance
began using Motorola Pocket PC handheld
devices. The units link with the CMMS, allowing
planners and schedulers to send PM work orders
(and repair work orders) electronically to mainte-
nance associates on the floor. An electronic work
order includes instructions and safety notes, and
has the capability to store pictures and graphics.
The PM can be opened, accessed and closed out
all without a voluminous paper trail.
We used to print out 2,500 to 3,000 pages of
PM tasks every month, says TPM specialist Bill
Mings. We arent doing that now. The third-
shift leader doesnt have to make paper piles to
hand out. And, it has smoothed out communica-
tion between departments because everyone can
know the status of a job. Anyone can access it
over the intranet.
While maintenance associates are the only
ones carrying around the handhelds for PM
tasks, manufacturing team leaders may get their
own within the next year or two. That way, they
can relay tasks to operators and make the PM
process completely paperless.
In the near future, maintenance also will be
able to take advantage of the Motorola Pocket
PCs bar-code-reading functionality. Every
production machine currently has an asset tag
that details its unique number and date of
purchase. That and additional information could
be infused into a bar-code-based tag.
If there is a bar code on the machine, the
associate can walk up, scan it and see the
outstanding work orders and PMs on that
machine, says Mings.

Made to Specification
Another significant way that TIEM maximizes
its time and resources is with Early Equipment
Product Management. This is a structured
process that seeks to reduce the complexity asso-
ciated with the operation and maintenance of
equipment. It brings lean principles to equipment
design and manufacturing.

Machinery Lubrication www.machinerylubrication.com March - April 2010 19

 COVER STORY
Working together, these elements provide Toyota with a
program to create equipment ideal for its production environment
equipment that is easy to operate, easy to maintain and right-
sized to aid in establishing flow.
When TIEM places an equipment order, it includes a four-page
list of equipment specifications. Lubrication-related references may
encompass items such as:
Final documentation shall include (among other things) lubri-
cation drawings and instructions, and a recommended
preventive maintenance schedule.
Lubrication label must be attached (manufacturer, type) by a
metal tag with black letters. Attach by screw or rivet.
Lubrication shall be Mobil Oil product exceptions must be
approved in writing.
Reservoir for oil, coolant, etc., shall have sight glass visible from
the outside of the machine to check level (no cover must be
removed to see sight glass).
Reservoir sight glass for oil, coolant, etc., shall have operating
zone marked in with green paint.
All lubrication points shall be below 1,600 millimeters (63
inches) in height.
TIEM also specifies what happens when the machine is put into
service. This includes regulations on how training is performed for
lubrication and other preventive maintenance tasks.
Lifting the Bar Higher
So TIEM, hows your process for maintenance and machinery
lubrication?
Crouch rates overall performance at a 7 to 7.5 on a 1-to-10 scale
(10 being optimum). In true kaizen spirit, he states, We are a
whole lot better than what we were, but there is still much more
that we can do.
Uptime on critical equipment exceeds 97 percent. For December
2009, uptime in main assembly was 99.76 percent, equating to an
average of one minute per day of downtime.
The department has logged a 27.8 percent reduction in repair
costs over the past three years.
20 March - April 2010 www.machinerylubrication.com
How the TIEM Plant Stores
and Manages Bulk Lubricants
TIEMs maintenance organization stores and manages
lubricants in the plants hazardous materials room.
Inventory, as you expect from a Toyota plant, is kept to a
minimum. A storage and dispensing rack holds drum cubes
that contain the 12 most-used oils in the facility. There is very
little backup stock since the plants lubricant supplier can
deliver it on a just-in-time basis.
Third-shift maintenance team leader Brian Napier invento-
ries the supply of oils and greases every Friday. Minimum
quantity levels trigger a reorder point.
Manufacturing team leaders dispense directly into transfer
containers on carts and bring them out to associates at the
point of use. Containers are tagged for easy identification by
the operators.
At the end of each year, the maintenance department
performs a survey to determine the total amount of lubricant
(by product) purchased and consumed by the facility. The
data helps to identify trends and pinpoint lubricants that may
be consolidated or completely eliminated.
And, with the focus on preventive and proactive work, just five
maintenance associates are assigned each day to handle fire-
fighting calls, a great improvement over a decade ago.
On the lubrication side, Crouch says, We are at around a 7 for
wet lubricants and a 5 for greasing. The numerical grade is not
based on the effectiveness of the program. It is the result of it not
being fully integrated. For greasing, I havent moved that process to
the manufacturing associate level as thoroughly across the board as
I have the wet lubricants. Maintenance is still very responsible for
greasing. Again, with only 19 maintenance associates, I need some-
body else to do the greasing.
OK, it doesnt manufacture cars and pickup trucks. And, it isnt
held to the same reverence as Georgetown. But by continually
improving its processes and people, establishing a team-based
approach to maintenance and lubrication, and developing strate-
gies to best use its time and resources, Toyotas lift truck plant in
Columbus, Ind., is worthy of notice (and a benchmarking tour).
TIEM is making the forklift industry seem, well ... pretty cool.
Machinery Lubrication
PRODUCT NEWS

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22 March - April 2010 www.machinerylubrication.com Machinery Lubrication

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The Model 230 Vibration Meter from Balmac stores overall
vibration measurements needed to check the condition
of rotating equipment. This easy-to-use meter can
provide an early warning of potential
machinery problems before a costly failure
occurs. With the Model 230 meter, mainte-
nance personnel can quickly and
accurately check the machinery
condition and store the measure-
ments for later recall and
analysis. The product stores a
typical workday of vibration
measurements.
Balmac Inc.
www.balmacinc.com
614-873-8222
Ideal 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
lubrication and long service life, even under extreme
operating conditions such as freezers and cookers. In
addition to being manufactured in equipment where
cross-contamination is minimized, Mobil
SHC Cibus Series lubricants are
formulated to be suit-
able under Kosher and
Halal dietary law.
ExxonMobil
www.mobilindustrial.com
800-662-4525

Synthetic Oil for Wire Rope

Lubrication Engineers introduced Wirelife Almasol Syn Coating
Thread Sealant Lubricant, an extremely tacky, non-asphaltic synthetic lubricant with high
Loctite 5452 thread sealant is specifically formulated for use on metal film strength. Perfect for extreme environments and conditions, it
fittings found in high-pressure hydraulic and pneumatic power systems. provides robust outer surface protection for wire rope and cable and
Curing four times faster than traditional anaerobic sealants, even on stain- comes from the same
less steel or inert metals, Loctite 5452 allows fittings under low pressure advanced technology that
to be returned to service immediately. Designed to fill, seal and secure the LE developed to protect
air space between threads, this large open gears in the
sealant contains no mining and quarry indus-
fillers or particles tries. Typical applications
that could contami- include standing and
nate system fluids, running lines, draglines,
foul valves or clog cranes, derricks, hoists
fine filters/screens.
and drilling rigs.
Henkel Corporation
www.henkelna.com/mronew Lubrication Engineers Inc.
800-562-8483 www.le-inc.com
800-537-7683

