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8COVER STORY
Purchasing Lubricants Based on Performance
Learn the pros and cons of using a specification system to purchase lubricants, how to launch such a system and
make it work, and how to handle exceptions.
November-December 2013
2 AS I SEE IT
Demand ‘Reliability Readiness’
from Equipment Builders
34 OIL ANALYSIS
6 Ways to Maximize Your
Oil Analysis Software Value
Reliability should have shared responsibility. It must be fixed in the DNA Selecting the proper oil analysis software and maximizing its features
of the machine as well as in the minds of operators and maintainers. can provide a huge payback for the user through reduced machinery
6
maintenance expenses.
44
FROM THE FIELD
How Lubricant Suppliers Impact LESSONS IN LUBRICATION
Machine Reliability Anatomy of an Oil Analysis Report
Plants often don’t take into account the effect that the lubricant In order to properly interpret an oil analysis report and make sense
of all the test data, you must understand a few important principles.
56
supplier can have on machine reliability. If left unchecked, the results
can be catastrophic.
16
CERTIFICATION NEWS
LUBE-TIPS World-Class Reliability Starts
Our readers offer excellent advice on a host of lubrication-related with a Solid Foundation
issues, including safety tips for oil storage areas. Technicians are the human foundation of any reliability-improve-
18
ment program and should be respected and supported in their
TURBINE LUBRICATION professional development.
Hydrodynamic Cleaning and Flushing
of Turbine Oil Systems
Discover how the technology of hydrodynamic cleaning and flushing
of oil systems can be an effective method of preparing new oil systems
60 HYDRAULICS
Become an Expert through Certification
Getting certified and holding multiple certifications demonstrates
that you take your career seriously and can be the key component to
and restoring operated oil systems.
28
increasing your worth to your employer.
GREASES
Using a Grind Gage for In-Service Grease Analysis
A quick and simple field test utilizing a fineness of grind gage can
provide immediate results on the overall contamination of grease.
62 BACK PAGE BASICS
How to Change Your Lubrication Culture
Changing your facility’s lubrication culture may take time, patience
and commitment, but the rewards will be well worth the effort.
Demand ‘RELIABILITY
READINESS’ from
Equipment BUILDERS
When it comes to modern concepts Users not only have a significant influence on • Design for functional robustness
in the field of lubrication and machine reliability during operation but also (functional design, material selection,
applied tribology, many users these days are by what is being done (or not done) by lab and field testing)
far more sophisticated than those who are equipment builders to “ready” machines for • Design for optimum maintainability by
designing and building the machines they optimum reliability. They want the machine’s the user (ease and effectiveness)
operate. This lack of sophistication by orig- design to have an implanted genetic code • Quality manufacturing to reduce defects
inal equipment manufacturers (OEMs) is that enables reliability. and other anomalies (e.g., Six Sigma)
very evident when you see what’s not Users define what’s expected from OEMs • Provide a documented equipment
included with the sale of new machinery. and the machines they deliver. Of course, maintenance plan (EMP) (see sidebar
One could assume that what’s missing from meeting the minimum required operating on page 3)
the machine and its documentation is func- performance is a basic need of every
• Training and education of field-service
tionally missing from the knowledge and machine, but prolonged sustainability of
technicians, operators and main-
awareness of the engineers and builders of that performance is also important. This is tainers to execute the EMP
this equipment. Ignorance is not bliss. The not simply a matter of quality manufacturing
same is true for complacency. to a design specification in order to avoid Developing Reliability Readiness
Reliability needs to have shared responsi- defects. From the standpoint of reliability, Investments in machine reliability should
bility. It must be fixed in the DNA of the it’s more about including design features be purposeful. Certainly, there will be costs
machine as well as in the minds of operators that have little to do with the machine’s and even risks associated with reliability
and maintainers. It’s like a reliability chain; functional performance. At first, this may initiatives. You aren’t trying to maximize
every link in the chain must be equally strong seem unnecessary and wasteful, but when reliability but rather optimize it in the
in order for the chain’s full length to bear the viewed over a timespan of several years, context of the user organization. OEMs
load. Machinery Lubrication magazine is these “extra features” could translate to must be keenly aware of how their machines
primarily devoted to advanced concepts in huge financial benefits. will be deployed, the operating environ-
lubrication from a user’s perspective, more In sum, OEMs can achieve machine reli- ment and the minimum needs for reliability.
specifically lubrication-enabled reliability. ability in the following ways (used collectively): Ideally, they should follow these steps:
GROUP PUBLISHER
Brett O’Kelley - bokelley@noria.com
SENIOR EDITOR
• Detailed and illustrated lubrication procedures (oil change, grease change, grease Jim Fitch - jfitch@noria.com
addition, oil top-up, etc.)
TECHNICAL WRITERS
• Detailed and illustrated flushing procedures and listing of suitable fluids for flushing Jeremy Wright - jwright@noria.com
Wes Cash - wcash@noria.com
• Oil change interval/regrease interval Bennett Fitch - bfitch@noria.com
Loren Green - lgreen@noria.com
• List of all lube points
• Recommended lubricants (performance specification) for all lube points and CREATIVE DIRECTOR
Ryan Kiker - rkiker@noria.com
operating conditions (speeds, loads, etc.)
GRAPHIC ARTISTS
• Brand/type cross-reference for all lubricants Julia Backus - jbackus@noria.com
• Equipment storage protection practices/products, including the use of fogging Terry Kellam - tkellam@noria.com
Josh Couch - jcouch@noria.com
agents, shaft extension sprays, breathers and vapor-phase rust inhibitors Patrick Clark - pclark@noria.com
• Contamination control guidelines including target cleanliness/dryness needs ADVERTISING SALES
Tim Davidson - tdavidson@noria.com
• Run-in procedures for gears and similar equipment 800-597-5460, ext. 224
• Seal compatibility information for system lubricants and other fluids
MEDIA PRODUCTION MANAGER
• Frequency and procedural information for all necessary PMs and inspections Ally Katz - akatz@noria.com
Every link in the chain must be equally strong in order for the chain’s full length to bear the load.
www.machinerylubrication.com | November - December 2013 |3
AS I SEE IT
the vast majority of the opportunity comes from paying close attention 1. Correct lubricant in use (meets reliability objectives)
to the “Big Four.” These are vital attributes to the optimum reference
state needed to achieve lubrication excellence. The “Big Four” individu- 2. Stabilized lubricant health (physical and chemical properties)
ally and collectively influence the state of lubrication and are largely 3. Contamination control
controllable by machinery maintainers, especially if a machine is
designed and built for optimum maintainability. The “Big Four” are: 4. Adequate and sustained lubricant level/supply
While it may seem to be an oversimplification to reduce lubrica- Consider having the specification carefully reviewed by an
tion excellence to just four basic objectives, as a practical matter, outside lubrication consultant, especially for the most reliability-
not much else is required. See the tables on pages 2, 4 and 5 to critical machines. Remember that the cost of retrofitting needed
learn how machine maintainability can be applied in the context of maintainability hardware will be many times the cost of the same
the Big Four. hardware when installed at the factory (as part of the original
bill-of-material).
Role of Buyers/Purchasing Conversely, buying machines stripped to the bones in an attempt
Before buying new machinery, an engineering specification to reduce costs is almost always false economy. The astute reli-
should be carefully and thoroughly developed. Engineers charged ability professional views new equipment in terms of the cost of
with writing these specifications should be educated on modern ownership, not simply the cost of purchase. Most important is the
concepts in machinery lubrication. Simply working as an engi- overall machine reliability, which includes repair costs but also
neer or having an engineering degree alone does not qualify. equipment utilization (uptime), maintainability (PMs, inspections,
Instead, training by leading consultants and instructors is etc.), safety and other factors. All of these should drive the business
strongly advised. decision to invest in reliability readiness.
