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Best Ways to Eliminate
-
Hydraulic Oil Leakage
Overcoming the Risks of
Cold Machine Starts
'
,-
How to Evaluate
a New Lubricant
DDDDD By Dave Wooton, Wooton-Consulting
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Program In Just 3-Days.
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Contents
6COVER STORY
How to Evaluate a New Lubricant
Take an in-depth look into industry-accepted tests for predicting lubricant life, including results from actual
commercial lubricants.
September-October 2017
2AS I SEE IT
Make the Lube Room Your Lubrication
Command Center
40 LESSONS IN LUBRICATION
Overcoming the Risks of Cold Machine Starts
By becoming aware of the potential effects that temperature can
have on your lubricants, you can better understand how a machine
For any plant seeking lubrication excellence, there needs to be a
could fail and hopefully prevent future failures.
46
visual starting point that sets the stage for whats to come elsewhere
in the facility. There is no better place for that than the lube room.
14
PERSPECTIVE
INDUSTRY FOCUS Understanding the Changing Requirements
2017 Salary Survey: Salaries for Lubrication for Food-grade Lubricants
Professionals Holding Steady With the full implementation of the Food Safety Modernization Act
The latest results from Machinery Lubrications annual salary survey (FSMA), there will be many changes in the requirements for compa-
50
reveal some interesting insights into the lubrication industry, as nies that make food and beverage products.
compensation rates appear to have remained steady over the past 12
TRAINING AND CERTIFICATION
24
months with less than a 1 percent change in earnings.
Newcrest Minings Cadia Valley Operations
HYDRAULICS Wins Gill Award
Best Ways to Eliminate Hydraulic Oil Leakage Newcrest Minings Cadia Valley Operations in Australia has been
By properly setting the pressures, installing accumulators and shock selected as the recipient of the 2016 Augustus H. Gill Award by the
suppressors, verifying that the system is piped and hosed correctly, International Council for Machinery Lubrication for excellence in
54
and adjusting pilot chokes, you should be able to reduce or even oil analysis.
eliminate shock and leakage in your hydraulic systems.
34
BACK PAGE BASICS
LUBE-TIPS Volatility vs. Flash Point: What You Should Know
Our readers offer advice on a host of lubrication-related issues, Learn the differences between an oils volatility and flash point,
including tips for testing lubricant compatibility, changing pillow- including how these properties correlate to each other, as well as
block bearings and sampling oil from hard-to-reach locations. the best methods for determining them.
MoreEditorial Features
32 GET TO KNOW
Departments
28 ASK THE EXPERTS
35 BOOKSTORE
36 PRODUCT NEWS
38 NOW ON MACHINERYLUBRICATION.COM 30 PRODUCT SUPERMARKET 39 TEST YOUR KNOWLEDGE
L ubricant S torage and Handling
AS I SEE IT
J im F itch | N oria C orporation
Make the
LUBE ROOM Your Lubrication
COMMAND CENTER
F or any plant seeking lubrica-
tion excellence, there needs to
be a visual starting point that
sets the stage for whats to come elsewhere
in the facility. There is no better place for
that than the lube room. In fact, Ive never
heard of a plant exhibiting excellence in
machinery lubrication that doesnt also
exude excellence in the lube room. The
lube room serves as the centerpiece and
reference state for lubrication excellence.
You have to get it right.
This is important because transfor-
mation can take a while for large plants.
Rome wasnt built in a day. To succeed,
you must have a solid foundation and a
constant reminder of what quality and
success should look like. It effectively The False Economies
punctuates that this standard of excel-
lence should be replicated at each machine
of Cheap
Experts agree that the best way to over-
where lubricants are in use. Theres a
come a catastrophic machine failure is not to
huge and very important psychological
have one. However, those in the maintenance
element here.
field understand that machine reliability
If you cut corners in the design and
comes at a price. On the one hand, focusing
quality of your lube room, more critical
on machine reliability alone may fail to control
corners will be cut elsewhere in the plant wasteful and excessive expenditures. To the
as well. Mediocracy becomes the norm and other extreme, initiatives that slash current
will be imbedded in the culture. When this maintenance expenditures without consid-
occurs, the lube room transforms into a ering long-term reliability consequences are
pigpen of tools, pumps, hoses, grease frequently penny wise and pound foolish.
guns, bottles, totes and drums. Dont let Poor reliability and premature machine
that happen. Be fussy and demanding, failures have a compounding financial
and set a high standard that encourages impact. Half-heartedly measuring one
reliability excellence throughout the rest element will spread like a cancer when
of the plant. measuring something else. Dont get me
GRAPHIC ARTISTS
Patrick Clark - pclark@noria.com
Josh Couch - jcouch@noria.com
Greg Rex - grex@noria.com
ADVERTISING SALES
Tim Davidson - tdavidson@noria.com
800-597-5460, ext. 224
CORRESPONDENCE
You may address articles, case studies,
special requests and other correspondence to:
Editor-in-Chief
MACHINERY LUBRICATION
Noria Corporation
1328 E. 43rd Court Tulsa, Oklahoma 74105
Phone: 918-749-1400 Fax: 918-746-0925
Email address: editor@noria.com
The test results for the blended fluids in ASTM D1401. This test blends 40 milliliters
TESTING MINERAL MINERAL
the study (shown on page 7) indicate that of water and oil, reporting the amount of oil,
SERIES PAG OIL 1 OIL 2
the lubricants passed the foam criteria for water and emulsion after a predetermined
Weight
compatibility at this concentration. amount of time. According to ASTM D4304, Change of
a lubricant should have less than 3 milliliters -0.367 -0.008 0.017
Copper Panel
Membrane Patch Test of stable emulsion. The results for the blended (mg/cm2)
The formation of solids is a serious fluids in the study are shown below and reveal Appearance
problem with lubricant compatibility. This that these lubricants failed the test. of Copper Shiny IB Shiny IB Shiny IB
Panel
is typically an additive issue in which one
additive has poor solubility in the other Rust Original
When water limits are exceeded, most Viscosity at 24.70 33.35 31.36
lubricants base stock, or the additives in one
40C (cSt)
lubricant react with the additives in the other condition monitoring programs alert
40C
lubricant. If severe, this can be observed in users about the lubricants condition due
Viscosity 26.17 33.31 31.36
visual testing. However, the concentrations to potential rust issues. Since the studied After (cSt)
are often too low for observation. lubricants were R&O fluids, passing a rust
% Change
ASTM D7843, commonly referred to as test was a primary concern. in Viscosity
ASTM D4378 defines water as critical 5.95% -0.12% 0.00%
the membrane patch colorimetry (MPC) (D445 at
test, can be used to observe solid formation. at 200 milligrams per gram (mg/g) of 40C)
Results are reported as a dE value based on lubricant. The synthetic PAG lubricant Original Acid
the CIE Lab scale. The MPC results for most failed this test. Even when blended, the Number
0.06 0.08 0.03
lubricants water levels still did not meet (D974) (mg
new lubricants are in the 2-5 dE range.