Machinery Lubrication www.machinerylubrication.com March - April 2010 23

HYDRAULICS AT WORK
How to Define a
Machines Optimum
BRENDAN CASEY
Operating Viscosity Range
T he most important proactive maintenance exercise you can do for
a piece of hydraulic equipment is to define its temperature oper-
ating window (TOW) and then ensure that the equipment always
operates within this window.
Operating temperature is inversely related to oil viscosity. So if oper-
ating temperature is too high for the grade of oil being used in the
hydraulic system, loss of full-film lubrication can result in scuffing and
adhesive wear. If operating temperature is too low for the grade of oil
being used in the hydraulic system, cavitation can occur, damaging
major components catastrophically in severe cases.
Within the allowable extremes of viscosity (TOW) required to main-
tain adequate lubricating film thickness for hydraulic components and
prevent cavitation, theres a narrower viscosity range (TOW) where
power losses through fluid and mechanical friction and internal
leakage are minimized, and, therefore, power transfer is maximized.
If the hydraulic machines temperature operating window is main-
tained in this optimum range, machine cycle times are faster
(productivity is increased) and power consumption (diesel or elec-
tricity) is reduced. And so, defining the machines optimum operating
viscosity range (and operating it within that range) is the ultimate goal
of this exercise.
Tabulating the Data
Before the correct oil grade (and viscosity index) can be chosen
for a particular hydraulic machine operating in a specific climate, it
is essential to tabulate the allowable and optimum viscosity data
for each type of pump and motor used in the hydraulic system.
Note that it is the pumps and motors in the hydraulic system
that we are most concerned with here because these components
feature the most critical and heavily loaded lubricated contacts.
It is also important to be aware that the allowable and optimum
viscosity range recommended can vary widely depending on the
design and construction of the pump or motor.
System Component Max Visc cSt Max Optimum cSt Min Optimum cSt Min Visc cSt
Rexroth A10VO140 1,000 36 16 10
Hagglunds CA50-50 10,000 150 40 20
Figure 1. Manufacturers Recommended Allowable and
Optimum Viscosity Values
24 March - April 2010 www.machinerylubrication.com
For example, consider a hydraulic system in which a Bosch
Rexroth A10VO140 axial piston pump and a Hagglunds Compact
CA50 radial piston motor are installed.
From the manufacturers data, the maximum allowable viscosity
for the Bosch Rexroth pump is 1,000 centistokes at cold start and
minimum allowable viscosity is 10 centistokes. The recommended,
optimum operating viscosity range is 16 to 36 centistokes.
The maximum allowable viscosity for the Hagglunds motor is
10,000 centistokes and the minimum allowable viscosity is 20
centistokes. The recommended, optimum viscosity range is 40 to
150 centistokes. This information is tabulated in Figure 1.
Looking at the figure, you can see that the viscosity requirements
for each of these hydraulic components are significantly different.
This is important; because to figure out the correct oil viscosity, we
need to be guided by the lowest maximum viscosity and the highest
minimum viscosity.
This will make more sense as we work through this example.
In Greater Details
The Hagglunds motor can cope with a maximum allowable
viscosity of 10,000 centistokes. But, this would likely destroy the
Bosch Rexroth pump. So in this column, the lower value of 1,000
centistokes is the defining number. Ive highlighted this value.
The same logic applies to maximum optimum viscosity. Here,
150 centistokes is still optimal for the Hagglunds motor, but not for
the Rexroth pump. Again, 36 is the lower of the two numbers and
is, therefore, the critical value in this column.
Conversely, the Bosch Rexroth pump is OK with a minimum
allowable viscosity of 10 centistokes, but the Hagglunds motor is
not. So, the higher of the two numbers, 20 centistokes, is the crit-
ical number in this column.
The same logic applies to minimum optimum viscosity. Here, 40
is the higher of the two numbers and is, therefore, the critical value
in this column.
So, for this system as a whole, the allowable operating viscosity
range is 20 to 1,000 centistokes.
Notice, though, that the minimum optimum viscosity value for
the Hagglunds motor of 40 centistokes is higher than the maximum
optimum viscosity value for the Bosch Rexroth pump.
Theres nothing we can do about this. It means that the Bosch
Rexroth pump must operate at a viscosity which is slightly higher
than its optimum. Priority should be given to maintaining optimum
operating conditions for the Hagglunds motor.
Machinery Lubrication
 What this also shows is the importance of doing this exercise. If we simply
took the recommended viscosity values for the Bosch Rexroth pump and
applied them to the system, its possible the service life of the Hagglunds
motor would be compromised.

Next Step
Having collected, tabulated and analyzed the above data, the next step is
to consider possible oil viscosity grades. This involves defining the tempera-
ture which corresponds to each of the highlighted viscosity values in Figure
1 for a particular grade and VI of oil, and then comparing these tempera-
tures to the expected operating oil-temperature range for the machine at its
specific location. This will be the subject of a future column in Machinery
Lubrication magazine.

About the Author

Brendan Casey has more than 20 years experience in the maintenance, repair and
overhaul of mobile and industrial hydraulic equipment. For more information on
reducing the operating cost and increasing the uptime of your hydraulic equipment,
visit his Web site, www.HydraulicSupermarket.com.

Hungry For More Information?

The Machinery Lubrication Web site is the home for hundreds of tech-
nical articles, columns and reports related to lubrication research,
solutions and best practices. Check out www.machinerylubrication.com
and learn more.

Machinery Lubrication www.machinerylubrication.com March - April 2010 25

FROM THE FIELD

The Rights and Wrongs of

Greasing: From Selection
STEPHEN SUMERLIN
NORIA CORPORATION to Application
selection process to the application process and try to expand your
W hen it comes to greasing, there are many ways to get it right
and many ways to get it wrong. Sometimes people think of
greasing as a simple task that doesnt require any skill or dedica-
perception of the dedication and precision required to get the most
from each stoke of the grease gun.
tion, and others believe it is more of an exact science and that
adhering to proper regreasing practices will yield the biggest return Grease Selection
on equipment availability. Precision greasing starts with the selection of the proper grease
Greasing is more of an exact science than not, stemming from for the application. Grease selection utilizes the same concepts as
weighing a shot of grease from your grease gun to calculating oil selection, but with a few more variables to consider. When
regrease volumes and frequencies. Greasing is one of the more selecting the proper grease, many times the best product wins out
simple lubrication tasks in execution, but it can be just as difficult simply because it is the most expensive and says it is a do all
as taking a proper oil sample without proper training, experience grease. This approach can be very costly, not just in the purchasing
and tools. This article will explore the subject of greasing from the expenses but the possibility of equipment failures. Just because a
particular grease says it is the best product on the market doesnt
mean it is the best product for your application.
1,000,000 Here is a short list of grease selection guidelines to aid in the
selection process. These guidelines may need to be adjusted to fit
ISO
5
your application needs.
1) Determine the proper base oil viscosity. There are many
500,000 ISO different ways to determine the viscosity requirement for a grease
400,000 7
application. One method is to use speed factors such as NDm
ISO
300,000 10 (NDm = rpm x [(bearing bore + outside diameter) 2]) or DN [DN
ISO = (rpm) x (bearing bore)] and the operating temperature to derive
15
200,000 the minimum viscosity requirement.
ISO
22 Typically, the NDm method is more accurate since it relies on the
ISO
DN Factor

32 bearings pitch diameter instead of just the bearing bore. Once you
100,000 ISO have properly selected the minimum viscosity, certain correction
46
ISO factors should be applied depending on operating conditions to
68 arrive at the optimum required base oil viscosity. Figure 1 is a
ISO
50,000 100 representation of the DN and operating temperature method.
40,000 ISO 2) Determine the proper grease thickener type and consistency.
150
30,000
Grease thickener type is becoming a more predominant criterion
ISO in grease selection due to the increasing number of thickener types
220
20,000 available. The thickener type is application dependent. Most
ISO
320
general-purpose greases will use lithium or lithium-complex thick-
ISO ener. For high-temperature applications, bentone or clay
460 thickener is preferred for its thermal stability against bleeding. For
10,000
-40 -20 0 20 40 60 80 100 120 heavy water environments, aluminum complex thickener is
Temperature C
preferred for its water washout stability. Also, be aware of thick-
ener type when changing greases in the same application as not all
Figure 1. DN vs. Operating Temperature types are compatible.