Training should be followed by certification compliant to ISO About the Author
18436-4 and similar standards. Noria recommends that engineering Jim Fitch has a wealth of “in the trenches” experience in lubrication,
specifications for new equipment only be written by professionals oil analysis, tribology and machinery failure investigations. Over the past
with Machine Lubricant Analyst (MLA) Level II and III certification two decades, he has presented hundreds of courses on these subjects.
credentials. A specification should address many, if not all, of the Jim has published more than 200 technical articles, papers and publica-
maintainability features shown in the preceding tables. It must also tions. He serves as a U.S. delegate to the ISO tribology and oil analysis
address hardware and design features that are not permitted. These working group. Since 2002, he has been director and board member of
might include ring oilers, drip oilers, screen filters, snorkel vents, the International Council for Machinery Lubrication. He is the CEO and
high-watt-density tank heaters, long pump suction lines, etc. a co-founder of Noria Corporation. Contact Jim at jfitch@noria.com.
62%
Plants often do not take into account the effect that the kept (even when in the sealed
lubricant supplier can have on machine reliability. If left drum), the longer it will last.
unchecked, the results can be catastrophic. If you can witness the handling
You might be surprised what you can learn from a quick visit to and transferring of lubricants
your lubricant supplier. Does your supplier know your reliability during your supplier visit, watch
and lubrication goals? How can suppliers help you succeed if they for instances of cross-contamina- of lubrication professionals
have no idea that you are playing for the same team? tion. Make sure that all transport never visit their lubricant
supplier, according to a
Supplier audits are a small part of Noria’s service offerings. In lines are product-dedicated or at
recent survey at Machinery-
this article, I will share a few key tips that have been learned over the least flushed well between uses. Lubrication.com
years so you can be better informed when visiting your supplier. For bulk incoming transfers,
I like to use a simple checklist when conducting a supplier audit. It check if samples are taken to verify compliance for both properties
helps remind me to be vigilant on key practices and physical attri- and performance. These samples should be kept on record for at
butes that are associated with the optimum reference state of least six months. Also, see if you can find current seals on all meters
handling lubricants. I usually start with an overview of the storage showing calibrations within the last year.
facility and how lubricants are handled. The first observation should In the packaging area of the plant, you will want to make certain
be related to the identification of lubricant-handling equipment. Are that at a minimum the supplier is filtering the incoming oil through a
all lines and tanks clearly marked for a specific lubricant? If not, the 60-mesh screen. Again, confirm that meters and scales are up to date
likelihood of cross-contamination becomes significantly higher. on their calibration. Inspect the condition of the drums prior to being
The warehouse should also be in good condition. It must be free filled. Are they reconditioned? If so, what processes do they have in
of spilled oil, settled water and dust. The building should be place to prevent clean oil from being put into a dirty drum?
enclosed and, if possible, climate-controlled. All products should Ensure that the empty drum inventory is stored appropriately as
be in sealed containers, stored indoors away from direct sunlight well. Every particle that contaminates the drum from this point will
and not allowed to collect rain water on the top edge. have an effect on your program. You will either have to remove it
The inventory in the warehouse should be rotated so that the oldest through filtration or suffer the consequences of particle contamina-
containers are being used first, while the newest containers are sent to tion in your machine. Keep in mind that the cleaner the supplier can
the back. Remember that the cleaner, cooler and drier the lubricant is keep the oil, the less time, energy and money you will have to spend
later in its life cycle to get it to an acceptable level for your machines.
Your lubrication knowledge will be a tremendous asset when
visiting your supplier. If you are not confident in your knowledge,
5 Tips for Dealing with Your just remember “clean, cool and dry.” Look at everything with this in
Lubricant Supplier mind and ask yourself if the lubricant is being kept as clean, cool
and dry as possible. You then will have your answer as to how well
1. Audit your oil supplier routinely. your supplier is helping you achieve your reliability initiatives.
2. Establish clear parameters and work with suppliers to help About the Author
them achieve the improvements that are necessary. Jeremy Wright is vice president of technical services for Noria
Corporation. He serves as a senior technical consultant for Lubrication
3. Expect the lubricant supplier to conform to new, higher- Program Development projects and as a senior instructor for Noria’s
quality expectations. Fundamentals of Machinery Lubrication and Advanced Machinery
4. Include mill mechanics and lube technicians in the process. Lubrication training. He is a certified maintenance reliability profes-
sional through the Society for Maintenance and Reliability Professionals,
5. Provide training to reinforce the necessity and benefit of and holds Machine Lubricant Analyst Level III and Machine Lubrication
the new measures. Technician Level II certifications through the International Council for
Machinery Lubrication. Contact Jeremy at jwright@noria.com.
6| November b 2013 | www.machinerylubrication.com
b - December hi l b i i
www.machinerylubrication.com | November - December 2013 |7
ML COVER STORY
Lubricants initially arrive in industrial plants usually via one ification was then written around those test results that could be
of two methods: placed out for bid by the purchasing department. If a lower bid was
1. New equipment generally comes with a “lubricant list” from received, the competitor was asked to submit a sample to an inde-
the equipment supplier with a few recommendations for each pendent lab to verify a few very important requirements. If
application. Brand names are typically listed, a selection is successful, the lowest bidder was awarded the business for a
made and, if it works satisfactorily, it is chosen. specific period.
Lubricants are unique in that objective lab tests are available to
2. Maintenance personnel express concern to a supplier or a
the user that will predict field performance. Very few maintenance
competitor about a lubricant’s performance, and a change
products have this advantage.
is made.
This article will outline the pros and cons of using a specification
There are other ways lubricants are acquired, but in each case,
system, how to launch such a system and make it work, and how to
maintenance personnel don’t know why a product does or does not
work; they simply accept the outside expert’s opinion. In these situ- handle exceptions. If a company’s lubricant purchases are substan-
ations, maintenance workers may not realize there are several tial and could benefit from a 10- to 15-percent reduction in costs,
products in the plant with different brand names but similar char- this system may offer an advantage while assuring only the highest
acteristics. They may be unknowingly contributing to the quality lubricants are used in the equipment.
proliferation of products in the plant. Without understanding what
makes the products work, the maintenance person may be reluc- What is a Performance Specification?
tant to consolidate. In this case, there is little encouragement for Every lubricant and hydraulic fluid has a detailed list of tests that
competition and no reason for any oil company to lower its prices. must be passed at the oil company before it is released for shipment.
Naturally, maintenance personnel want their equipment to have the The experts at the oil company know how the fluid must perform in
highest quality lubricants but at a reasonable price. How can this your equipment. Several organizations (ASTM, SAE, etc.) have devised
be accomplished? lab tests that will measure various aspects of this performance.
Jim Fitch’s “Hazards of Changing Lubricant Brands” article in For instance, because viscosity and viscosity index are very
the November-December 2013 issue of Machinery Lubrication put important in most lubricants, numerous tests have been devised
the maintenance person’s concerns in perspective. The article and agreed upon by industry experts to measure these parameters.
brought to mind a system that was developed and used for many Figure 1 provides a list of some of the more common tests for oil
years at a U.S. steel company. In order to address the concerns and grease.
discussed in Fitch’s article, the company established a system Once a list of important performance specifications is compiled
whereby lubricants and hydraulic fluids were purchased by perfor- for a given product such as a gear oil, any successful product must
mance specifications. If a product worked in an application be tested to determine the numbers or evaluation for each test.
satisfactorily, it was tested to determine which ASTM tests (or Compatibility is always a concern when switching products. The
others) it would pass that were relevant to the application. A spec- steel company’s solution was to give the competing supplier the
4. Tanks permanently installed in the plant may have the MC developments in the field. New tests may be devised that assess a
number stenciled on them if there is little chance a change will parameter better than previous versions. The consensus of opinion
be required. among industry experts might also change regarding which param-
eters are important or which test provides the best measurement.