KOH/g)
The test results for the blended fluids in the recommended amount.
the study (shown below) indicate that the The initial study evaluated the new Acid Number
lubricants (PAG, mineral oil 1 and mineral After (D974) 2.44 0.05 0.13
lubricants passed the liquid-solid criteria for
(mg KOH/g)
compatibility at this concentration. oil 2) and determined that they passed the
rust criteria. The next step was to perform Change in
Demulsibility the tests with aged lubricants. For this, the Acid Number
(D974) (mg
2.38 -0.03 0.10
Demulsibility is the lubricants ability to lubricant was run to 75 percent to the end KOH/g)
separate from water. It is measured using of a rotating pressure vessel oxidation test
(RPVOT). This is based on ASTM D4378, Total Acidity
of Water
BLENDED LUBRICANTS dE VALUE which explains that a fluid is at its end of 6.93 2.85 0.95
Layer (mg
90% PAG/10% Mineral Oil 1 4.3 life when the RPVOT reaches 25 percent KOH)
of the new fluid (75 percent to the end of
90% PAG/10% Mineral Oil 2 4.5 Percent
the RPVOT). RPVOT adds excess water to 0.004% 0.000% 0.012%
MPC test results Insolubles
the lubricant as part of the test, so water
is already present to cause potential issues. End of Test
EMULSION Fluid ICP
BLENDED (TIME IN The rust test (ASTM D665A) for the new 5 Nil Nil
Copper
LUBRICANTS OIL WATER MINUTES) and oxidation-tested lubricants showed (ppm)
90% PAG/10% 1
passing results. The rust inhibitor in all
0 mL 79 mL (30) three fluids was found to be sufficient to
Mineral Oil 1 mL Hydrolytic stability results for the
90% PAG/10% 2 protect equipment even at high water levels. tested lubricants
1 mL 77 mL (30)
Mineral Oil 2 mL
5% Mineral Oil 1
0 mL 79 mL (30)
2/95% PAG mL
95% Mineral Oil 0
32 mL 48 mL (30)
2/5% PAG mL
Demulsibility test results
AMOUNT OF
BLENDED LUBRICANTS WATER
90% PAG/10% Mineral Oil 1 3,900 mg/g
New Oils PAG 75% to EOT Mineral Oil 1 75% to Mineral Oil 2 75% to
90% PAG/10% Mineral Oil 2 4,400 mg/g
2272 EOT 2272 EOT 2272
Rust test results
The results of the rust test include a visual rating of steel pins as shown above.
8 | September - October 2017 | www.machinerylubrication.com
COVER STORY
However, the synthetic PAG lubricant indi- and sediment layers are separated for anal-
cated some discoloration that could be of ysis. This test reveals the maximum weight NEW LUBRICANTS ASTM D2272 - RPVOT
concern, but it was not defined visually as change of copper and the maximum total PAG 657
rust, so the sample passed. acidity of the water layer. Mineral Oil 1 1531
Both mineral oil lubricants passed this Mineral Oil 2 1285
Hydrolytic Stability test, but the PAG lubricant failed. The Mineral Oil 3 2383
The hydrolytic stability of a lubricant is change in lubricant viscosity was another IN-SERVICE LUBRICANTS
its ability to hold up to the ingress of water. important parameter the PAG did not pass.
Mineral Oil 1:
Water can be a very reactive component to These experiments also indicated water 1304
5 years in service
the lubricants additive system. Hydrolytically sensitivity in the PAG lubricant, which should
Mineral Oil 2:
unstable hydraulic fluids form acidic and make keeping it dry a maintenance objective. 1344
4 years in service
insoluble contaminants, which can cause
system malfunctions due to corrosion, valve Oxidative Aging Stability Mineral Oil 3:
8 years in service
1414
sticking or a change in lubricant viscosity. ASTM D2272 is one of the most popular
RPVOT results for the tested lubricants
ASTM D2619 is the standard method for tests for evaluating how lubricants behave
defining the hydrolytic stability of a lubricant. during aging. This test method utilizes an
In this test, a lubricant is mixed with oxygen-pressurized vessel to determine the oxidation stability of the test sample. With
water and a copper test specimen, sealed oxidation stability of turbine oils in the pres- just a 50-gram sample, you have enough fluid
in a pressure-type beverage bottle and ence of water and a copper catalyst coil at 150 to perform additional experiments.
rotated for 48 hours at 93 degrees C. At degrees C. The number of minutes required to Two types of experiments were
the end of the reaction time, the oil, water reach a specific drop in oxygen pressure is the performed using the D2272 test. The first
reacted the fluid until the defined end of test.
The second reacted the fluid until the time
reached 75 percent of the new fluid value (25
TESTING SERIES MPC - ASTM D7843 (dE) TESTING SERIES MPC - ASTM D7843 (dE)
percent of the RPVOT time remaining). Once
PAG: RPVOT EOT 86.0 PAG: 75% RPVOT 65.5
the fluids have oxidized, their condition can
Mineral Oil 1: Mineral Oil 1: be assessed with additional tests.
97.9 54.9
RPVOT EOT 75% RPVOT
Mineral Oil 2:
RPVOT EOT
76.8
Mineral Oil 2:
75% RPVOT
61 Varnish
ASTM D7843 is the industry standard
Mineral Oil 3: Mineral Oil 3:
75.4 74.6 for testing the varnish potential of in-service
RPVOT EOT 75% RPVOT
lubricants. All four tested lubricants exhibited
Varnish potential test results Test results with 25 percent of the RPVOT
time remaining similar failing varnish values at the end of the
RPVOT test. Even the MPC patches showed
the lubricants were in a failing condition.
According to ASTM D4378, you should
consider replacing an in-service lubricant when
the RPVOT results reach 25 percent of the new
lubricant values. Therefore, the new lubricants
were tested until they reached 75 percent of
the new lubricant value (or 25 percent of the
PAG: RPVOT EOT Mineral Oil 1: RPVOT Mineral Oil 2: RPVOT Mineral Oil 3: RPVOT RPVOT time remaining). MPC values for these
EOT EOT EOT
oxidation samples were then obtained. Again,
MPC patch test results the MPC patches showed the lubricants were
in a failing condition.
The results of this test indicated lower
than expected varnish levels. However, the
levels were still considered critical, so it was
recommended to change all four lubricants at
or before 25 percent of the new oils RPVOT
value. The varnish formation of both the
PAG: 75% RPVOT Mineral Oil 1: 75% Mineral Oil 2: 75% Mineral Oil 3: 75% mineral oils and the synthetic PAG lubricants
RPVOT RPVOT RPVOT showed similar varnish levels at the recom-
MPC patch test results with 25 percent of the RPVOT time remaining mended change value (25 percent of the new
lubricant value).
10 | September - October 2017 | www.machinerylubrication.com
COVER STORY
Mineral Oil 2: New Oil 0.01 Acid Number What if the lubricant has been changed and no
Mineral Oil 2: 75% RPVOT 0.47 Acid number, as defined by ASTM D974, longer exists?
Mineral Oil 2: RPVOT EOT 5.31 has often been described as the criteria for
Do you rely on the new lubricants promotional materials?
a lubricants end of life. For years, this was
Acid number test results Do you rely on the experiences of your colleagues?
the condemnation standard for mineral oils.
ASTM D4378 recommends a warning level of Should you obtain your own performance testing data?
LUBRICANT COPPER (PPM) 0.3-0.4 milligrams of potassium hydroxide
Answers to these questions will be valuable
(KOH) per gram increase over the new oils in your decision-making process.
PAG: New Lubricant Nil
acid number. PAG lubricants have a suggested
PAG: 75% RPVOT 66 limit of 5 mg KOH/g.
PAG: 100-minute RPVOT 793 At 75 to 100 percent of the end of the The copper sensitivity found in the
Mineral Oil 1: RPVOT test, all three lubricants had an acid
Nil hydrolytic stability test for the PAG lubri-
New Lubricant number in the range suggested by ASTM cant was again detected in this test. It
Mineral Oil 1: 75% RPVOT 11 D4378 as the end of the fluids life. The high was observed at a higher level due to the
Mineral Oil 2: acid number in these results might also explain higher oxidation of the lubricants. This
Nil
New Lubricant the rust observed in the ASTM D665 test for offers some distinguishing parameters for
Mineral Oil 2: the PAG lubricant. comparing the lubricants.