26 March - April 2010 www.machinerylubrication.com Machinery Lubrication

 FROM THE FIELD

Grease consistency is controlled by thickener type, thickener tency which ranges from 000 (semi-fluid) to 6 (block grease). The
concentration and base oil viscosity. It should be noted that a most common NLGI number is 2. Figure 2 depicts the relationship
grease with a high base oil viscosity does not always have a high of consistency, base oil viscosity, speed and loading.
consistency, and vice versa. The National Lubrication Grease 3) Determine the proper base oil type. Base oil type selection
Institute (NLGI) developed a scale for determining thickener consis- always has been a fundamental argument. Many argue that mineral
oil is the way to go, while others argue for synthetic oil. Actually,
Applications: NLGI ISO High High
both of these arguments can be true or false at any given time. Base
High Consistency (higher NLGI numbers) Grade VG Load Speed oil type is another variable determined by operational conditions.
Journal bearings, slow-speed, such as
locomotive block grease (high viscosity) 3 15 For most conditions, a mineral oil will suffice; but for those condi-
High-speed ball/roller bearings tions that are on the extreme ends of the temperature spectrum, a
(with low-viscosity base oil)
2 46 synthetic will more than likely be the base oil type of choice.
To avoid water washout
To avoid bleed Synthetic base oil selection also can be justified if extended lubri-
To avoid excessive leakage problems 2 100 cant life is required and costs can be justified.
High ambient or operating temps
To seal out environmental dust
4) Determine the proper additive package. Additive packages
2 220
(very dusty conditions) also are determined by operational conditions and requirements.
Low Consistency (lower NLGI numbers) Most additives found in lubricating oils are also found in greases,
Low-speed rolling element bearings 1-1/2 460
(with high viscosity)
such as anti-wear (AW), extreme pressure (EP), rust and oxidation
Cold temperature operation inhibitors (RO), and so on. The additive package selected solely
1 1500
Pumpability requirements depends on the application requirements. For example, a slow-
Gearbox - lubed-for-life
moving, standard-temperature conveyor bearing may use either an
EP or AW additive package, but a high-speed, high-temperature
Figure 2. Grease Consistency
electric motor will require only AW, not EP. The reason EP isnt used
in electric motors is due to its high chemical corrosiveness at high
Calculated
When the acoustic signal regrease
temperatures. For this reason, additives are just as important in the
Bearing quiets
upon application
increases but doesnt volume grease selection process as base oil viscosity/type and thickener
come back down,
of grease discountinue greasing or ... type. Additives are included in the formulation to help with the
... discontinue
performance and durability of the grease, but selecting the wrong
additive package for the application can have a reverse effect.
Decibels (dB)

greasing upon
reaching the
calculated
5) Determine the required performance properties. As with
maximum lubricating oils, greases have their own specific performance prop-
volume
erties, such as dropping point, mechanical stability, water washout,
Stopping here
Additional shots of grease results in a
may not leave
temporary increase in acoustic emission
bleed characteristics and pumpability. Based on these properties, a
enough reserve
grease
until excess grease can purge away from grease selection method should contain testing on greases chosen
moving elements
to perform under adverse conditions. This means that if a grease is
being used in a very slow-speed, highly loaded application, you
Volume (Grease) should perform a test for the greases ability to withstand this
Figure 3. Ultrasonic-assisted Relubrication Volume
loading; but for a standard application, where operational and
performance conditions arent subjected to the extremes, choosing
a standard-performing grease should suffice as long as all other
selection steps have been followed.
Calculated
Ultrasonic Alarm Regrease Interval
Threshold Relubrication Volume
Once you select the proper grease, it is time to determine the
30
Ultrasonic Trend proper relubrication volume. There are many methods used to
Regrease when
Decibels (dB)

the ultrasonic derive the relubrication volume. These can range from a general
alarm threshold calculation to using ultrasonic technology. To build a world-class
is exceeded, or
when the time lubrication program (not just for greasing), employ multiple tech-
threshold is nological disciplines to ensure that you have accounted for all of
exceeded,
whichever the variables.
Use ultrasonic trend comes first Two of the many methods used to determine the relubrication
data to adjust
scheduled interval volume of a grease-lubricated bearing is the calculated volume and
6 Months
ultrasonic-assisted greasing.
Time
The calculation is:
Figure 4. Calculated and Ultrasonic Re-lubrication Frequency Gq = 0.114 x D x B