Vendor Relationships Therefore, vendors are encouraged to offer suggestions on ways to
One of the main reasons for the specification system is to improve the specifications. Their input can be valuable.
prevent “cozy” relationships between vendors and plant personnel.
When this situation occurs, prices tend to rise whether quality rises Exceptions
or not. Conflicts then occur between plant personnel and the It does not pay to employ performance specifications on low
purchasing department, as the latter attempts to stabilize prices. volume items. Below a certain dollar amount, the use of specifica-
Using the specification system allows an “arm’s length” relation- tions is a waste of time. Simply find something that works and use
ship. Looking primarily at the test results promotes objectivity. Of it if the cost is not excessive. However, in a multi-plant organization,
course, quality consistency, dependable deliveries and knowledge- small quantities in several plants can add up to enough money to
able service are considered as well. No one likes vendors who make using a specification worthwhile. Every situation is different,
provide inconsistent quality, unreliable deliveries or spotty service. and good judgment must be used.
One of the questions that might be asked when considering the
Adjusting Specifications use of specifications is: “Do we need to consolidate our products?”
The performance specification should be considered a “living” According to the Pareto principle (80/20 rule), 80 percent of the
document. It must be periodically adjusted to reflect new knowl- lubricant volume in a plant should be concentrated in 20 percent of
edge. Once written, the specification may become outdated by new the individual products. Take a survey of the products and the
www.machinerylubrication.com | November - December 2013 | 11
COVER STORY
volume used of each. If the results do not conform to the 80/20 products you obtain while forcing oil companies to compete.
rule, your plant might be a candidate for lubricant consolidation. In However, by instituting a specification system, plant maintenance
other words, if relatively equal volumes of many products are in use, people are compelled to learn what works and why. This may be a
duplication might exist. challenge in some plants.
The willingness to perform testing is critical. You do not need
Benefits and Disciplines of to have an onsite laboratory, but you must find a quality offsite
the Specification System lab. While a few tests can be performed onsite with inexpensive
The most obvious benefit of the specification system is lower equipment, most require expensive equipment and a qualified
prices. This can be easily seen. What goes unseen is the high-quality technician. A few ways to reduce these costs are discussed below.
These two disciplines — learning what works
and why, and the willingness to conduct
testing — are essential.
Intangible Benefits
When you have a “system” in place for
purchasing lubricants, vendors tend to be
more careful with your products’ quality.
Knowing that you test and won’t hesitate to
complain or have a bad load pumped out at
their expense will keep everyone honest. Also,
those vendors who live by “sharp” practices
or high costs don’t even bother to solicit your
business. My personal experience has proven
this to me repeatedly.
Testing
As mentioned previously, it is recom-
mended to randomly test every truckload of
bulk oil and drum shipments. The steel
company did this because of the large
volumes purchased. Tests are generally priced
individually, and some are expensive. To
lower costs, the steel company selected a few
critical tests for each load and assumed the
rest were OK. However, this may have been
overkill. You could take a sample, label it and
store it in case of future problems. As confi-
dence in a vendor grows, this would be an
acceptable practice.
FOOD-GRADE GREASE
Interflon’s Food Grease HD00 is a semi-fluid lubricant for industrial
gearboxes and machine components using automatic oil and grease
lubrication. Based on MicPol technology, the heavy-duty grease is
NSF H-1 accredited for use within the food industry and can also be
utilized as a solvent-free corrosion inhibitor. The grease is suitable for
extreme high-pressure applications, dusty and wet environments, and
high temperatures. During field tests, it has shown an improvement in
wear protection as well as a reduction in energy consumption.
Interflon
www.interflon.com
877-346-5823
DRAIN PLUG
TOOL
The Drain Plug Pro is a new tool
for easily removing oil drain plugs.
By keeping hands and fingers away
from possibly hot draining oil, the one- FLUID DISPENSING/METERING PUMP
size-fits-all tool makes the oil changing The PDS-100 from Fluid Metering Inc. is a programmable
process a more efficient, cleaner and safer fluid metering and dispensing system that integrates valve-
operation. It attaches to any steel compo- less pump technology with precision, programmable drive
nent, including an oil pan, to hold and keep motor control. The pump head internals are made from
the drain plug free from contaminants as oil chemically resistant, sapphire-hard ceramics, which are
is draining while also serving as a reminder that ideal for dispensing a broad range of fluids, including silicone
the drain plug is still out. The tool’s integrated lubricants. The PDS-100 is available in both single and dual
magnets allow particles attached to the drain plug pump head configurations. The displacement and speed
to be removed. of each pump head can be individually controlled. Duplex
OTC Tools configurations can also provide two-channel dispensing,
www.otctools.com effectively doubling production capacity.
800-533-6127 Fluid Metering Inc.
www.fmipump.com
800-223-3388
14 November - December 2013 | www.machinerylubrication.com
METAL CONDITIONER
Everrev is an anti-friction metal conditioner formulated to improve the
performance of gas and diesel engines as well as hydraulics and most
metal-to-metal transmissions. It treats ferrous-based metals through
a molecular change within the metal surfaces. The chemical reaction
forms a smoother and denser surface without residual buildup or
change in the tolerances of working parts. It is activated by heat and
pressure, and is carried by motor oil, transmission oil, hydraulic fluid
and greases to friction points, reducing heat and wear.
Everrev
www.everrev.com
386-295-4343
SINGLE-POINT AUTOMATIC
LUBRICATORS
SKF’s new System 24 LAGD Series single-point automatic
lubricators were created to deliver the proper preset
amount of lubricant needed for bearings in machinery
HYDRAULIC TESTER across industries. The gas-driven feed versions can per-
The SDMKR reversible flow device from Stauff was developed form reliably on a 24-hour basis without manual inter-
for rapid and accurate monitoring of hydraulic components vention and can resolve issues typically associated with
and systems. It provides simultaneous measurement of flow, hard-to-access or poten-
pressure and temperature. Each tester includes a flow meter tially hazardous lubrica-
with a visual display and a built-in thermometer, as well as a tion points. Each lubri-
loading valve. The loading valve makes it possible to safely cator features flexible,
increase the working pressure gradually and continuously for a user-adjustable dispense
realistic simulation of normal machine operation. The portable settings and transparent
flow device can be installed in both pressure and return lines. lubricant containers. The
Stauff lubricators also integrate
www.stauffusa.com tool-free activation and are
201-444-7800 available in two sizes (60
and 125 milliliters).
SKF
www.skf.com
267-436-6000
outside of the bottle before drawing a vacuum with the hand pump.
The rigid plastic sleeve prevents the bottle’s collapse, and the clear
plastic enables the sampler to see when the bottle is full.
The fit or gap between the sleeve’s inner diameter and the
sample bottle’s outer diameter does not need to be snug. However,
The “Lube-Tips” section of Machinery Lubrication maga-
the larger the gap, the less effective the sleeve is in preventing the
zine features innovative ideas submitted by our readers.
bottle’s collapse.
Additional tips can be found in our Lube-Tips email news-
letter. If you have a tip to share, email it to us at editor@noria.
com. To receive the Lube-Tips newsletter, subscribe now at
Post Your Oil Cleanliness Trends
www.MachineryLubrication.com/page/subscriptions.
Place a trend chart of ongoing oil cleanliness for all to see on the
front of all major reservoirs. Any change in the trend (up or down)
can promote questions and actions within the maintenance team.