5
75% RPVOT
Mineral Oil 3:
Nil Elemental Analysis RULER
New Lubricant
Elemental analysis is a test that isnt Oxidation is often studied in relation to
Mineral Oil 3: 75% RPVOT 24
generally studied in relation to RPVOT. the quantity of antioxidant remaining in the
Copper test results RPVOT uses a copper metal catalyst coil lubricant. This parameter is measured using
in the fluid. If the copper dissolves into the the Remaining Useful Life Evaluation Routine
It should be noted that the RPVOT life lubricant, it acts as an oxidation catalyst and (RULER) test (ASTM D6971). ASTM D4378
of the new mineral oil lubricants was more could accelerate the test. If copper corrosion suggests a warning limit of less than 25 percent
than 1,000 minutes, while the PAG lubricant poses a potential problem at the end of the of the new lubricants antioxidant level.
was measured at 657 minutes. When the ASTM D2272 test, it should be seen in the Based on the test results shown in the
test for the PAG lubricant was extended to elemental analysis as an increase in copper. table bellow, it was recommended to change
the lubricant at 75 percent of the end of tests? Field samples are difficult to obtain A Better Approach
the RPVOT time (25 percent of the new for many reasons, not the least of which is
When evaluating new lubricants, it can be
oils value) for both the PAG and mineral the time required to generate them. difficult to determine whether the information
oil examples. In examining the data below, you can see being advertised by manufacturers is valid. A
the same trends in the field as in the bench better approach is to utilize these standard
In-service Samples testing of the lubricants. This should provide performance tests that have been used success-
Now the question becomes what do you confidence in bench testing and allow for fully in the industry for years. They can enable
see in the field. Is the field behavior of the rational conclusions about the lubricants you to make better business decisions and help
lubricants the same as the bench oxidation being studied. optimize your lubrication program.
www.pruftechnik.com/us
The results from Machinery Lubrications annual survey of lubrication professionals in the United States have been tabulated, and they reveal
that salaries held steady from 2016 to 2017, with less than a 1 percent change in earnings. Other interesting findings from the survey include
the number of raises received over the past year reaching its highest level since 2014, and men earning almost $10,000 more per year on average
than women. More younger workers also seem to be entering the industry, as not only did the average age drop two years from 2016, but the
number of respondents who have been with their current employer for less than five years increased by 10 percent. Certification continues
to rise in popularity, with the number of survey participants who have earned at least one certification increasing by nearly 15 percent from
a year ago and by almost 25 percent since 2015. We would like to thank everyone who took the time to complete the online survey.
HOW MANY YEARS HAVE YOU WORKED WHAT IS THE HIGHEST LEVEL OF SCHOOL
FOR YOUR CURRENT EMPLOYER? YOU HAVE COMPLETED OR THE HIGHEST
DEGREE YOU HAVE RECEIVED?
28% BACHELORS DEGREE
28% COLLEGE/NO DEGREE
HIGH-SCHOOL DIPLOMA 17%
<5 YEARS 5-10 YEARS 11-20 YEARS 20+ YEARS
36% 22% 21% 21% ASSOCIATE DEGREE 19%
The longest tenure reported was 42 years. GRADUATE DEGREE 8%
MIDWEST:
29%
SOUTHEAST:
AVERAGE SALARY BY REGION
SOUTHWEST:
21% 26%
NORTHWEST:
,43 T:
3
05 EAS
$76,031
$1 NORTH
MIDWEST:
$77,440
The states with the most responses were Texas, Wisconsin, Ohio and South Carolina.
SOUTHEAST:
WHAT IS YOUR JOB TITLE? SOUTHWEST: $87,280 $75,395
ENGINEER: 10%
RELIABILITY ENGINEER: 9%
MAINTENANCE/RELIABILITY MANAGER: 10%
PREDICTIVE MAINTENANCE TECHNICIAN: 8%
LUBRICATION TECHNICIAN: 14%
JOB TITLE AND AVERAGE SALARY
ENGINEER: $107,212
HOW MANY EMPLOYEES RELIABILITY ENGINEER: $95,217
DO YOU SUPERVISE? MAINTENANCE/RELIABILITY MANAGER: $85,030
PREDICTIVE MAINTENANCE TECHNICIAN: $68,414
LUBRICATION TECHNICIAN: $61,916
0: 57%
DESCRIBE THE PRIMARY BUSINESS
1-10: 31% ACTIVITY OF YOUR FACILITY:
PETROLEUM PRODUCTS: 11% POWER GENERATION: 6%
11-25: 8%
CHEMICALS: 10% FOOD PROCESSING: 6%
PAPER: 8% MINING: 5%
>25: 4%
RUBBER/PLASTIC: 6% MISC. MANUFACTURING: 4%
Among the companies participating in the survey included Bridgestone, the Hershey Co.,
Northrop Grumman, Chevron, Goodyear, Exelon, Kimberly-Clark and Ford Motor Co.
16 | September - October 2017 | www.machinerylubrication.com
REDEFINING
HIGH-PERFORMANCE
SYNTHETIC
GEAR LUBRICANTS
Lubriplate
SYNTHETIC GEAR OILS
SYN LUBE SERIES Follow-Up Oil Analysis Monitoring Service
High-Performance, 100% Synthetic, Polyalphaolefin (PAO)-Based Fluids.
Compatible with Petroleum-Based Oils for Easy Conversion.
Available in ISO Grades 150 through 1000.
Is Included At No Additional Cost
On All Lubriplate Gear Oils. 3
SYN LUBE HD SERIES
Heavy-Duty, Polyalphaolefin (PAO)-Based Synthetic Gear Lubricants.
Meets AGMA EP (Extreme Pressure) Requirements.
For Heavy-Duty Applications.
ESP
Complimentary Extra Services Package
Plant Surveys / Tech Support / Training
Newark, NJ 07105 / Toledo, OH 43605 / 800-733-4755 Color Coded Lube Charts & Machine Tags
www.lubriplate.com / LubeXpert@lubriplate.com Lubrication Software / Follow-Up Oil Analysis
2017 SALARY SURVEY
ON AVERAGE, HOW MANY HOURS DO YOU HOURS WORKED AND AVERAGE SALARY
WORK EACH WEEK?
DO YOU BELIEVE
HOW DO YOU EXPECT YOUR SALARY TO YOU ARE COMPENSATED FAIRLY?
CHANGE IN THE NEXT YEAR?
INCREASE: 69%
STAY THE SAME: 30%
DECREASE: 1%
HOW SATISFIED ARE YOU WHAT FACTOR MOST
WITH YOUR JOB? CONTRIBUTES TO SATISFACTION
WITH YOUR JOB?
CHALLENGE AND STIMULATION: 44%
WORK ENVIRONMENT/CULTURE: 22%
SALARY AND BENEFITS: 17%
COLLEAGUES: 7%
5% 21% 43% 31% CAREER/PROFESSIONAL DEVELOPMENT:
MAKING PRODUCTS THAT HELP PEOPLE:
6%
4%
DISSATISFIED SOMEWHAT SATISFIED VERY
SATISFIED SATISFIED
WHAT DO YOU DISLIKE ABOUT YOUR JOB? DO YOU CONSIDER YOUR JOB SECURE?
LACK OF MANAGEMENT SUPPORT: 38%
LACK OF RECOGNITION: 28%
SALARY AND BENEFITS: 20%
HOURS AND WORKLOAD:
WORK ENVIRONMENT:
17%
17% 84% 16%
UNABLE TO MAKE A DIFFERENCE: 13%
COMMUTE AND TRAVELING: 13% The number of respondents who consider their job secure rose by more than 10
percent over the previous year.