28 March - April 2010 www.machinerylubrication.com Machinery Lubrication

 Where ...
Gq = Relubrication volume (ounces)
D = Bearing outside diameter (inches)
B = Bearing total width (inches)
Both of these methods are acceptably accurate
when used by themselves, but when they are used in
conjunction, the accuracy of the relubrication
volume increases substantially. Figure 3 is a represen-
tation of adjusting the relubrication volume with the
help of ultrasonic technology. As shown here, the
calculated relubrication volume can be increased or
decreased depending upon the ultrasonic signal.
Relubrication Frequency
As with determining the relubrication volume,
there are many methods for determining the
appropriate relubrication interval. This is a vari-
able that depends on a host of outside factors,
including contamination, operating time, temper-
ature, etc. For the sake of consistency, a calculated
and an ultrasonic approach will be discussed. The
most accurate but most subjective method, due to
determining certain correction factors, is the
calculated frequency.
T=K x [( 14,000,000
n x (d0.5) )
- (4 x d) ] Having an increased knowledge of the factors
Where ...
T = Time (hours)
K = Product of correction factors (see chart)
n = RPM
d = Bore diameter (inches)
Using ultrasonic technology here will help you
hone in on the most accurate relubrication
interval achievable. It will take time, dedication
and data, but it can show big savings in manpower
and cost if implemented correctly. Figure 4 shows
the correlation between the calculated relubrica-
tion frequency and ultrasonic technology.
As shown in this figure, the alarm limit for relu-
brication frequency either can be triggered by the
calculated interval or the ultrasonic threshold
being surpassed. This technology will help ensure
that over- or under-greasing is kept to a minimum.
Relube Application Method
There are many application methods available
to choose from depending on the applications
requirements, available manpower and allowable
budgets. There are two typical methods for
applying grease: manual grease gun and central
grease system or single-point lubricator (SPL).
Each of these methods has benefits and drawbacks.
Some benefits of using a manual grease gun
are: the lubrication engineer gets to see how the
Machinery Lubrication
equipment is performing and if any important
maintenance items need to be addressed before a
catastrophic failure occurs. Some of the draw-
backs are: it is more labor intensive and can be less
accurate depending on the lubrication engineers
knowledge and experience levels.
Some benefits of using a central grease system
or SPL are: less manpower is needed and it can be
used in remote locations for easier and safer relu-
brication. Some of the drawbacks are: the
lubrication engineer is less aware of the operating
conditions and maintenance needs of the equip-
ment due to the length of time between reservoir
refills, and over- or under-lubrication can easily
happen depending on the calibration of the lubri-
cating unit.
When using the manual grease gun application,
it is important for the lubrication engineer to
know the exact amount of grease expelled from
the grease gun with one stroke. To know this,
simply use a digital scale and dispense one strokes
worth of grease and weigh it.
Summary
that are needed to employ proper greasing, it is
easy to see why this fundamentally easy task can
lead to ill-advised decisions and inaccurate
results. A proper regreasing strategy should
include fundamental methods along with some
new technologies, such as ultrasonic-assisted
functions, and a lubrication engineer with proper
training and knowledge.
References
Jarrod Potteiger. Step-by-Step Grease Selection.
Machinery Lubrication magazine, September 2005.
Figures 1 and 2 are courtesy of ExxonMobil.
About the Author
Stephen Sumerlin is a technical consultant with
Noria Reliability Solutions, working on Lubrication
Process Design Phase II projects for Noria clients. He is
a mechanical engineer and a certified Level I Machine
Lubrication Technician (MLT) through the International
Council for Machinery Lubrication. Contact Stephen at
ssumerlin@noria.com.
Would You Like to Contribute?
Are you a technical expert? If so, we want to
publish your lubrication article in Machinery
Lubrication. To submit a technical article, please
send it to editor-in-chief Paul V. Arnold via e-mail
at parnold@noria.com.
www.machinerylubrication.com March - April 2010 29
PRODUCT SPOTLIGHT
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Oil Eater introduced emergency spill kits that are designed to
contain and clean up hazardous spills as required by the Occupational
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include Oil Eater Original cleaner/degreaser for cleaning surfaces after
absorption of a spill. Kits are available in 25-, 65- and 95-gallon over-
packs which can handle the corresponding volume of liquid. Each kit
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Industrial-strength Cleaners
The Zep Professional line of industrial-strength degreasers, hand
cleaners, lubricants and penetrants can handle tough tasks and soils.
Heavy-Duty High Alkaline Cleaner and Soy Industrial Hand Cleaner
are among the products in this line. High
Alkaline Cleaner is a concentrated, multi-
purpose, low-foam, powerfully alkaline
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Cleaner is an environmentally
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30 March - April 2010 www.machinerylubrication.com
Green Force Cleaners
CRCs Green Force cleaner line is formulated to meet strict environ-
mental requirements without sacrificing performance. Green Force
Multi-Purpose Cleaner, Heavy Duty Cleaner and Glass & Surface Cleaner
are recognized by the U.S. Environmental Protection Agencys Design for
the Environment (DfE) Formulator Initiative. Green Force products are
biodegradable, plastic-safe, non-flammable and can be used in many
applications around your facility. Heavy Duty Cleaner quickly removes
petroleum-based soils such as grease, grime and oil found in manufac-
turing and warehouse environments. Multi-Purpose Cleaner is safe and
versatile. Its concentrated formula effectively cuts greasy film and soils,
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CRC Industries
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BLUE WORKS Product Line
BLUE WORKS from WD-40 Company is a new line of industrial-
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and deliver superior performance under tough conditions. The BLUE
WORKS product line consists of eight products: Contact Cleaner,
Degreaser, Dry Lube PTFE Formula, High-Performance PTFE Lubricant,
Multi-Purpose Lubricant, Penetrant, Silicone, and White Lithium Grease.
Developed at the WD-40 Research and Development Center, BLUE
WORKS is the first line of products that carries the WD-40 Company
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WD-40 Company
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Machinery Lubrication
LUBE-TIPS
Helpful Hints and Neat Ideas
from Fellow Readers
T he Lube-Tips section of Machinery
Lubrication magazine features innova-
tive 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 editor-in-chief Paul V.
Arnold at parnold@noria.com. To sign up
for the Lube-Tips e-mail newsletter, visit
www.machinerylubrication.com and click
on the Newsletters link found near the top
of the home page.
How to Time
Filter Changes
This technical tip was submitted by Jason
Frankiewicz, a member of the reliability
team at Holcim (US) Inc.:
When is the correct time to change a
filter? Is it when the differential pressure
gauge reads 25, 40 or is topped out? Some
systems have a built-in pressure relief that
may never allow the back-pressure to indicate
the need for a filter change. Writing the date
that the filter was last changed on the filter or
tag can help. Including the filter part number
also has proved useful. Consider covering the
date and part number with plastic so that it
isnt wiped off during cleaning.
Outdoor Lube Storage Tip
This tip is courtesy of David Turner, a
lubricants technical advisor at Shell Global
Solutions:
To minimize water and particulate
contamination from entering new drums of
oil, it is preferred to keep drums indoors
and stacked horizontally. However, when it
is necessary to store drums outdoors and
uncovered, here is a technique that may be
32 March - April 2010
out; I had two-inch collars welded into the
holes. I then put an oil absorption pad in
the bottom of the drum. I spray-painted the
top blue and screwed the color-coded drum
adapters into the lid. I also would recom-
mend using dust caps. This storage method
helps control contamination, safely stores
drum adapters and keeps them where they
are easily found.
A paper towel absorbs water and trans-
fers it off the top of an oil drum.
used to remove water from the top of a
drum. Attach a paper towel to the top of
the drum. In the above photo, a magnetic
clip was used. Allow the paper towel to
hang over the edge of the drum so that the
water wicks through the towel and down
the side of the drum. Water will continue to
travel from the top of the drum to the
ground. This reduces breathing of water
through the bungs.
A grease drum has been outfitted to
Reuse That Grease Drum hold a myriad of drum adapters.
This tip was sent in by Mark D. Jones Sr.,
a lubrication consultant at Lubrication
Engineers:
Advice for Spotting
When I design a lubrication storage Oil Leaks
room using Norias best practices, there is This tip came from Josh Redington, a reli-
never a way to properly store the Des-Case ability facilitator at Jennie-O Turkey Store:
drum adapters. Afterward, I always find When possible, add dyes to your
them lying in the bottom of the tote hydraulic oil to make it easier to spot leaks.
containment vessel or stacked into a corner Colors such as purple or red will stand out
collecting dust and becoming contami- much more than the natural color of the oil,
nated. In a recent lube storage room especially in sunlight. Confirm dye compat-
conversion, I noticed an empty grease drum. ibility with your lubricant manufacturer
I then found the lid and had five holes cut before adding.
www.machinerylubrication.com Machinery Lubrication
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Spectroil Q100 new oil analysis spectrometers.
Easiest and fastest elemental analysis of wear
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Spectro Inc.
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34 March - April 2010
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Quickly monitor the remaining useful life of
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March - April 2010 35
 Get a Printable Version
CROSSWORD PUZZLER of This Puzzle Online at:
MachineryLubrication.com/puzzle