Remember, cleanliness control is the responsibility of everyone, and
Advice for Oil Sampling having a visual representation of cleanliness prominently mounted
Before taking a large number will promote improved housekeeping by keeping reservoirs and
of oil samples using pre-labeled equipment clean and sealed.
bottles, mark the bottle caps
with enough information to Safety Tips for Oil Storage Areas
enable quick recognition of Consider the following safety tips for your oil
which bottle you need to pull storage areas:
out for sample points. This • Fire extinguishers should be located
procedure enables you to go strategically throughout the
directly to the correct sample lube room. They should also
bottle without having to search be inspected and tested on
through the entire box looking at a regular basis.
labels to find the right one. It • All spills should be cleaned
also saves a lot of time and helps up promptly.
eliminate using the wrong bottle.
• Used rags and absorbents
should be placed in approved
Magnet on a Dipstick for Quick Inspection containers immediately after
For better visual inspection of an oil’s color, paint a magnet
use. The container should be
white and permanently attach it to the dipstick of a reservoir. If
emptied at the end of each shift.
particles become stuck to the magnet, you know further investiga-
tion is required. • Good ventilation is required
in the lube room to vent
Prevent Sample Bottle Collapse hazardous fumes such as
When you are sampling using a vacuum-type pump, hot oil or those related to solvents.
exceptionally viscous oil • Solvents should rest on a
can result in the plastic grounded surface to prevent
sample bottle col- sparks from static electricity.
lapsing, making it
difficult if not impos- Improving Oil Change Procedures
sible to pull sufficient While quick-connect couplings may be considered best practice,
vacuum to draw out the if they are not in the maintenance budget, you might try the
oil sample. following method to help keep a gearbox drain plug clean during an
To prevent this, get oil change. After capturing particles from the magnetic plug to
a short piece of clear, examine later, clean and dry the plug, then place it in a zip-lock bag.
rigid PVC pipe with an Label the bag with a magic marker. If the gearbox case is ferrous,
internal diameter that stick the bag on the case near the filling point. If the case is not
closely matches the ferrous, tie the bag with a strap or similar fastener near the fill point
outer diameter of the to remind you to put in the plug before filling the gearbox with oil.
plastic sample bottle. This will keep the drain plug clean, prevent it from getting lost and
Slide this over the remind you to replace it before filling with fresh oil.
ATSELE
ATS LECCTR
RO-LUBE
E
I N T E R N AT I O N A L I N C O R P O R AT E D
Serving
erving the
ervin t Lubrication
tion
ion Com
Comm
om unity
TURBINE LUBRICATION
is not enough. Immediate cleaning of the entire interior of the oil boxes, drive-shaft seals,
system with subsequent turbulent flushing should be performed. pumps, oil coolers, filters
Often, if the oil doesn’t meet specific requirements, oil replace- and reservoirs.
ment (exchange) is also required. The most common
Because proper cleaning of an oil system is not easy within an impurities are metal
overhaul process or when assembling a new system, a variety of debris from machining,
technologies and strategies have been used, such as mechanical welding slag, sealants or
cleaning with ramrods, chemical cleaning (with solvents, oil other materials used
additives, etc.), steam blowing or utilizing different oil flushing during assembly or
procedures. In dirty oil systems, most of these practices do not repairs, oil system corro-
produce the desired results within a reasonable amount of time sion products (mainly
and money. Frequently, positive results do not last long but rust), solid impurities,
diminish, resulting in the need for additional cleaning. wear metal particles, and
With the cost of operating dirty lubrication systems in water from oil coolers or
turbines far too significant to neglect, more efficient solutions steam gland leaks and
have been developed. One effective method of preparing new from ambient humidity.
oil systems and restoring operated oil systems for future reli- Impurities sometimes
able operation involves the technology of hydrodynamic include gases (e.g., light A dirty oil pipeline (sludge and
corrosion in the return line)
cleaning and flushing of oil systems. This alternative to obso- hydrocarbons or ammonia)
lete or inefficient methods has become a preferred choice of and cooling liquids. Other troublesome impurities involve oil
many original equipment manufacturers (OEMs) and degradation products from aging and thermal stress, which
power-generation repair companies. create insoluble chemical compounds that are responsible for
varnish and sludge formation.
The Problem of Dirty Oil Systems
One of the most expensive and underestimated problems
associated with the use of machinery is the inadequate cleanli-
ness of the oil system. It results in low oil cleanliness, thus leading
to most maintenance problems and to related extra expenses
(production outages, repairs, penalties and loss of customers).
Impurities can enter the oil system during assembly, upon
execution of overhauls or simply from the immediate surround-
ings. They also are created during operation due to oil
degradation and corrosion processes. In process machinery,
compressed gas often carries different impurities and can
interact with the base oil or oil additives while entering the oil
system through wet seal glands. These contaminants accumulate
in the oil system interiors, creating different deposits.
Impurities are the main cause of premature wear and can
lead to equipment breakdown. The most vulnerable parts
include bearings, hydraulic actuators and controllers, gear- An oil cooler covered by sludge from oil-aging products
The core of this technology involves cleaning all the inner greases and corrosion-pro-
surfaces of the oil system with high-pressure water jets tective layers), as well as
utilizing suitable nozzles, immediate drying and application of hard deposits like corro-
a protective turbine oil spray to the dried surfaces, followed sion products, rust,
by flushing with continuously filtered oil at sufficient pressure welding slag, varnish
and flow rates. residue and machining
residue that is partially
Step 1: Hydroblasting attached to the surface.
During hydroblasting, the inner surfaces of the system are The following activities are An oil pipeline after
blasted with high-pressure water in order to detach soft deposits carried out in the course of hydroblasting
(loose wear debris, sand and dust grains, products of the the cleaning process:
oil-aging process, sludge, biological deposits, resins, asphalts,
• High-pressure water hydroblasting of all the interiors of
pipelines and other elements of the oil system (coolers,
reservoirs, bearing stands, etc.) using suitable equipment
(elastic lances, nozzles, water guns, etc.).
• Immediate drying of cleaned surfaces using filtered,
compressed air.
• Application of anti-corrosive protection on dried surfaces
(spraying with lubricating turbine oil) until flushing occurs.
• Protection of open flanges from environmental dust and
dirt until the flushing process takes place.
This advanced technology allows disassembly of only neces-
sary small parts of the oil system (pumps, valves, fittings, coolers,
etc.). The goal of hydroblasting is to ensure all of the system’s
The hydroblasting process interiors are free of corrosion, sludge, varnish and other deposits.
small amount
of contaminants
that remain in the
system are then easy
to flush out. In addition,
hydroblasting is quite useful
before an oil exchange and permits deep
Manifolds and temporary connections on a small investigation of the oil system by endoscope prior to flushing.
steam turbine Flushing after hydroblasting is fast and efficient, allowing a
Safe and Effective completion date to be set and a schedule to be maintained
The technology of hydrodynamic cleaning and flushing with no extra time needed for prolonged flushing. With this
with oil at turbulent flow rates provides a highly effective technology, proactive maintenance based on oil analysis can
method for the renewal of dirty and corroded systems to “like be implemented.
new” condition while also being suitable for newly assembled The method is entirely safe for the natural environment, as
oil systems. pure water is the cleaning medium, and the wastewater
Hydroblasting not only disinfects the system from aging contains only impurities detached from the inner system
products, old oil, protective layers or other chemicals that might surfaces along with trace quantities of oil washed from the
contaminate fresh oil, but also shortens the future flushing system. Long-term warranties in regards to the system cleanli-
process because most impurities are removed by water. The ness are also a possibility.