18 | September - October 2017 | www.machinerylubrication.com
ML
WILL YOUR COMPANY BE ADDING ANY DOES YOUR COMPANY EXPECT TO LOSE
LUBRICATION-RELATED JOBS NEXT YEAR? LUBRICATION-RELATED JOBS NEXT YEAR?
DONT KNOW
NO
31%
64%
YES NO DONT KNOW YES
305.591.8935 | www.KeepItRunning.com
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Best Ways to
Eliminate Hydraulic Oil
Leakage
B y A l Smiley, GPM H ydraulic Consulting
Hydraulic oil in a pressure line can the suppressor near the pressure port of
travel at a speed of 15-30 feet per the valve. When the valve rapidly closes and
second, depending on the pres- the shock spike occurs, the nitrogen will
sure. When a valve is rapidly closed to block compress and absorb the pressure spike.
flow or a cylinder fully strokes, a pressure The suppressor is also useful in systems
spike will occur. that contain 90-degree bends in the piping
Unlike air, hydraulic oil is generally consid- or tubing. An additional benefit of the shock
ered to be non-compressible. Oil will only suppressor is that it also reduces noise. This
compress 0.5 percent when pressurized to can be useful in systems that utilize high-
1,000 psi. When a pressure spike occurs in the volume pumps and/or accumulators.
system, the pressure can increase four or five
times above the normal operating pressure. System Piping and Hoses
Since the average duration of a shock spike
When plumbing a system, eliminate the use
is 25 milliseconds, the pressure gauge cannot
of 90-degree fittings in the pipe and tubing.
respond fast enough to give an accurate
indication. Pressure transducers are normally When oil enters the fitting at a high velocity
The use of 90-degree fittings in piping
used to record pressure spikes. Shock spikes and rapidly takes a 90-degree turn, turbulence and tubing should be avoided when
will exist and shock will be generated. This plumbing a system.
that are not properly dampened or absorbed
can result in leakage and damage to the lines
and components in the system. One drop of
oil that drips once per second will result in a Nitrogen
loss of 405 gallons in a years time. At the cost Charging Valve
of $9 per gallon, that one leak costs $3,645
in one year.
Shock Suppressors
A shock suppressor acts very much like a
hydraulic accumulator except that it can be
mounted directly in the line. The suppressor
is pre-charged with dry nitrogen. The rubber
bladder separates the nitrogen from the oil.
The recommended pre-charge of nitrogen
is half the maximum system pressure. The
suppressor should be installed as close as Hydraulic 3-Baffle Nitrogen Bladder (Black Line)
Oil (Red) Chamber Charge (Blue)
possible to where the shock is occurring. Diffuser Tube
For example, if shock is generated by the
rapid closing of a directional valve, install A cross-section view of a shock suppressor
will result in leakage at the fitting or elbow. be spaced every 5-8 feet, depending on the
A 45- or 90-degree sweep ell will reduce size of the line, and must be tightened on a
the turbulent flow as the oil flows through regular basis to eliminate movement of the
the line. pipe and subsequent leakage. A clamp should
Proper clamping is essential to reduce shock also be installed within 6 inches of the termi-
in the system. In the photo on the right, U-bolts nation point.
have been used to clamp the pipes. In this instal- When properly placed, hoses can absorb
lation, you can see that the pipe has moved due shock in the system. A hose should be
to hydraulic shock. This eventually will lead installed at the outlet of the pump prior to
to wearing of the pipe and leakage. U-bolts, entering the manifold or main header. This
conduit clamps and beam clamps are not built will reduce shock at the pump when the oil
flow is rapidly deadheaded.
to withstand the shock in a hydraulic system.
Hoses should also be installed prior to
A proper hydraulic clamp should be used
connecting to a valve, manifold or cylinder.
(as shown in the photo below). Clamps should
The only exception is if the cylinder is
mounted vertically. In these applications,
pilot-operated check valves or counterbalance U-bolts should not be employed to
valves are used to maintain oil in the cylinder clamp pipes.
Introducing the new Flexxpump 1500, a Translucent new oil is visually assumed
high-performance system to automati- The Original Gurtech Grease Coupler: No to be clean, but many times con-
cally lubricate racks and pinions, open hands, no mess and no wasted grease! tains more contamination than the
gearing, linear guideways, ball screws The patented grease coupler locks on with existing oil being replaced. Find out
and chain drives. Available in two sizes: a leak-proof seal. Easy greasing! Use on why, plus the critical proactive main-
400/500 and 1500/2000. extreme angles and high pressure. tenance step to assure the new oil
Big Gator Tools is clean.
Andantex USA, Inc
www.andantex.com 888-428-6748 Harvard Corporation
www.biggatortools.com www.harvardcorp.com
andrew@andantex.com
877-986-1156 sales@bgtools.com 800-523-1327
Lubrication Practices
Frank Sutcliffe
Age
50
Quick Test for Lubricant Compatibility Your sample bottle hand pump can be easily converted so the
suction unit will draw the sample directly into the bottle as the hand
Suppose you run out of a lubricant and are in critical need to top
pump did. Just install a new bottle and turn on the suction unit.
off the reservoir. If the equipment is force-lubricated from a sump,
You now can use both hands and all your concentration to get the
it usually is better to leave it a little low until you can obtain the
tubing into the oil in the sump. These units can be obtained from
proper fluid. If you simply cannot resist the temptation to conduct
any medical-supply store.
a science experiment, take a few minutes to perform the following
test: In a clean, clear plastic bottle, add equal amounts of both
lubricants, leaving some headspace. Shake the bottle vigorously
and allow to settle. Do you see more than one layer, a hazy or milky
appearance, any color change or sediment? Any of these results is
a red flag and a warning not to mix these fluids. In two separate
bottles, vigorously shake the samples of the two fluids separately.
Do the bubbles rise to the top and pop as quickly in the mixture as
they do in the individual fluids? If you skip the test and go ahead
and mix the lubricants, a foaming problem and subsequent major
disaster could be heading your way.
CENTRIFUGAL SEPARATOR
US Filtermaxxs 10,000G Centrifuge is an enclosed-base, programmable
centrifugal separator for fluid contamination problems. It is engineered
to quickly and easily remove heavy contamination that plugs standard oil
filters as well as submicron-sized particles that pass through some filters.
Suitable for batch cleaning or continuous cleaning of oils, coolants and
fuel, the high-speed centrifuge can separate water, antifreeze and partic-
ulate, allowing users to recover heavily contaminated oil and fuel while
reducing their waste oil stream and lowering waste oil collection costs.
US Filtermaxx
www.usfiltermaxx.com
904-334-2838
METALS ANALYZER
The new Spectroport from Spectro Analytical Instruments is a portable arc/spark optical
emission spectrometry (OES) metals analyzer for analyzing elements at low and critical
levels. It features point-and-shoot performance, flexible portability, ease of use and mini-
mal standardization. The device is designed to be as fast as a handheld X-ray fluorescence
(XRF) analyzer, with many analyses taking only a few seconds. Unlike handheld XRF ana-
lyzers, the Spectroport can analyze elements such as carbon, sulfur, phosphorus, boron,
lithium, beryllium, calcium, silicon, magnesium and aluminum at low and critical levels.
Spectro Analytical Instruments
www.spectro.com
800-548-5809
FILTER ELEMENTS
Swift Filters new series of metal-felt filter ele-
ments are engineered for high-pressure, highly
corrosive, highly viscous and radioactive appli-
cations. The elements incorporate filter media
made of thin filaments of nonwoven stainless
steel. The metal felt employed is highly porous,
which allows for high flow rates of up to 20 times
those of other media types as well as long life.
Random fiber filtration (metal felt) can also pro-
vide absolute particle retention, longer on-stream
time and high dirt-holding capacity for less than
60-micron filter elements.