1 2 3

4 5 6 7

9 10

11

12

13

14

15

16 17

18

19 20

21

ACROSS DOWN
4 The author of As I See It columns in Machinery 1 The total number of API basestock categories (groups)
Lubrication 2 A non-ferrous wear metal
8 This type of additive uses magnesium, calcium 3 Direct reading ferrography uses this to collect ferrous
and/or barium particles
9 This additive uses silicon 5 The subject of this issues Get to Know ... article works
11 The type of wear caused by rolling contact for this company
13 Instrument used to measure levels of iron, tin, lead and 6 What the GL stands for in oils labeled API GL 4 or GL 5
copper in an oil sample
7 The TIEM plant featured in this issues cover story is from
14 What the F stands for in FTIR this state.
16 If high pressure were applied to a lubricant, would the 10 Early, random and time-dependent are the three
viscosity decrease or increase? classes of what?
17 The prime acronym used in Brendan Caseys column 12 According to Drew Troyers column in this issue, nearly
in this issue 80% of equipment failures are attributable to what?
18 Jeremy Wright writes about these in this issues Back Page 15 Abrasive wear is the result of this type of contact
Basics column
19 Breakdown maintenance is also known as what?
20 If diesel engine exhaust shows white smoke, what is likely to
show up in the oil analysis?
21 The type of contamination explored in the article by SKF in
this issue Get the solution on Page 45.
36 March - April 2010 www.machinerylubrication.com Machinery Lubrication
CONTAMINATION CONTROL
Addressing Oil Contamination
in Paper Machine Applications
BY JOHN YOLTON, SKF
O il contaminated by water is a common problem in the recircu-
lating oil systems used on paper machines. This article looks at
how contamination may occur and discusses methods for
preventing and removing water contamination.
An Introduction
Experience tells us that no bearing lubricant exists that completely
protects a bearing against the effects of moisture. Water-contaminated
lubricants suffer a range of problems, the most serious being corrosion
and lubrication breakdown. Relatively small amounts of water in lubri-
cants can have drastic effects on bearing life.
Experience suggests that contamination levels as low as 0.02
percent (200 parts per million) can have an effect on bearing life.
The relationship between contamination and life reduction is,
however, non-linear and complex. Factors such as oil
type/solubility, additive packages, degree of degradation, etc., all
affect the susceptibility of a lubricant to this problem.
Bearings used in the paper industry are particularly prone to
such problems due to the nature of the application. There are many
possible sources of water contamination, including:
Leaking steam joints
Oil reservoirs open to the atmosphere or prone to condensation
in the tank
Spraying of clean-up water
Figure 1. Left: new grease. Right: milky grease as the
result of water inclusion.
38 March - April 2010 www.machinerylubrication.com
Oil systems associated with the wet end of a paper machine are
particularly vulnerable. The nature of the paper forming process
means that the air in this area is inevitably moisture-laden. Bearing
housings are generally warmer than the surrounding atmosphere
and frequently employ sealing arrangements that afford little
protection from spraying water.
Vents in oil drainage headers intended to facilitate oil flow back
to the reservoir have been found in some cases to contribute to
moisture contamination of the oil.
Transportation, handling and storage problems can result in mois-
ture contamination of new oil, perhaps even as much as 1,000 ppm.
Numerous studies have demonstrated the detrimental effect
that water has on the wear characteristics of rotating and hydraulic
equipment. Oil, when mixed with water, loses some of its lubri-
cating properties. The oil film between the rotating elements in a
bearing is a critical factor in the bearing life. Presence of water in
the oil will reduce film thickness.
Water in Oil
There are several elements of water-in-oil contamination. These
include:
Free water: Free water typically settles toward the bottom of the
oil reservoir. This factor usually is allowed for when designing the
reservoirs used in oil circulating systems for paper machines.
Typically, the reservoir will be sized so as to ensure that the oil is
retained for at least 30 minutes in the reservoir; this allows free water
to settle before the oil is recirculated. This usually means that the
reservoir capacity will equate to 10 times the rated pump capacity.
Indeed, for wet-end oil circulating systems, some manufacturers
recommend a reservoir sized for 60 minutes of retention time.
Emulsified water: Emulsified water exists as very fine bubbles
suspended in the oil. It is characterized by the whitish or hazy
portion that is often seen in contaminated systems. The bubbles
are usually about five to 10 microns in diameter. Emulsification of
water can result from a number of courses:
Use of high-shear pumps
High-velocity pipelines
Fine filtration medium
Additive packages designed to emulsify water
Machinery Lubrication
 Dissolved water: Oil, like air, can hold water in solution, up to its
saturation point, which will depend upon the oil type and temper-
ature. Oil containing dissolved water may still appear clear and
bright. Once the saturation point is exceeded, the oil usually
appears cloudy or milky.
Detection Methods
Several methods exist for detecting and measuring water contam-
ination of oil. These range from largely subjective methods to
sophisticated laboratory techniques offering a high level of accuracy.
Fluorescing dyes are available that allow the user to judge the
amount of water that is present by the degree of fluorescence, but this
method is really only suited to confirm a suspect condition. Experience
shows it to be limited in terms of repeatability and accuracy.
A more accurate method involves driving off the water in the
form of steam and then quantifying the amount. At least one
supplier of oil systems offers this technology to mills for their own
in-house use. The method offers accuracies to 0.01 percent.
Lab services are now commonly available from oil and filter
companies. However, experience suggests that sampling is often
not undertaken frequently enough to prevent formation of damage
on bearing races. Damage will, in time, lead to failure.
Preventing Contamination
Undoubtedly, the best way to avoid these moisture-related prob-
lems is to prevent the contamination from occurring. Effort
Machinery Lubrication www.machinerylubrication.com
expended in this area can have significant effects on mill reliability
and availability.
Steam joints: Leaking steam joints are a major source of water
contamination. Typically, escaping steam is blown against bearing
housings on the back side of dryer sections. The resulting conden-
sate contaminates the oil system. Some mills employ flingers to
prevent this. The best solution is to avoid having steam leaks at all.
Seals: Most bearing housings are fitted with a labyrinth-type
seal that allows water to pass through into the bearing housing.
Flingers or stationary add-on shields improve the protection
afforded to the bearing.
Inspections: Check lubrication drainage systems for holes or
openings that allow water or water vapor to get into the system.
Such problems are commonly found in vents. Rigorously check
piping for holes.
Oil/water heat exchangers: The purpose of these units is to cool
the oil as it returns to the reservoir. The design of modern systems
is usually such that the oil pressure is higher than the pressure of
the cooling water so that any leaks should result in oil contami-
nating the water, rather than the other way around. Severe leaks of
this kind can be a serious problem, but its usually of a different
kind (e.g., environmental).
Some older-type reservoirs also use steam coils to heat oil in the
reservoir before it goes to the machine. Leaks here can cause water
to enter the tank, and shutting off the heaters may be a short-term
solution. However, sending cold oil to the bearings results in other
March - April 2010 39
 CONTAMINATION CONTROL
lubrication problems, and so this is not a perma-
nent solution. Modern systems tend to employ
electric immersion heaters to avoid this problem.
Sweep air: Oil returns to the reservoir at a
higher temperature than its environment.
Moisture in the returning oil, or in the air
surrounding it, may condense in the free air space
above the oil in the reservoir. If the tank design
doesnt allow sufficient retention to allow settling
to occur, this moisture will contaminate the oil in
the reservoir. One solution is to pass filtered air
across this air space by means of an exhaust fan.
Some system suppliers use a more elaborate air
dryer to condition the air in the air space.
Removing Contamination
There are several methods with which to
remove contamination. These include:
Vacuum dehydrators: The contaminated oil is
heated in a vacuum. This lowers the boiling point
of the water. The water contained in the oil (both
free and emulsified) is thus released as water
vapor, which is then condensed and removed.
Unlike other methods, this process doesnt also
remove oil additives, and air and other non-
condensable gases are removed through the