Distributor Inquiries Welcomed! Because viscosity measurement should New Clear View oil reservoirs are
Sublime Water Descaler is safe, be simple, CANNON is excited to intro- lightweight, durable, and econom-
biodegradable, environmentally duce the SimpleVIS™ portable visco- ical. Polycarbonate endplates have
friendly and changes color from meter. Everything is included to get you a slim profile and broad chemical
yellow to purple when spent. U.S. started, minus your sample and solvent. compatibility. Capacities from 2 ½
Navy Approved & NSF A3 Regis- Contact us for more information. ounces to 1 gallon. Many styles,
tered. Private labeling available. Cannon Instrument Company all made in the USA.
Summit Industrial Products www.cannoninstrument.com Oil-Rite Corporation
www.sublimedescaler.com 800-676-6232 www.oilrite.com 920-682-6173
800-749-5823 sales@cannoninstrument.com sales@oilrite.com
Grind Using a
Gage Grease Analysis
for In-Service
Gage Design
Freshly purged grease should be collected and analyzed
The gage’s design features a large block of steel (typically stain-
for wear debris and contaminants. less or chromium plated) and tapered grooves or “raceways”
machined into the surface. One groove may range from a depth of
The value of grease sampling has been recognized and is now 0 to 250 microns, with a second groove from 0 to 50 microns.
even an ASTM standard (D7718-11). This standard describes a A wiper blade is fabricated from the same material as the
method for taking a representative grease sample from an in-ser- block. It draws the sample across the block’s surface for analysis.
vice bearing. While this is the first step in grease sampling, the The wiper blade and the surface of the block are milled as
second phase involves conducting tests on the sample. smooth as possible to allow for zero clearance between them
Several laboratories can perform grease analysis and check during the testing process. After many uses, the wiper may lose
for contamination, changes in viscosity or consistency, as well as its profile and may need to be retooled.
28 November - December 2013 | www.machinerylubrication.com
www.machinerylubrication.com | November - December 2013 | 29
GREASES
Applications
Early applications of these gages were seen in the pharmaceu-
tical and paint industries, which had issues determining the
fineness of particles in suspension. For example, in the paint
industry, the earliest method for inspecting dispersion quality
involved obtaining a small sample of the product to test for
particle fineness. Testing in this manner had its drawbacks
because it required considerable experience and agreement
between testers to predict the final product quality. To assist
testers in determining dispersion quality, the North Standards
were developed. These were actual pigment dispersions covering
a broad range of grind quality. A sample was checked by
comparing it to the selected standard on a glass plate.
The wiper blade is used to wipe the sample Skid marks left in used grease
down the block. indicate hard contaminants.
References
Doubleday, D. & Barkman, A. (1950). Reading the Hegman
Grind Gage. Paint, Oil and Chemical Review.
This is an example of a hard particle found in a Lafferty, G.J. & Gross, H.M. Application of the Hegman
grease sample. Gage to Medicinal Particle Fineness in Ointments. Journal of
the American Pharmaceutical Association, Vol. XLIV, No. 4.
Although knowing the size and concentration of particles
suspended in grease is beneficial, this test can be taken a step About the Authors
further to analyze the particles and identify the contaminants. Wes Cash is a technical consultant with Noria Corporation.
By looking at the particles under a microscope, you can begin He is a mechanical engineer who holds a Machine Lubrication
to distinguish environmental contaminants from wear debris Technician (MLT) Level II certification and a Machine Lubricant
originating in the bearing/race/cage assembly. These findings Analyst (MLA) Level I certification through the International
can then be used to determine wear patterns and modes as Council for Machinery Lubrication (ICML). Contact Wes at
well as give feedback on any contamination control devices wcash@noria.com.
being utilized. Rick James is an industrial services technician with Noria
This test offers the most information on grease that has been Corporation. He holds a Machine Lubricant Analyst (MLA) Level
directly purged from the bearing’s core. If the grease can be I certification and a Machine Lubrication Technician (MLT) Level
sampled, either through a grease purge trap or a grease sampling I certification through the International Council for Machinery
device, it will provide direct information on the current state of Lubrication (ICML). Contact Rick at rjames@noria.com.
TEST your
KNOWLEDGE
This month, Machinery Lubrication continues its “Test Your Knowledge” section in which we
focus on a group of questions from Noria’s Practice Exam for Level I Machine Lubrication
Technician and Machine Lubricant Analyst. The answers are located at the bottom of
this page. The complete 126-question practice test with expanded answers is available at
store.noria.com.
6
BY CARY F ORGERON, A NALYSTS INC.
share them with colleagues. The delivery cycle has also been cians to use the Internet to input comprehensive data about each
condensed from several weeks to within 24 hours. oil sample. This improvement has reduced the risk of incorrect
“I can do oil analysis 24 hours a day, seven days a week, 365 information gleaned from hand-written forms as well as
days a year,” says industry expert and consultant John Under- increased the amount of information technicians can provide to
wood. “I used to have to wait for weeks for the paper to show up laboratories about each sample.
in the mail two weeks after I submitted the sample.” Enhanced Functionality
Current oil analysis software programs offer improved
Sample Identification
reporting capabilities that extend far beyond the examination
Within the last decade, technology has allowed field techni-
of a single sample. In addition to maintenance program
management tools, software developments have enabled
cross-comparison of makes, models and lubricant types within
the asset population. Maintenance administrators can manage
equipment information online and provide it to laboratory
experts, which in turn enables data-mining capabilities that can
identify critical trends. Graphing tools can also give a visual
representation of the results.
“Technology cannot make up for a bad sample,” Under- repetitive, information-rich and credible samples to ensure
wood warns. quality and meaningful reports. When more data points are
Incomplete or illegible information can lead to data-entry given during the sampling process, laboratory analysts can
errors and limited testing that yields suboptimal reporting. Once deliver more comprehensive reports. With consistent and
restricted to whatever information could be scribbled on a small complete sample information, labs can ensure normalization of
label, the latest software programs allow maintenance techni- results based on the organization’s result history.
cians to input critical information, including equipment (make,
model, identification number, location, etc.), hours of operation, Take Advantage of Data Mining
maintenance activities, drain interval and more. A highly technical area of computer science, data mining
extracts information from a set of data and transforms it into
While incomplete information doesn’t affect the test results,
understandable and actionable information. In oil analysis, this
it significantly impacts the analyst’s ability to draw conclusions
process uses data management and complex metrics to detect
or detect trends. Therefore, it is essential that users provide
abnormalities in single samples or groups
of samples.
While laboratory experts excel in
extracting comprehensive information
from a sample, end users may find it diffi-
cult to put technical information into
practical terms. The average manager typi-
cally isn’t interested in particle counts or
the presence of iron or metals in a single
piece of equipment. However, the ability to
recognize trends across a population of
equipment can signal a bigger problem that
could result in lost revenue from downtime
or expensive repairs.
According to Underwood, data mining is
particularly helpful when managing fleets.
Comparison graphing offers a visual comparison of equipment
“The ability to compare units and equiv-
performance against a population of data, allowing plant personnel to alent services helps companies determine
determine which makes and models are best suited for each site. what the best product on the market is for
their particular business,” he says.
It is important to note that data
mining is not the end user’s responsi-
bility but rather an important and
integrated component of any effective
software program.
Q: What professional certifications have you Q: What is the amount and range of equipment that
attained? you help service through lubrication/oil analysis
tasks?
A: In terms of lubrication, I currently hold the following certifi-
cations from the International Council for Machinery A: I service all of our facility’s equipment, ranging from our oven
Lubrication (ICML): Machine Lubrication Technician (MLT) machinery to our belt conveyors. I also handle all lubrication
Level I and Machine Lubricant Analyst (MLA) Level I, II and tasks that are of a precision nature, including pulling oil
III. I also hold multiple certifications in different predictive samples. We conduct condition-based oil changes, so proper
maintenance technologies. sampling practices must be followed accurately to evaluate the
health of our machinery and lubricants. I also perform the
Q: Are you planning to obtain additional training or lubrication on all of our electric motors and high-speed bear-
achieve higher certifications? ings using airborne ultrasonic technology to apply lubricant
with precision.