Swift Filters WIRE ROPE LUBRICANT
www.swiftfilters.com The new Biogen marine rope dressing from Rocol
877-887-9438 is an environmentally acceptable lubricant (EAL)
that is intended to help extend the operational life
of critical wire ropes. It is formulated specifically to
perform in the most challenging industry conditions,
including anywhere the environment is wet, humid
and salt-saturated. The formulation uses a unique
additive package that provides a high-performance
hydrophobic barrier and water wash-off resistance in
wet and submerged conditions.
Rocol
www.rocol.com
+44 (0)113-232-2600
How to Choose the Right this common misconception and why the or making it appear cloudy. Air entrain-
problem is often not a lack of resources but ment can also lead to other issues such
Engine Oil rather how they are allocated. as foaming, cavitation and an increased
To choose the right lubricant for your oxidation rate. Access this 1-minute,
vehicles, use the viscosity grade(s) The Truth About 34-second video to find out how you can
recommended by the original equipment Fuel-economy Oils reduce air entrainment and control other
manufacturer serious air-related problems.
Fuel-economy oils have become popular
(OEM) for the
over the last several years, especially the
life of the engine Selecting the Right
and especially Lubricant Supplier
during the engines
Many of todays lubricant suppliers offer
warranty period.
an a la carte program of goods and
Viscosity grades
services. Some provide full service, while
are primarily
others serve niche-specific markets, each
recommended with varying value propositions. Check
according to the out this article on the ML site to learn the
expected ambient temperatures, particu- main criteria that must be assessed as
larly the starting temperatures. Read this well as a 10-step process for selecting a
0W20 and 5W20 oils. Most of these
article on the ML site to discover other lubricant supplier.
oils will provide at least a 1 to 2 percent
important considerations when choosing
increase in fuel economy over using the
an engine oil as well as when you should
next viscosity grade. Understand the many FEATURED WHITE PAPERS
use a synthetic lubricant.
variables to consider when switching to MachineryLubrication.com is the
place to turn for white papers on a
3 Simple Ways to Justify a a fuel-economy oil, including how the
host of lubrication-related topics.
vehicle will be used, by reading this article
Lubrication Program on the ML site.
Heres a sampling of the latest
white papers that are currently
Many organizations mistakenly believe they available for download:
do not have enough money or resources How to Control Oil Aeration A Case for Capturing and
When oil aeration occurs, air bubbles can Analyzing Trends in Your
Alignment Data
Keeping Out Contaminants:
Understanding Ingress
Protection Ratings
How to Work with Your OEM
to Find the Best Lubricant
Check out the full list of white
to implement a lubrication excellence papers by visiting www.Machinery-
program. Access this 1-minute, 55-second Lubrication.com and clicking on the
video to hear three ways to overcome become suspended throughout a hydraulic White Papers link.
or circulating system, darkening the oil
57%
of lubrication professionals use
hydrostatic drives or transmissions at
their plant, based on a recent survey at
MachineryLubrication.com
Answers http://www.youtube.com/user/noriacorp
Viscosit y
LESSONS IN LUBRICATION
B ennett F itch | N oria C orporation
Overcoming the
RISKSof COLD
Machine Starts
T Startup Temperature
he lubricant is arguably one of the appropriate lubricant viscosity, since
the most essential components viscosity has a dependent relationship with
Startup temperature is the ambient
of a machine, but it also happens the surrounding temperature.
temperature upon initial startup of a
to be one of the most vulner- machine before the lubricant has a chance
able. Greatly influencing this to reach the operating temperature. During
Cold Machine Starts
vulnerability is the temperature, which has typical operation, the many contributors The term cold machine starts refers
an inverse correlation to the most important to heat generation such as friction will to low ambient temperatures that can be
lubricant property viscosity. By becoming cause the temperature to rise and reach detrimental to a machines operability.
aware of the potential effects that tempera- an equilibrium with its surroundings, The vehicle and mobile equipment indus-
ture can have on your lubricants, you can also known as the machines operating tries have long been developing solutions
better understand how a machine could fail temperature. Knowing a machines oper- for this challenge of dealing with extreme
and hopefully prevent future failures. ating temperature is crucial when selecting temperatures, including those in very cold
Multigrade High VI
(smallest rate of change)
VISCOSITY
Multigrade High VI
(small rate of change)
Monograde
(large rate of change)
TEMPERATURE
As mentioned previously, if the oil is designed determine how grease restricts motion in a freely turning over at startup, if the oil sump
to flow through piping, such as a lube oil bearing under cold temperatures. is still in a gelled state, the lubricant cannot
circulating system, the oil can become greatly perform its role properly. This can lead to
restricted and starve the machine. Other Gearbox Systems engine seizure. Air pockets can form in the
oil-lifting devices can also lose their effective- Most types of gearboxes are at risk of gelled oil, called air binding, and starve the
ness under such conditions. Ring oilers start starvation, including splash-lubricated, pump of oil. To prevent this, pan heaters
to drag, causing unwanted friction, while oil wet sump circulating systems or forced and higher quality lubricants are often used
slingers hold onto the viscous oil, resulting lube oil circulating systems. When the oil to help keep the viscosity down. When condi-
in an insufficient distribution of lubricant to is too viscous during startup, it cannot tions are uncertain, you can observe the oil
higher lubrication zones. reach the gear meshing zones due to a lack flow from the tip of the dipstick for assurance
of injector pressure or channeling of the oil of the oils viscous state.
Grease Applications in splash-lubricated systems. As a result,
Grease has similar risks in cold envi- the unlubricated high-pressure contact Journal Bearings
ronments since the oil within the grease pivot points on the gear teeth can become The oil wedge formed during rotation of
still abides by the temperature-viscosity damaged. In addition, any gear system that a journal in the bearing housing is a careful
relationship. The potential for lubricant must overcome the churning effects applied balance of speed, viscosity and load. In any
starvation from a lack of grease application by the viscous oil will experience limited circumstance when the viscosity is undesir-
is a common issue. With any application power transmission as well. ably high, such as when temperatures are
method designed to push grease through an very low, the oil can begin to whip around
orifice or grease line, such as a centralized Engines the journal, causing the shaft to wobble.
grease system, single-point lubricator or even Nowadays, it is common for machines Excessive wear can then occur from the
manual greasing, grease movement may be in cold environments to be equipped with reduced working clearances.
significantly restricted in cold temperatures. heating elements to allow the machine to
Consequently, the grease may not be prop- start. However, as temperatures continue Hydraulics
erly applied in the components friction to drop, simply using block heaters does For hydraulic systems, the biggest risks
zones. Certain greases intended for cold not eliminate the risk to engine components in cold temperatures are cavitation and
temperatures are formulated to handle these which have not yet mitigated localized oil filter element failures in hydraulic pumps,
conditions. Test methods such as ASTM that remains below the pour point. For as mentioned previously. Another problem
D4793 and D1478 have been developed to instance, even though the machine may be that can arise involves hydraulic seals. While
contamination and installation issues are the temperatures be the root cause of unfavorable Hochmann. M. (2013, March). Gear
most common reasons why seals leak and lubricant conditions, but their presence can also Lubrication Gear Protection Also at Low Oil
fail, cold starts and cold operating tempera- trigger a chain reaction, leading to highly viscous Temperature. Gear Solutions.
tures also pose a threat of seal embrittlement. lubricants, which introduce the opportunity for Khonsari, M. & Booser, E.R. (2007, March). Low
lubricant starvation, increased contamination, Temperature and Viscosity Limits. Machinery Lubrication.
Bearings premature wear generation, inactive additives Manney, D. Extend the life of your gearbox
and other impending effects. Once machine with predictive maintenance. Retrieved from www.