vacuum pump. Commercial systems are available
to implement this process, and some of these also
feature separate filters for particulate removal.
Such systems are usually rated in terms of
throughput capacity. However, water removal effi-
ciency is dependent upon the level of vacuum
obtained. As a result, it can vary widely from
system to system.
Centrifugal cleaners: Centrifuges are effective in
removing free water but are ineffective for removing
emulsified or dissolved water, which will not separate
by gravity. Centrifuges also are limited in their appli-
cation because of their inability to remove entrained
gases and air that are present in lubricating systems.
Also, centrifuges are often perceived to be high-main-
tenance pieces of equipment.
Other methods: Coalescence-type separators
speed the process that oil and water do naturally
(i.e. separate). This is achieved by use of filters
(known as coalescence media) made of materials
that are hydrophobic (water repellent) and
oleophilic (oil attracting). These cause the oil to
form into droplets that float to the surface of the
separation chamber. This effectively forms two
zones of liquid in the chamber. The separated oil
flows into a collection chamber for removal, while
the clear water underflows the oil and is
discharged on a continuous basis. Solids also
settle out through the filter media and are
collected in a sludge tank.
40 March - April 2010 www.machinerylubrication.com
Other filter-type approaches involve use of
absorbent filter media to remove free and emulsified
water as it passes through the cartridges. Such
methods are considered by some to be cumbersome
because of the need to periodically renew the filters
and because of the uncertainty of operation.
Conclusions
Presence of water in lubricating oil is detrimental
to bearing life. The best way to prevent this is to
avoid water contamination of the oil, rather than
use techniques for removing water from the oil.
However, if resources arent available for preventing
the problem at the source, then money must be
spent on removal processes. Removal systems vary
in cost and effectiveness, and choice is dictated by
the specific requirement and the resources avail-
able. Expenditure incurred in keeping water out of
lubrication systems will have a payback in terms of
increased machine uptime. Avoiding the need for
maintenance staff to undertake bearing replace-
ments on an emergency basis also avoids
compromising planned maintenance activities and
the problems that can arise as a result of such activ-
ities not being timely undertaken.
About the Author
John Yolton is a maintenance strategy consultant
for SKF Reliability Systems and its @ptitudeXchange
knowledge resource. For more information, visit
www.skf.com and www.aptitudexchange.com or
e-mail info@aptitudexchange.com.
Sign Up for Norias
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Machinery Lubrication
CERTIFICATION NEWS
More Facts, Clarifications on
Changes to Certification Exams
BY SUZY JAMIESON, ICML
T he International Council for Machinery Lubrication is
entering its 10th year of operations, having certified more
than 5,000 professionals in 67 different countries and through
exams in eight languages. There are more than 1,000 companies
around the world with ICML-certified personnel. And for more
than seven years, ICML has been considered the de facto world
standard when it comes to certification of lubrication and oil
analysis professionals.
The global recognition of ICMLs credentials and programs is
vast; and in 2004, it was proposed to ISO that the councils work,
including its bodies of knowledge for the Machine Lubricant
Analyst (MLA) programs, be incorporated into a then-developing
standard on certification of field analyst professionals. In 2008, the
standard was published with a great approval rating by the member
countries. ICML is very honored that its bodies of knowledge for
the MLA Level I, MLA Level II and Machine Lubrication Technician
(MLT) Level I certifications were pioneered into the first-ever ISO
international standard on qualification and assessment of field
lubricant analysts. The ICML MLA I and MLA II certification
programs subject areas were brought into ISO 18436-4 as
Category II and Category III.
To reflect the equivalence with the ISO 18436-4 standard, ICML
recently decided to rename its original MLA I and MLA II certifica-
tions as MLA II and MLA III, since MLA I and II are equivalent to
categories II and III, respectively, within ISO 18436-4.
MLA Program Changes
ICMLs original top category in the oil analysis track, MLA II, is
equivalent to the top category of the 18436-4 standard, Category
III, because the ISO version was designed to be a three-tier
program, not two tiers like the original ICML program.
ICMLs original MLA I was considered too challenging to be
used as an entry-level international standard category, too high a
bar for the world as a whole. Therefore, a more basic category
was added to the oil analysis series. As it turned out, this entry
level was actually based on the MLT I, with some basic oil
sampling, basic lubricant health and a general view of wear debris
knowledge added, since the standard was for oil analysis, not
machinery lubrication alone.
42 March - April 2010 www.machinerylubrication.com
The syllabus of this modified MLT I, which is the new MLA I,
was accepted by ISO into the 18436-4 for its importance in
machine and lubricant knowledge and for being a more basic, suit-
able entry level for an international standard dealing with the
qualification and assessment of field-based oil analysts. So, think
of the ISO standard 18436-4 categories I, II and III at ICML as basi-
cally the original MLT I plus three oil analysis subject areas (now
available through the new MLA I); the original MLA I (now
renamed MLA II) and the original MLA II (now renamed MLA III).
MLT Program Changes
The pioneering of the MLT I from a machinery lubrication scope
in nature into an oil analysis standard creates a possible overlap in
the two career tracks at ICML for individuals interested in both oil
analysis and machinery lubrication.
There was some rearranging of percentages on the original MLT I
subject areas to make space for adding the needed oil analysis
subject areas. However, these are meant to be covered at a very basic,
entry level. This means that the new MLA I and the original MLT I
have bodies of knowledge that are approximately 80 percent similar
in subject area content. Despite this, ICML decided to keep the orig-
inal MLT I exam available for people interested only in machinery
lubrication (not oil analysis) as a career. For those who prefer the
choice of both machinery lubrication and oil analysis career
tracks/certification, the entry point to both is the new MLA I exam.
Granted that a new MLA I certificate holder meets the requirements,
he or she can pursue MLA II and then the MLA III or MLT II exam.
As for whether there are plans to add an MLT III, the new MLA
III is essentially the original MLA II, just renamed for clarity sake.
ICML has not added a higher level to the MLA series and doesnt
envision adding a higher level specific to the MLT series, either.
ICML does have plans for and is working on a Machinery
Lubrication Engineer (MLE) certification, which targets the person
above both the MLT II and original MLA II, now called MLA III.
Therefore, the proposed career path would be:
Machinery Lubrication
MLT I, MLT II, MLE
Field Oil Analysis (18436-4 equivalent)
MLA I, MLA II, MLA III, MLE
Machinery Lubrication
Mature Student Clause
The alignment with ISO meant ICML now
offers a three-tier program on the oil analysis
track, where before, entry level was at what is
now called the MLA II. However, for the seasoned
oil analysis professional, nothing changes.
ICMLs original requirement allowed people
with two or more years of full-time experience in oil
analysis to sit for the MLA I, now called MLA II.
Despite the creation of a more basic entry level to
the program (new MLA I), professionals that
would have originally qualified to sit for the orig-
inal MLA I need not take the new MLA I exam as a
point of entry, despite the prerequisite now in exis-
tence in ISO. You may actually qualify to still enter
the ICML oil analysis career path via the same
exam, now called MLA Level II. This is possible via
a mature student clause. This clauses intent is to
allow the knowledgeable, experienced pro to
bypass the training and exam requirements of the
prerequisite entry category (new MLA I).
To qualify for exam as a mature student
candidate, there are additional experience
requirements, which are comparable to ICMLs
pre-ISO requirements. There is also the require-
ment of having a knowledge base in the MLA Is
body of knowledge subject areas. Such knowl-
edge in the MLA I syllabus subject areas,
however, need not have been acquired through
formal training. On-the-job training and experi-
ence are acceptable for demonstrating MLA I
knowledge under this mature student clause. Of
course, formal training in the MLA II exam body
of knowledge would still be required, even for
entry under this mature student clause.
For more information on the specifics of
ICMLs mature student entry clause for
the MLA II program, or if you have any
general certification-related questions, e-mail
info@lubecouncil.org.