A: I plan to increase my knowledge in every predictive mainte-
nance technology to the maximum certification level allotted Q: What have been some of the biggest project
in each field. I feel that doing so will benefit both me and my successes in which you’ve played a part?
40 | November - December 2013 | www.machinerylubrication.com
A: The biggest success has been the development of the PdM
programs, including the lubrication program here at Suncoke
Energy Middletown Operations. The strides the company has
made and the full support of reliability are helping make these
programs flourish. At the rate of development, it will not be
long before Suncoke is named a world-class facility. That is the
overall goal for us all.
This is the fifth part of a series of “anatomy” lessons within personnel who receive these lab reports do not understand the
Machinery Lubrication. In this issue, a specific device or object basics of how to interpret them.
will not be dissected but rather the content provided in a typical oil Typically, an oil analysis report comes with a written summary
analysis report, including how to interpret the data and other find- section that attempts to put the results and recommendations in
ings. These interpretations may decide either the cost or avoidance
of machine failure and downtime.
Interpreting an oil analysis report can be overwhelming to the
untrained eye. Oil analysis isn’t cheap, and neither is the equipment
Interpreting an oil analysis
on which it reveals information. Every year, industrial plants pay report can be overwhelming
millions of dollars for commercial laboratories to perform analysis to the untrained eye.
on used and new oil samples. Unfortunately, a majority of the plant
layman’s terms. However, since the laboratory has never seen the
machine or know its full history, these recommended actions are
What to Look for When Reviewing mostly generic and not precisely tailored to your individual
an Oil Analysis Report circumstances. Therefore, it is the responsibility of the plant
personnel who receive the lab report to take the proper action
based on all known facts about the machine, the environment
1. Read and check the data on the oil type and machine type for accuracy.
and recent lubrication tasks performed.
2. Verify that reference data is shown for new oil conditions and that
trend data is at an understood frequency (preferably consistent).
3. Check the measured viscosity. Why Perform Oil Analysis
4. Verify elemental wear data and compare to reference and trended data. An obvious reason to perform oil analysis is to understand the
Use a wear debris atlas to match elements to their possible source. condition of the oil, but it is also intended to help bring to light the
5. Check the elemental additive data and compare to reference and condition of the machine from which the oil sample was taken.
trended data. Use a wear debris atlas to match elements to their There are three main categories of oil analysis: fluid properties,
possible source. contamination and wear debris.
6. Verify elemental contamination data along with particle counts
and compare with reference and trended data. Use a wear debris Fluid Properties
atlas to match elements to their possible source. This type of oil analysis focuses on identifying the oil’s current
7. Check moisture/water levels and compare to reference and physical and chemical state as well as on defining its remaining
trended data. useful life (RUL). It is designed to answer questions such as:
8. Verify the acid number and base number and compare to reference
• Does the sample match the specified oil identification?
and trended data.
9. Check other analyzed data such as FTIR oxidation levels, flash • Is it the correct oil to use?
point, demulsibility, analytical ferrography, etc. • Are the right additives active?
10. Compare any groups of data that are trending toward unacceptable
levels and make justifications based on these trends. • Have additives been depleted?
11. Compare written results and recommendations with known • Has the viscosity shifted from the expected viscosity? If so, why?
information on the oil and machine, such as recent changes in envi-
ronmental or operational conditions or recent oil changes/filtration.
• What is the oil’s RUL?
12. Review alarm limits and make adjustments based on the new Contamination
information. By detecting the presence of destructive contaminants and
44 | N
November
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December hi l b i i
Seeing Oil Like Never Before!
Introducing the New
™
Built-in oil
sampling port
Probe detects
abnormal corrosion and
varnish conditions
Easy-to-remove and
view magnetic plug
narrowing down their probable sources (internal or external), oil asked to the patient. Likewise, with oil analysis, careful oil samples
analysis can help answer questions such as: are taken, and elaborate machines yield the test results. Laboratory
• Is the oil clean? personnel interpret the data to the best of their ability, but without
crucial details about the machine, a diagnosis or prognosis can
• What types of contaminants are in the oil? potentially be inaccurate. Some of these important details include:
• Where are contaminants originating? • The machine’s environmental conditions (extreme tempera-
• Are there signs of other types of lubricants? tures, high humidity, high vibration, etc.)
• Is there any indication of internal leakage? • The originating component (steam turbine, pump, etc.), make,
model and oil type currently in use
Wear Debris
• The permanent component ID and exact sample port location
This form of oil analysis is about determining the presence and
identification of particles produced as a result of mechanical wear, • Proper sampling procedures to confirm a consistently repre-
corrosion or other machine surface degradation. It answers a sentative sample
number of questions relating to wear, including: • Occurrences of oil changes or makeup oil added, as well as the
• Is the machine degrading abnormally? quantity of makeup oil since the last oil change
• Whether filter carts have been in use between oil samples
• Is wear debris produced?
• Total operating time on the sampled component since it was
• From which internal component is the wear likely originating?
purchased or overhauled
• What is the wear mode and cause?
• Total runtime on the oil since the last change
• How severe is the wear condition?
• Any other unusual or noteworthy activity involving the machine
Ultimately, you need to know if any actions should be taken to that could influence changes to the lubricant
keep the machine healthy and to extend the life of the oil. Oil analysis
for machines can be compared to blood analysis for the human body. Oil Analysis Tests
When a doctor pulls a blood sample, he puts it through a lineup of For a standard piece of equipment undergoing the normal recom-
analysis machines, carefully studies the results and reports his mended oil analysis, the test slate would consist of “routine” tests.
conclusions based on his education, research and detailed questions Alternatively, if additional testing is needed to answer advanced ques-
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the oil. Many techniques can be used to assess this data, which is
WAVENUMBER OIL PARAMETER
typically reported based on ISO 4406:99. This standard designates
1750 Oxidation (for mineral oils) three numbers separated by a forward slash providing a range
3540 Oxidation (for organic ester) number that correlates to the particle counts of particles greater
815 Oxidation (for phosphate ester)
than 4, 6 and 14 microns. To view an illustration of how different
particle counts are assigned specific ISO codes, visit http://www.
Sulfation (possibly from high-sulfur
1150 machinerylubrication.com/Read/29525/sample-new-oil.
fuel contamination)
Nitration (typically with natural gas
Moisture Analysis
1630 Moisture content within an oil sample is commonly measured
engines)
with the Karl Fischer titration test. This test reports results in parts
3625 Water ingression (for organic ester)
per million (ppm), although data is often shown in percentages. It
3400 Water ingression (for mineral oils) can find water in all three forms: dissolved, emulsified and free. The
Soot (combustion chamber blow-by crackle test and hot-plate test are non-instrument moisture tests
2000
contamination) for screening before the Karl Fischer method is used. Possible
880, 3400, reasons for a moisture reading being too high or too low would
Glycol ingression
1040, 1080 include water ingression from open hatches or breathers, internal
800 Diesel fuel ingression
condensation during temperature swings or seal leaks.
especially wear particles. For example, the originating piece of the root cause. One likely explanation for these spikes is that as
equipment can help associate reported wear particles with certain dirt (silicon) enters the oil from an external source, three-body
internal components. The lubricant information can provide a abrasion occurs within the machine, causing wear debris including
baseline for several parameters, such as the expected viscosity aluminum, iron and nickel to increase.
grade, active additives and acid/base number levels. These details With a better understanding of the metallurgy within the
may seem straightforward but are often forgotten or illegible on system’s components, any spikes in wear metals can be better
the oil sample identification label or request form. associated, allowing a proper conclusion as to which internal
The next section (Section B) of the oil analysis report to components are experiencing wear. Keep in mind that for trend
examine is the elemental analysis or FTIR breakdown. This data analysis, it is important that samples are taken at an appropriate
can help identify contamination, wear metals and additives and uninterrupted frequency.