Bearings with rolling elements will have
lselectric.com/extend-the-life-of-your-gearbox-with-
reduced mobility when oil or grease becomes operators and reliability engineers are aware of
predictive-maintenance.
too viscous in cold temperatures. Viscous the risks that cold temperatures present, partic-
OWI-Lab invests in -40C cold start-up
oil leads to churning losses and skidding of ularly at startup, adjustments can be made to
test bench for wind turbine drivetrain compo-
the rollers. Skidding will damage the rolling prevent these chain reactions from occurring.
nents. Retrieved from www.owi-lab.be/content/
elements and cage structure. Friction increases
References owi-lab-invests-40%C2%B0c-cold-start-test-bench-
as these components are damaged and can wind-turbine-drivetrain-components.
Applied Hydraulics Magazine. (1956, February).
result in a failure. In grease applications, the oil Wikstrm, V. (2000, November). Lubrication of
67-70.
in the grease becomes considerably challenged Bearings at Low Temperatures. Retrieved from http://
Bbehrouz, A. (2014, September). Dead
at low temperatures. The base oil separation evolution.skf.com/us/low-temperatures.
Sensor. Mechanical Engineering Magazine.
rate will be insufficient at low temperatures
Cash. W. (2016, April). Best Ways to Combat
because the viscous oil will stay trapped in the
Oil Gelation. Machinery Lubrication. About the Author
thickener held outside the raceway. During Diemand. D. (1990, December). Lubricants Bennett Fitch is a senior technical consultant
these conditions, lubricant starvation can cause at Low Temperatures. Cold Regions Technical Digest. with Noria Corporation. He is a mechanical engi-
early bearing failure. Fitch, E.C. (2002, July). Temperature neer who holds a Machine Lubricant Analyst (MLA)
Stability of Lubricants and Hydraulic Fluids. Level III certification and a Machine Lubrication
Avoiding Machine Failure Machinery Lubrication. Technician (MLT) Level II certification through the
During Cold Starts Fitch, J.C. (2012, August). The Hidden Dangers International Council for Machinery Lubrication
of Lubricant Starvation. Machinery Lubrication. (ICML). Contact Bennett at bfitch@noria.com.
Thankfully, over the last few decades,
lubricant manufacturers have become aware
of the effects that cold temperatures can have
on machines. This has led them to develop
formulations that can handle these conditions,
including during machine starts. The base
oil plays a major role, as many highly refined
mineral oils and synthetics are less affected by
temperature swings. This is represented by the
viscosity index. Viscosity index improvers can
enhance this property. The higher the viscosity
index, the less change in viscosity per a change
in temperature. Pour point depressants can
also improve the characteristics of oil in cold
temperatures. These base oil and additive prop-
erties, along with a correctly selected viscosity
grade or multi-viscosity grade, offer viable solu-
tions in cold temperatures.
Nevertheless, at times lubricant formula-
tions may not be enough to avoid the pitfalls
of cold starts. In these cases, machines can
be equipped to overcome the frigid elements
through the installation of block and pan
heaters, as mentioned previously, as well as
pre-lube systems that prepare the machines
components for a cold start.
The consequential failure that can arise from
not properly preparing for cold-start conditions
will be gradual and indirect. Not only can cold
PERSPECTIVE
L oren G reen | N oria C orporation
Understanding the
CHANGING Requirements for
FOOD-GRADE LUBRICANTS
FSMA Regulations
facturing and other related The FSMA has created six new types of
A Focus on Prevention
One of the cornerstones of the FSMA is the realization that the
FDA likely would not be staffed sufficiently to oversee all the changes
mandated by the law. Much of the burden falls on a companys CEO
and board of directors to ensure that the food they produce is safe.
The primary guiding principle is the application of the Hazard Anal-
ysis and Critical Control Points (HACCP) to the roughly 80 percent of
the food supply regulated by the FDA. This represents a major shift
in ideology. Previously, the focus had been on responding to contam-
ination in the U.S. food supply. Now the focus is on prevention.
Section 103 of the Food Safety Modernization Act deals specif-
ically with prevention. It requires the owner, operator or agent in
charge of a human or animal food facility which manufactures,
processes, packs or holds food to evaluate hazards that could affect
food safety, identify and implement preventive controls to prevent
those hazards, monitor those controls and maintain monitoring
records, and conduct verification and reverification activities. In
addition, the responsible parties are to identify and evaluate hazards
55%
compromising the safety of the finished it is possible to identify the points in the
product. These measures may include using process where the preventive measures can
only approved chemicals, such as food- be applied to prevent, eliminate or reduce
grade lubricants, having detailed product the hazard to an acceptable level.
specifications for chemicals entering the
of MachineryLubrication.com
plant, inspecting trucks used to ship the
Critical Limits for Critical
visitors use food-grade lubricants
at their plant, according to a
finished product, properly labeling and Control Points
recent survey storing all chemicals, and training employees A critical limit is defined as the maximum
who handle chemicals. or minimum value to which a physical,
ML
biological or chemical hazard must be sible personnel signing an acknowledgement. Validation of the HACCP plan will demon-
controlled at a critical control point to If a corrective action is required that has strate that it prevents, eliminates or reduces
prevent, eliminate or reduce to an acceptable not been previously identified in the HACCP all identified microbiological, chemical
level the occurrence of the identified food plan, this should be documented as well. It and physical hazards to a regulated and/or
safety hazard. In the case of lubricants, the may be necessary for the product to be held commercially feasible level. The responsibility
FDA has set this limit at zero parts per million for further investigation. This investigation for this validation rests on the regulated
for non-food-grade lubricant contamination. may include product testing, consultation industry. The validation assembles the data
with a third party or processing authority, or to prove that the HACCP plan developed and
Monitoring Procedures a thorough records review. implemented by a company will control the
Monitoring is essential to an HACCP process and prevent food safety hazards.
system. It can warn of an impending loss Record-keeping Procedures A reassessment should be performed at
of control so action can be taken before a Accurate and complete records are least annually to determine if the HACCP
critical limit is exceeded. Monitoring gener- important because they serve as written docu- system is adequate. A reassessment is also
ally will be more effective if the personnel mentation of compliance with the HACCP necessary any time new hazards have been
responsible for monitoring understand its plan. These records will allow you to trace the identified or when changes have occurred
purpose and importance, and are clearly history of an ingredient, finished product or in the process, ingredients, raw materials,
identified and properly trained. Monitoring in-process operation should problems arise. vendor, product volume, personnel, pack-
procedures usually relate to online processes. They can also help you identify trends in an aging, distribution or any other factor that
operation that could result in a deviation. could affect the hazard analysis.
Corrective Actions HACCP systems should include records for
In conclusion, as the FDA continues its
efforts to fully implement the Food Safety
Once the HACCP plan is implemented, critical control points, establishment of critical
Modernization Act, companies that manu-
corrective actions must be taken any time a limits, how deviations were handled and the
facture food and beverage products must
critical limit is not met. These actions should results of verification activities. These records
prepare for the changing requirements. If
include determining the disposition of a must contain the product identification, crit-
they fail to comply, their plant managers
non-compliant product, correcting the cause ical criteria, time and date of the observation,
could face hefty fines, criminal prosecution
of the non-compliance to prevent a repeat, and the monitors and reviewers signatures.
or even imprisonment.
examining the process or product again at the
control point to ensure the results are within the Verification Procedures About the Author
limits, and maintaining a record of the correc- The HACCP system should be assessed
Loren Green is a senior technical consultant
tive actions and results of the applicable testing. periodically to ensure it is working correctly.
with Noria Corporation, focusing on machinery
Under HACCP, the actions to be taken in Among the points to evaluate would lubrication and maintenance in support of
the event a critical limit is not met at a critical include the monitoring equipments cali- Norias Lubrication Program Development
control point must be established in advance. bration process, any corrective actions, (LPD). He is a mechanical engineer who holds
Personnel responsible for monitoring the and observations of monitors and moni- a Machine Lubrication Technician (MLT) Level
critical control points should understand the toring activity. A periodic evaluation of II certification and a Machine Lubricant Analyst
process and be trained on how to perform employees is also recommended to ensure (MLA) Level III certification through the Inter-
the corrective actions. All corrective actions that corrective actions are performed and national Council for Machinery Lubrication
should also be documented, with the respon- documented properly. (ICML). Contact Loren at lgreen@noria.com.