About ICML
The International Council for Machinery
Lubrication (ICML) is a vendor-neutral, not-for-profit
organization founded to facilitate growth and devel-
opment 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. ICML is an independently chartered organiza-
tion consisting of both paid professional staff
members and volunteer advisors. It provides lubrica-
tion and oil analysis standard development support,
scholarship, skill-based testing and certification, and
recognition of excellence. For more information
about ICML, visit www.lubecouncil.org.

Machinery Lubrication www.machinerylubrication.com March - April 2010 43

PERSPECTIVE
The Dos and Donts
of Oil Sampling
JASON KOPSCHINSKY
NORIA CORPORATION
P eople love dos and donts lists. A quick Google search will
yield 10.9 million hits for what to do and not do. A quick scan
through the endless supply of D&D lists will show that many of the
subjects people feel the need on which to provide unsolicited
consulting really dont have a defined method of approach beyond
common sense. For example, the dos and donts of air travel barely
stretch outside the realm of common sense. Advice such as Do not
place your firearm in your carry-on luggage or Do not smoke
while in the aircraft goes without saying. Then there are the do and
do-not-do lists for topics that are highly subjective such as fashion
(Dont wear white after Labor Day).
Thankfully, in the realm of oil analysis and machinery lubrica-
tion, few dos and donts can be considered subjective. In this case,
were talking about what to do and not do related to oil sampling
for analysis. These simple rules will make or break the integrity of
your sample, which is meant to drive your maintenance and relia-
bility decisions.
Follow the Rules
Oil analysis is a condition monitoring tool designed to monitor:
fluid properties, or the condition of the oil and the additives;
fluid contamination; and,
machine wear.
However, the analysis of a sample greatly depends on the quality
of the sample itself. A high-quality sample translates into one that
is rich with data and free from noise. The content of this article is
nothing new. Dozens (if not hundreds) of articles, papers and
books have had some advice for us to follow when extracting a
sample of oil from a machine for analysis. However, as an industry,
we dont seem to get it right.
The same rules for oil sampling still apply, just like they always
did. Here is the most recent do and do-not-do list for oil sampling
from my perspective.
1) DO sample from running machines. DO NOT sample cold
systems. This rule goes beyond simply starting the machine to take
the sample. The ideology behind oil analysis is to capture a snap-
shot of the system at the time of sampling. The timing of the
sampling should be when the system is under the greatest amount
of stress. Typically, the best time to sample a system is when the
system is under normal working load and normal conditions. This
can be a tricky task when sampling from a system that continuously
cycles during normal production, such as the hydraulic system on
44 March - April 2010 www.machinerylubrication.com
an injection molding machine. Its under these conditions that well
capture a sample that best represents the machine conditions most
likely to cause accelerated wear.
2) DO sample upstream of filters and downstream of machine
components. Filters are designed to pull out wear debris and
contaminants, so sampling downstream of these data-strippers
provides no value. However, taking a sample before and after a
filter for a simple particle count will allow you to see how well the
filter is currently operating. Obviously, we expect the particle count
before the filter to be higher than after the filter. If its not, its time
to change the filter. Condition-based filter changes can be very
important for sensitive systems and expensive filters.
3) DO create specific written procedures for each system
sampled. DO NOT change sampling methods or locations.
Everything we do in oil analysis and machinery lubrication should
have a detailed procedure to back up the task. Each maintenance
point in the plant should have specific and unique procedures
detailing who, what, where, when and how. Oil sampling proce-
dures are no different. We need to identify the sample location, the
amount of flush volume, the frequency of sampling, the timing
within a cycle to sample, and indicate what tools and accessories to
use on that specific sample point based on lubricant type, pressure
and amount of fluid required.
4) DO ensure that sampling valves and sampling devices are
thoroughly flushed prior to taking the sample. DO NOT use dirty
sampling equipment or reuse sample tubing. Cross-contamination
has always been a problem in oil sampling. The truth of the matter
is that flushing is an important task that is often overlooked.
Failure to flush the sample location properly will produce a sample
with a high degree of noise. Flushing prior to sampling needs to
account for the amount of dead space between the sample valve
and the active system multiplied by a factor of 10. If there is a run
of pipe 12 inches long between the sample valve and the active
system that holds one fluid ounce of oil, you need to flush a
minimum of 10 fluid ounces before taking the sample for analysis.
Flushing the dead space also will flush your other accessories such
as your sample valve adapter and new tubing.
5) DO ensure that samples are taken at proper frequencies. DO
NOT sample as time permits. Many of those responsible for taking
oil samples rarely see the results of the analysis. One of the most
powerful aspects of oil analysis is identifying a change in the baseline
of a sample and understanding the rate at which the change has
Machinery Lubrication
occurred. For example, a sample of new oil should have zero parts
per million (ppm) of iron when tested as the baseline. As regular
sampling and analysis continues, we may see the iron level increase.
An increase of 10 or 12 ppm per sample may be considered critical;
however, if the frequency is not consistent, what is considered normal
becomes very subjective. If our frequency of sampling is 12 months, a
rise in iron of 12 ppm isnt a major cause of concern. If our frequency
is weekly, a rise in iron of 12 ppm is very concerning. Setting up the
appropriate sampling frequency and adhering to it will allow for
precise analysis and sound maintenance decisions.
About the Author
As technical operations director for Noria Reliability Solutions, Jason
Kopschinskys primary responsibilities include managing numerous and
varied projects in the areas of: plant audits and gap analysis, Lubrication
Process Design, oil analysis program design, lube PM rationalization and
redesign, lubricant storage and handling, contamination control system
design, and lubrication and mechanical failure investigations. Contact
Jason at jkopschinsky@noria.com.
Crossword Puzzler Solutions: From Page 36

6) DO forward samples immediately to the oil analysis lab after F B M

J I M F I T C H R J G A I
sampling. DO NOT wait more than 24 hours to send samples out.
V O D E T E R G E N T
As mentioned earlier, oil sampling is much like taking a snapshot of D E F O A M A N T N N A N D
your system at a point in time. The health of a lubricated system A Z N R E I
can change dramatically in a very short period of time. If a problem S U R F A C E F A T I G U E I L T A
is detected in a system, the earlier it is detected, the less cata- H P E U I N
I E O B S A
strophic potential it may have. Jumping on a problem early will not
E L E M E N T A L S P E C T R O M E T E R M
only allow you time to plan for a repair, but the repair will poten- E P U I
tially be less significant. F O U R I E R L R C
S Y E K A
Apply Them Today L F
I N C R E A S E
I
S
E
Y
N
T O W
This dos and donts list for oil sampling could go on and on. D I O I L S E N S O R S
Each and every system will have unique and specific considerations I L U T
for what to do and not do when sampling. The tips in this article N R U N T O F A I L U R E C O O L A N T
G R S R
will provide big bang for your buck and can be applied to most
W A T E R I N O I L E
systems in your sampling program.