present within the oil. These parameters are reported in parts per With elemental data related to contaminants and wear metals,
million (ppm). Nevertheless, this does not mean a contamination alarms are set for upward trends in the data. For elemental data
particle, for example, can only be indicated by sodium, potassium pertaining to additives, alarms are set for downward trends. Having
or silicon spikes. In the example above, the rise in silicon and a baseline of new lubricant reference data is critical in assessing
aluminum could potentially indicate dust/dirt contamination as which additives are expected and at what levels. These baselines are
then established to help determine any significant reduction in When analyzing the acid number, you should have both a refer-
specific additives. ence value and the ability to trend from past analysis. The acid
Another section of the oil analysis report presents previously number often will jump considerably at some point. This may be
identified sample information from the customer such as oil manu- your best indicator for when the oil is oxidizing rapidly and should
facturer, brand, viscosity grade and in-service time, as well as if an be changed.
oil change has been performed. This is important data that can The last section of the oil analysis report generally provides
provide an explanation for what could be false positives in alarming written results for each of the final few test samples along with
data changes. recommendations for required actions. Typically, these recom-
The “physical tests” section of a report offers details on viscosity mendations are entered manually by laboratory personnel and
at both 40 degrees C and 100 degrees C, along with the viscosity based on information provided by the customer and the data
index and percentage of water. For common industrial oils, the collected in the lab. If there is an explanation for the data that
viscosity measurement at 40 degrees C is usually given, since this stems from something not explicitly stated by the customer, the
correlates to the oil’s ISO viscosity grade. If the viscosity index must results must be reinterpreted by those familiar with the machine’s
also be calculated, such as for engine oil, then these additional history of environmental and operating conditions. Under-
viscosity measurements will be identified. The viscosity for engine standing the information given here is critical. Remember, there is
crankcase oils is typically reported at 100 degrees C. always an explanation for each exceeded limit, and the root cause
Water contamination, which commonly is measured by the Karl should be investigated.
Fischer test, is presented in percentages or ppm. While some In addition to the raw data shown throughout the oil analysis
systems are expected to have high levels of water (more than 10,000 report, graphs can help illustrate notable trends in the data.
ppm or 10 percent), the typical alarm limits for most equipment are Below is an example of trended data points from analyzed data,
between 50 to 300 ppm. with the water test having the most notable unfavorable spike.
The “additional tests” section shows two final tests: acid Along with the trend data, graphs should show typical averages,
number (AN) and particle size distribution (aka, particle count). warning (marginal) limits and alarm (critical) limits. These limits
Graphs in an oil analysis report can help illustrate notable trends in the data. (Ref. Fluid Life)
5. FTIR
a. Ox/Nit/Sul R R R R R R R R R R -
b. Hindered - R - R R - - R R - -
Phen
c. ZDDP - R - R R - R R - - -
d. Fuel Dil./Soot - - R - - - - - - - -
6. Flash Point - - R - R* - - - - E(2b,5d) -
7. Glycol-ASTM - - E(14b) - - - - - - - -
Test
8. Ferrous Density E(1) E(1) R R R R R R E(1) E(1) R
9. Analytical E(8,14 a) E(8,14a) E(8,14 a) E(8,14 a) E(8,14a) E(8,14a) E(8,14a) E(8,14a) E(8,14a) E(8,14a) E(8,14a)
Ferrography
10. RPVOT - - - - R - - - R R -
11. Crackle R R R R R** R R R R - R
12. Water by KF E(11) E(11) E(11) E(11) E(11)** E(11) E(11) E(11) E(11) - E(11)
13. Water Separability R - - - R** - - - R - -
14. Elemental Analysis
a. Wear Metals R, E(1) R, E(1) R R, E(1) R, E(1) R, E(1) R R, E(1) R, E(1) R R,E(1)
b. K, Na, B, Si R R R R R R R R R R R
c. Additives R R R R R R R R R R R
*Gas compressors only ** Air compressors only ***For phosphate ester fluids, consult the fluid supplier and/or turbine manufacturer.
R = Routine testing
E = Exception test keyed to a positive result from the test in parentheses
should be modified depending on the type of data collected, the human error in sampling or analysis. If exception tests are needed,
type of lubricant and the machine’s known operating conditions. the chart above shows which tests would be appropriate when a
Standard alarm limits will be set by the oil analysis laboratory. given routine test limit has been exceeded.
However, if there is any reason to adjust these limits higher or
lower, they should be identified properly. Examples of limits that About the Author
should be lowered would be those for highly critical assets or Bennett Fitch is a technical consultant with Noria Corporation. He is
assets that are consistently healthy. A small spike in data would be a mechanical engineer who holds a Machine Lubricant Analyst (MLA)
cause to run an exception test or an immediate second sample for Level II certification and a Machine Lubrication Technician (MLT) Level
analysis. In such cases, a second sample would ensure the data II certification through the International Council for Machinery Lubrica-
received is representative of the oil conditions and not simply a tion (ICML). Contact Bennett at bfitch@noria.com.
80%
of lubrication professionals do not have
thing that relates to machinery lubrication is available now on a grease analysis program at their plant,
MachineryLubrication.com. according to a recent survey at Machinery-
Lubrication.com
The Importance of Machine Criticality
Criticality is very much a part of making informed decisions on
scheduling, whether it be a simple sight-glass inspection or as
complex as a turbine rebuild. Critical equipment most definitely An Introduction to the Principles of Lubrication
should be checked more often than non-critical equipment. These This video explains the importance and methods of mechanical
assets deserve the focus of your limited time, money and energy. Of lubrication for various equipment. In order to use lubricants
course, it is important to know how you define an asset as critical. correctly, you need
Discover how to determine the criticality of an asset by reading this to know some of the
article on the ML site. key terms describing
their specific char-
acteristics, such as
viscosity, viscosity
index, pour point,
flash point and fire
point. Access this
4-minute, 2-second
video at www.MachineryLubrication.com.
World-Class RELIABILITY
STARTS with a Solid
FOUNDATION
BY SUZY JAMIESON, ICML
When it comes to developing, implementing and sustaining fad or actually achieve the results you have set out to accomplish. It
a reliability-improvement program, long-term success ulti- is also important to know the elements that are in place will with-
mately depends on a solid foundation. Indeed, it is the foundation stand the test of time and weather the storms that will inevitably
that will determine whether the current initiative will be just another come your way.
Sometimes we overlook the obvious.
As a society, we invest considerable
time and energy aiming for great
Benefits of ICML Certification heights yet often forget that crucial
ingredient for making sure we do not
Quality certification programs not only can provide standards and guidelines for profes-
fall flat on our faces once we have
sional recognition but also a multitude of benefits for individuals, organizations and industry.
reached the top. In other words, you
For Individuals have to crawl before you can walk. No
Earning an ICML certification acknowledges your expertise in machinery lubrication
matter how great an idea seems in
and/or oil analysis to troubleshoot and ensure reliability of lubricated equipment. The lubri-
cation and oil analysis community, your employer, clients and peers will recognize your theory, it is a long, uncertain journey
ICML credential as a symbol of the skills and knowledge you’ve gained through experience. from design to actual results, especially
ICML certification shows that you are a professional with the ability to successfully utilize for anything worthwhile.
machinery lubrication and/or oil analysis for your organization or client. As with most other things in life, you
As an ICML-certified professional, you also receive the following benefits: must start at the bottom. In the case of
• Industry recognition of your knowledge and proficiency in machinery lubrication
reliability programs, this means the
and/or oil analysis techniques.