Abubaker Elsiddig Elmahi Razanakolona Harison Fidele, C&W Services Delgrosso S.P.A.
Suliman, MLA I MLT I & MLA I Brian Cook, MLT I Giovannino Atzori, MLT I
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Mark Baines, MLA I Anglo American CertainTeed Gypsum Brittany Chambers, MLT I ICML regularly holds exam
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Jake Miller, MLT I
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Samuel Garrett, MLT I Chemours
ArcelorMittal Energy Solutions exams can be found at
ALS Ashton West, MLT I
Justin Nichols, MLA I Chris Hardcastle, MLA I www.lubecouncil.org.
Michael Holloway, MLA I Dan Grant, MLT I
Ash Grove Cement Jacob Logue, MLT I Entergy
Ambatovy
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ICML Certifications
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A nalyst Level I
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Rakotomalala Andriantsoa, Delbert Griffin, MLT I M achine Lubricant
BHP Billiton Finning
MLT I & MLA I James Whitley, MLT I A nalyst Level II
Camila Veronica Orellana Julio Cesar Sepulveda Solis,
Rakotomanga Rija Mandimby, Michael Taylor, MLT I
Sotelo, MLA II MLA II
MLT I & MLA I MLA III
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Products M achine Lubricant
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Ralaivao Tolojanahary Pierre, Kevin Hutcheson, MLT I A nalyst Level III
Brian Bauer, MLT I Fluid Specialty Services
MLA I Francisco Martinez, MLT I Costa Rican Institute MLT I
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I & MLA I Boise Paper MLA I M achine Lubrication
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Benjamin Brown, MLT I & Carlos Martin Mejia Garay, Technician Level I
Ranarivelo Herinomenjana- Porras, LLA I
MLA I MLA I
hary, MLT I & MLA I
Randrianarivelo Abela Valison,
Chris Payne, MLT I CRH Canada Javier Alberto Chavarria MLT II
Taylor Roberts, MLT I & MLA I Shawn Berube, MLT I Salazar, MLA I M achine Lubrication
MLA I
Ratovohery Franck Tsiory, Bunge Dale Technical Services Fuchs Technician Level II
MLA I Paulo Merlim, MLT I Jimmy Zednick, LLA II Timothy Vaughan, MLA I
VOLATILITY
VS.FLASH POINT:
What You Should Know
Flash Point
The flash point test dates back to the
mid-19th century as one of the earliest iden-
tifiers of an oils physical properties. It was
originally used to determine the fire hazards
of fuels and oils being stored and transported.
The flash point test measures the
tendency of an oil to form a flammable
mixture with air. Once the oil sample is
heated, a flame is exposed to the headspace.
Ignition is the determining point. The lowest
measured temperature at which the oil will
ignite or flash is recorded as its flash point.
If the test is performed over a longer period
of time, the oils fire point can be obtained.
The fire point is when ignition is sustained
for five seconds.
Several methods can be employed to
determine an oils flash point. Each varies
degrees F) and flash points below 93 degrees C (140 to 374 degrees F).
depending on the fluids viscosity and the
chosen technique. Among the ASTM tests C (220 degrees F). ASTM D92, Flash and Fire Points by Cleve-
that are available include ASTM D56, Flash ASTM D93, Flash Point by Pensky-Martens land Open Cup, is another option for obtaining
Point by Tag Closed Cup Tester. It is utilized Closed Cup Tester, is used for petroleum prod- an oils flash point. Although the technology
for viscosities below 5.5 centistokes (cSt) at ucts with a temperature range of 40 to 360 has evolved, the open and closed cup tests of
40 degrees C (104 degrees F), as well as for degrees C (104 to 680 degrees F) and biodiesel today closely resemble the practices of more
viscosities below 9.5 cSt at 25 degrees C (77 with a temperature range of 60 to 190 degrees than 100 years ago. While often seen as a
Volatility
The Noack volatility test was developed by
about an oils volatility,
an oils volatility can
Dr. Kurt Noack in the 1930s and first used in
Europe. It was introduced as a way to reveal
flash point.
United States to determine the performance
of motor oils. Volatility testing became stan-
dard for North America in 1992 with the
creation of the American Petroleum Institutes
SH/International Lubricant Standardization
There are three different procedures as poor oil circulation throughout the engine,
and Approval Committees GF-1 oils, which
for ASTM D5800: Procedure A, which uses greater oil consumption, higher wear rates
set the bar for the current standards in envi-
the Noack evaporative testing equipment; and increased emissions.
ronmental emissions and fuel economy.
Volatization is a term used to describe the Procedure B, which employs the automated
boiling off of lighter molecules in fluids. It non-Woods metal Noack evaporative appa- Tests That Serve a Purpose
ratus; and Procedure C, which utilizes the Flash point and volatility tests serve a
is closely related to oil consumption in auto-
Selby-Noack volatility test equipment. purpose, just for different conditions. They
mobile engines. The test simulates the oils
Procedure A was first introduced in the are also related. After all, for an oil to reach
reaction to internal temperatures associated
1930s using a toxic mixture of compounds its flash point, it must first volatize. While the
with piston rings and cylinder walls.
known as Woods metal for sample heating. flash point tells you very little about an oils
Known as ASTM D5800, the Noack
Woods metal, also called Lipowitzs alloy, volatility, an oils volatility can tell you a lot
volatility test reveals the evaporation loss of
contains bismuth, lead, tin and cadmium. The about its flash point. Volatility testing has
lighter oil molecules and additives at high
toxicity comes from the lead and cadmium. proven that with better base oils, improved
temperatures. Depending on the method,
The Selby-Noack test was developed in emissions and fuel economy will follow.
a measured sample quantity is placed in a
the mid-1990s by Theodore Selby and his Keep in mind that synthetic lubricants
crucible or reaction flask and heated to 250
generally have higher flash points and do not
degrees C (482 degrees F), with constant air colleagues using a noble metal heater. It elim-
begin to evaporate until a much higher
flow drawn through for 60 minutes. Assessing inates the need for Woods metal and utilizes
temperature is reached. On the other hand,
the before and after weight will determine the a collection of evaporated material for later
mineral oils may start to vaporize much earlier
evaporation loss. analysis. This is particularly useful in identifying
than their flash points. If you are dealing with
elements such as phosphorus, which is known
hazardous conditions, a flash point test is a
to lead to premature failure of catalyst systems.
staple that simply must be conducted.
Volatility testing plays an important role in
84%
engine lubrication where high temperatures About the Author
occur quite frequently. Evaporation losses can
Garrett Bapp is a technical consultant with
be seen in the amount of oil consumption or
Noria Corporation, focusing on machinery lubri-
the need for top-ups. This can also result in a cation and maintenance in support of Norias
of lubrication professionals change in the oils properties, as additives may
do not conduct flash point Lubrication Program Development (LPD). He
or volatility testing to evaporate during the volatilization process. is a certified lubrication specialist through the
assess new or used oil, As lighter molecules burn off or evapo- Society of Tribologists and Lubrication Engineers
based on a recent poll at
MachineryLubrication.com rate, heavier molecules remain, causing a shift (STLE) and holds a Machine Lubrication Tech-
in the fluids viscosity. Leaving behind heavier nician (MLT) Level II certification through the
or thicker oil can contribute to reduced fuel International Council for Machinery Lubrication
economy due to added viscous drag as well (ICML). Contact Garrett at gbapp@noria.com.