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BACK PAGE BASICS
An Overview of Oil Level
Sensors and How They Work
JEREMY WRIGHT
NORIA CORPORATION
il sensors and analyzers are used in automotive and industrial
O applications to gather or send valuable information. They can
range from a simple, float-type oil level indicator to a complex, in-
line laser particle counter and everything in between. This article
will outline the different types of oil level sensors, demystify how
they work and explain the results they return to the user.
Mechanical Sensors
The mechanical sensor is the simplest and most widely used level
sensor. The principle behind magnetic, mechanical, cable and other
float level sensors involves the opening or closing of a mechanical
switch, either through direct contact with the switch or magnetic
operation of a reed. With magnetically actuated float sensors,
switching occurs when a permanent magnet sealed inside a float
rises or falls to the actuation level. With a mechanically actuated
float, switching occurs as a result of the movement of a float
against a miniature (micro) switch. The choice of float material
also is influenced by temperature-induced changes in specific
gravity and viscosity; such changes directly affect buoyancy.
Dont use float-style sensors with very high-viscosity (thick) oils,
oils that have a tendency to form sludge and varnish, or heavily
contaminated oils. Other sensing technologies are better suited for
these applications.
A special application of float-type sensors is the determination
of interface level in oil-water separation systems. You can use two
floats, with each float sized to match the specific gravity of the oil
on one hand and the water on the other. Another special applica-
tion of a stem-type float switch is the installation of temperature or
pressure sensors to create a multi-parameter sensor. Magnetic float
switches are popular for simplicity, dependability and low cost.
Pneumatic Sensors
Use pneumatic level sensors where hazardous conditions exist,
where there is no electric power or its use is restricted, and in appli-
cations involving heavy sludge or slurry. Since the compression of a
column of air against a diaphragm is used to actuate a switch, no
process liquid contacts the sensors moving parts. These sensors
are suitable for use with highly viscous liquids such as grease. This
has the additional benefit of being a relatively low-cost technique
for point-level monitoring in a lube system.
Ultrasonic Sensors
Use ultrasonic level sensors for non-contact level sensing of highly
viscous liquids, as well as bulk solids. The sensors emit high-frequency
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(20 to 200 kilohertz) acoustic waves that are reflected back to and
detected by the emitting transducer.
Turbulence, foam, steam, chemical mists (vapors) and changes
in the concentration of the process material also affect the ultra-
sonic sensors response. Turbulence and foam prevent the sound
wave from being properly reflected to the sensor. Steam and chem-
ical mists and vapors distort or absorb the sound wave. Variations
in concentration cause changes in the amount of energy in the
sound wave that is reflected back to the sensor. Use stilling wells
and wave guides to prevent errors caused by these factors.
Proper mounting of the transducer is required to ensure best
response to reflected sound. In addition, the tank should be relatively
free of obstacles such as weldments, brackets or ladders to minimize
false returns and the resulting erroneous response, although most
modern systems have sufficiently intelligent echo processing to
make engineering changes largely unnecessary except where an intru-
sion blocks the line of sight of the transducer to the target.
The requirement for electronic signal processing circuitry can be
used to make the ultrasonic sensor an intelligent device. Ultrasonic
sensors can be designed to provide point-level control, continuous
monitoring or both. Due to the presence of a microprocessor and
relatively low power consumption, there also is capability for serial
communication to other computing devices, making this a good
technique for adjusting calibration and filtering of the sensor signal,
remote wireless monitoring or plant network communications.
To summarize, the ultrasonic sensor enjoys wide popularity due
to the powerful mix of low price and high functionality.
Conductive Sensors
As most all oils have an insulating property, conductive level
sensors arent exactly the best choice for an oil level sensor.
However, many liquids in industry are conductive, so these sensors
are included in this article.
Conductive level sensors are ideal for the point-level detection of
a wide range of conductive liquids such as water, and is especially
well suited for highly corrosive liquids such as caustic soda,
hydrochloric acid, nitric acid, ferric chloride and similar liquids. For
those conductive liquids that are corrosive, the sensors electrodes
need to be constructed from titanium, Hastelloy B or C, or 316
stainless steel and insulated with spacers, separators or holders of
ceramic, polyethylene and Teflon-based materials. Depending on
their design, you can use multiple electrodes of differing lengths
with one holder. Since corrosive liquids become more aggressive as
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temperature and pressure increase, consider these extreme condi-
tions when specifying these sensors.
Conductive level sensors use a low-voltage, current-limited
power source applied across separate electrodes. The power supply
is matched to the conductivity of the liquid, with higher voltage
versions designed to operate in less conductive (higher-resistance)
mediums. The power source frequently incorporates some aspect of
control, such as high-low or alternating pump control. A conduc-
tive liquid contacting both the longest probe (common) and a
shorter probe (return) completes a conductive circuit.
Conductive sensors are extremely safe because they use low volt-
ages and currents. Since the current and voltage used is inherently
small, for personal safety reasons, the technique also is capable of
being made intrinsically safe to meet international standards for
hazardous conditions.
Conductive probes have the additional benefit of being solid
state devices and are very simple to install and use. In some liquids
and applications, maintenance can be an issue. The probe must
continue to be conductive. If buildup insulates the probe from the
medium, it will stop working properly. A simple inspection of the
probe will require an ohmmeter connected across the suspect
probe and the ground reference.
Build on Knowledge Base
There are many other techniques and technologies used to
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monitor sump levels, but the devices covered in this article are
going to be the most prevalent in nearly all plants.
I hope this article gives you a better base knowledge of the
different types of sensors used. As always, if you would like more
information or wish to discuss this subject in greater detail, feel free
to contact me.
About the Author
Jeremy Wright is a certified Machinery Lubricant Analyst (MLA) Level I
and Level II and Machinery Lubrication Technician (MLT) Level I by the
International Council for Machinery Lubrication (ICML). In addition, he is
a Certified Maintenance and Reliability Professional (CMRP) by the Society
for Maintenance and Reliability Professionals (SMRP). Contact Jeremy at
jwright@noria.com.
Sensor technology
reduces costs, downtime
Fluid condition sensors, which can track a variety of fluid
condition metrics including viscosity, conductivity and dielectric
constant provide the continuous monitoring capability required
to ensure the uninterrupted operation of equipment. Read an
exploratory article on this topic from SenGenuity at
www.machinerylubrication.com. Access it by typing SenGenuity
in the Search box.
Machinery Lubrication