Most organizations conduct maintenance that includes lubrication, but few recognize the serious potential of comprehen-
sive analysis, training and implementation of excellent lubrication practices particularly those that are proactive.
Noria can give your organization an individualized lubrication system, personnel training on best practices and continued
access to a network of industry experts all in one comprehensive program.
1328 East 43rd Court | Tulsa, Oklahoma 74105 | Phone: 800.597.5460 | noria.com
Lubrication Program Development (LPD)
Achieving lubrication excellence translates into major benefits for your company,
but it can be an overwhelming endeavor for busy plants that need effective, sus-
tainable solutions you can use immediately. With Norias Lubrication Program De-
velopment (LPD), we deliver just that. We will guide you through the entire program
to create the individualized, high-performing system you need.
Program Results:
Significant Cost Savings: Operational costs decrease, fewer necessary
repairs, less downtime, more profit
Greater Efficiency: Achieve ROI ahead of schedule, increase life and function-
ality of plant machinery
Right Place
Every lube point dont miss any
Right Amount
Precise calculated volume for greases
and oils
Right Time
Precise calculated interval and condi-
tion-based
Right Tools
Inspection, sampling, contamination
control, procedures, etc.
Right People
Background, skills, training,
ownership
1328 East 43rd Court | Tulsa, Oklahoma 74105 | Phone: 800.597.5460 | noria.com
Launch Phase
Getting your lubrication program off to
the right start has never been easier.
The launch phase of Norias Lubrication
ICANT SELECTION
Program Development will help you LUBR
S2P
achieve best practice while avoiding S1P
S3P
pitfalls and wasted resources. Youll L RE
SA R1
P C
receive a customized roadmap in line
EP
P S4M S5M
SP
TIO
with your priorities and budget which
D2
DI
R2
AL
N
is designed to rapidly deliver value R
AN
M
NT
D3
5M
S6K
DS
ME
and quick wins with each phase. The
ON
TOR
R3P
launch phase includes:
ENVIR
AGE
D1P
R7
K
D4M
D5
A 540-point Onsite Assessment
R6M
K
R4P
This onsite assessment is an important
step in evaluating the health of your
H8M
lubrication program. A Noria expert A5M
A4P
H3P
ION
spends a full day assessing your current
H7M
A8
K
H9
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lubrication practices.
ICAT
LUBR
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A6
A3P
H6
PPL
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5M
P
A7 H
H2
DA
NT
AN
AN
C3M C4 M
AL
G
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IN
YS
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IS
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the future is created. You will gain an HA
C2P C1P
understanding of what you are doing
CON
well, where you can and should imme- TAMINATION CONTROL
diately improve, and where there might
be low-hanging fruit that you can take
advantage of immediately.
LPD Sample Chart
Analysis of 40
Program Elements - There are
40 critical elements to lubrication
PLATFORM
LUBRICATION
MANAGEMENT SELECTION
(S)
KPIs
ENVIRONMENTAL RECEPTION
DISPOSAL & STORAGE
(D) (R)
CONTAMINATION
CONTROL
(C)
Management Levels
Management Levels Program
Program Stages
Stages Elements
Elements
1328 East 43rd Court | Tulsa, Oklahoma 74105 | Phone: 800.597.5460 | noria.com
Launch Phase Cont.
25 Priority Next Steps - The 40 critical elements are weighted and prioritized
to determine which actions should be performed first to maximize your investments
and make the biggest reliability and ROI impacts.
1328 East 43rd Court | Tulsa, Oklahoma 74105 | Phone: 800.597.5460 | noria.com
Engineering Phase
During the Engineering Phase, a team
of Noria experts will survey all your
lubricated assets to collect informa-
tion needed to engineer an optimized
lubrication program. From this data,
we strategically engineer every pro-
cedure from a proactive maintenance
mindset, seeking to eliminate the root
causes of machine failure that stem
from poor practices. Each procedure
includes a job plan and complete
description for each task.
Why Procedures?
Work Scope - Procedures clearly
specify the work an individual is ex-
pected to perform.
1328 East 43rd Court | Tulsa, Oklahoma 74105 | Phone: 800.597.5460 | noria.com
Engineering Phase Cont.
Engineering Deliverables
Lubricated machine master list in functional hierarchies (location, area,
machine, component, lubrication point)
Oil analysis test slates and sampling frequencies for all critical oil-
lubricated assets
Manpower assessments
Lubricant consolidation
1328 East 43rd Court | Tulsa, Oklahoma 74105 | Phone: 800.597.5460 | noria.com
Implementation
Implementation involves taking the procedures, guidelines and practices de-
veloped in the Launch and Engineering Phases and integrating them into your
plants lubrication program. Noria supports you with integrating procedures
and pertinent data into your plants CMMS or scheduling software, scoping and
installing lubrication hardware and accessories, safely changing lubricants where
needed, building lubrication routes, managing an oil analysis program, coaching
and developing your team, and establishing key performance indicators (KPIs)
and metrics for sustainable program success.
Vendor Neutrality
Norias vendor neutrality ensures an impartial, unbiased presentation of the require-
ments necessary for hardware implementation. Noria does not recommend one
suppliers products over anothers, maintaining the strictest vendor-neutral integrity.
HELP Training
Norias Hands-on Excellence in Lubrication Program (HELP) is a training program
that facilitates consistent and accurate implementation of the lubrication program.
HELP primarily focuses on demonstrating the hands-on skills necessary to run a
successful program.
Knowledge & Skill - Using task lists, work procedures and job descriptions,
we define and map your organizations knowledge and skill requirements to
perform all tasks.
1328 East 43rd Court | Tulsa, Oklahoma 74105 | Phone: 800.597.5460 | noria.com
(HELP) Training Courses
Max #
Course Attendees Week 1 Week 2 Week 3 Week 4
Lubrication 101 (Classroom) 25 1 day
Sustain
Maintaining lubrication excellence
beyond Norias Lubrication Program
Development means personnel must
seek continuous improvement. Noria
addresses this need by providing ac-
cess to its technical team for as-needed
consulting, failure investigation, training,
job skills assessments and diagnostic
support.
Lubrication Program
Enables Simmons Feed
to Cut Downtime
by 50 Percent
The Simmons Feed Ingredients plant in Southwest
City, Missouri, brought in Noria consultants to develop
a roadmap for lubrication excellence. After implement-
ing Norias Lubrication Program Development and
training, the facility was able to achieve cleaner oil,
prevent machine failures, avoid lost production and
save up to $1 million a year.
About Noria
Since 1997, Noria has been
delivering world-class lubrica-
tion programs for a wide variety
of customers and industries,
including power generation,
food and beverage, heavy man-
ufacturing, mining, etc. Major
lubricant manufacturers turn
to Noria to train their teams,
design world-class lubrication
programs and solve lubrication
problems.
1328 East 43rd Court | Tulsa, Oklahoma 74105 | Phone: 800.597.5460 | noria.com
Customer List
Many of Norias customers view our services as a competitive advantage, so we cant provide a complete list of
everyone with whom we have worked. Heres a small sample of the companies we have helped:
www.noria.com/LPD
1328 East 43rd Court | Tulsa, Oklahoma 74105 | Phone: 800.597.5460 | noria.com