• Logos and a certificate to enable you to identify your ICML-certified status to hands-on personnel, the shop-floor
colleagues or clients. staff or the technicians. They are the
human foundation of any reliability-im-
For Employers and Organizations
Through certification, organizations can maximize their return on investment in oil provement program. Without them,
analysis. ICML certification delivers the following benefits: their buy-in and a solid foundation of
• A standardized method of determining training needs and measuring results technical skills, no amount of reliability
• A reliable benchmark for hiring, promoting and career planning theory, philosophy or trendy gadgetry
• Employee recognition and rewards that validate their expertise will make the program stand when it is
• Improved employee ability to ensure machine reliability
shaken — and it will be shaken. After all,
• Quality assurance for outsourced oil analysis and lubrication services
as any maintenance and reliability
For Industry professional knows, things do not
Certification brings much-needed credentials to an up-and-coming lubrication and oil
always go according to plan.
analysis community. Benefits to the community include:
• Respect for oil analysis and lubrication professions Be sure to value and respect the tech-
• Increased professionalism within the community nicians and the crucial role they play in
the outcome of any plant reliability-im-
56 | November
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December hi l b i i
provement program. It is in your best interest to recognize the operators, followed by an audit of their skill set, i.e., competency
direct impact they have on the culture change. Respecting and testing in the technologies they will utilize when monitoring the
supporting them in their professional development and teaching condition of your assets.
them not only what they should or need to be doing but also why As you develop technicians to be future leaders within your
will make all the difference. program, new mentors will emerge. Empowering them with
Common sense and mutual respect can go a long way, even in career potential and recognition of their worth and contribu-
our plants. Give technicians a solid start by providing them with the tions to the overall health of the plant’s reliability and availability
proper tools they need to succeed. This means ensuring they have will instill the pride everyone deserves in his or her professional
role. Suddenly you will find yourself with in-house experts eager
to make a difference. The intangible benefits you will see are the
Recognize that the same as those experienced and documented by many world-
technicians are ultimately class operations.
The crucial first step is to understand where you are currently.
the foundation of Establish your starting point, not only in relation to your practices
your reliability- and your team’s skill level (be it in lubrication, for example, or other
areas), but also where you aim to be, such as a benchmarked world-
improvement program. class parameter. Knowledge of the steps needed to get where you
want to go is an obvious necessity, as is knowing where your limited
resources are best spent — and everyone has limited resources. Ulti-
the appropriate job description and pre-established procedures mately, wherever your higher return-on-investment opportunity
that are clearly taught and monitored through proper supervision. lies, that is where your focus should be.
The importance of skills development cannot be overempha- To learn more about ICML’s certification programs, please visit
sized. This will require technical training for tradesmen as well as www.lubecouncil.org.
Ron Francis, MLT I Cargill Ethicon LLC Holcim Juan Figueroa, MLT I
Sheldon Brown, MLT I Doug Leischner, MLT I Joel Delgado, MLT I Michael Fink, MLA I Lubrication
Williard Popplestone, Tanner Rix, MLT I Julio Rodriguez, MLT I Tyler Reed, MLT I Engineers Inc.
MLT I
Catalyst Paper Excell B Enterprises Hyundai Gary Jacobs, MLT I
A.W. Chesterton Brian Lundberg, MLT I Palanisamy Duraisaamy, Sung-Ho Hong, MLT I Steven Hays, MLT I
Mark Guenther, MLT II MLT II Steven Petrehn, MLT I
Ceng LLC Industrial Oils
AES Brian Koscielniak, MLA II Fate Unlimited Adam Serwinski, MLT II
David Rossler, MLA I Gastón Argañaraz, MLT I Kyle Kress, MLA II & MLT I McCain Foods
Central Motor Wheel
Anthony Woods, MLA II Interflon Jonathan Allen, MLT I
of America FilterMag Inc.
Gregory Lilley, MLA II Gerd Hulsmann, MLA II Joshua Lesniak, MLT I
Hal Hastings, MLT I Randy Yount, MLA I
Heather Mawhinney, Michael Monteith, MLT I
Ron Mosley, MLT I Flint Hills Resources JD Irving
MLA II
Kevin Perrin, MLA II Chevron Mike Davis, MLA I Jacques Theriault, MLT I Michelin
Md. Alam, MLA II Jimah O&M Al Arnette, MLT I
Allied Reliability Florida Power & Light
Minhaj Ahmad, MLA II Michael Schilling, MLA II Kathiresan Maniam, MLT I MillerCoors Brewing Co.
Melissa Woodward, MLT I
Mohammad Chowdhury, Carroll Wyant, MLT II
Alto Parana MLA II Fuchs Johnson Controls
Gonzalo Gatti, MLA II Sadeaque Ul Islam, MLA II Alexander Franke, MLT I Richard McKenzie Jr., Monition
Juan Fortuny, MLT I G&G Sales MLA I Robert Webster, MLA II
Chicago Bridge and Harley Register, MLT I
AMRRI Iron Co. Hank Gilley, MLA I & MLT I Mosaic Co.
Bobby Kennedy, MLT I Charles Ray, MLT I General Mills Jones Engineering Sean Greenlee, MLA I
Marcus Duhe, MLT I Arthur McCarthy, MLA II Billy Gunter, MLT I
Apache Corp. Ben Rosenbauer, MLT I
Matthew O’Brien, MLT I Cirra Consultants Chak Man Chan, MLT I Kaiser Aluminum MRG Laboratories
Charly George, MLA II Joe Pequignot, MLT I Rich Hoy, MLT I Lisa Williams, LLA I
Atlas Wade Falconberry, MLT I
Pradeep Nair, MLA II City of Largo Katech Richard Wurzbach, MLA II
Garry Rice, MLA I Georgia-Pacific Jonghyuck Park, MLT I NAES Corp.
Axiall Corp. Aaron Swoyer, MLT I
Chester Guidry, MLT I CPS Energy Korea Midland Mike Walker, MLA I
Andrew Overton, MLT I Power Co.
Daniel Miller, MLT I Ryan Mcdonnell, MLT I New Gold Inc.
Chad Marcell, MLT I Jae-Gun Hwang, MLT I
Donnie McDonald, MLT I Clinton Burton, MLA I
Croda Chemicals Corey Marcell, MLT I
Henry Verbick, MLT I La Plata Cogeneración
Shantanu Das, MLA III Daniel Massie, MLT I Noria Corporation
Jace Dickerson, MLT I Adrián Lella, MLA I
Glenn Noack, MLT I
Jeffrey Eastwood, MLT I DaimlerChrysler Gerald Putt, MLA I & MLT II
Kyle Bowman, MLT I Michael Leggett, MLT I
James Marcusen, MLT I Laboratorio Dr. Lantos Loren Green, MLT II
Joel Krause, MLT I Gabriel Lucchiari, MLT II
Lionel Bonin, MLT I Dalrymple Bay Coal Joshua Nackers, MLT I
Seth Cannon, MLT I Terminal Julie Longtin, MLT I
Lagan Cement
Taylor Richard, MLT I Andrew Marshall, MLA I David O’Rourke, MLA II
Mark Wnuk, MLT I
Todd Haydel, MLT I
DTZ Mike Maciejewski, MLT I
Stephen Beirne, MLA II Need to take
BACTS Barton Dewey, MLT I Mitch Sokolski, MLT I Lartex SRL an exam?
Pablo Savall, MLT I Chris Hanna, MLT I Peter Stengl, MLT I Roberto Zapata, MLT I ICML regularly holds
Baxter Healthcare Donald Haapapuro, MLT I Randy Malcore, MLT I Laurentide Controls exam sessions throughout
Carlos Falu-Vazquez, Eamon Reilly, MLT I Ron Wilde, MLT I Magali Jarry, MLA II the United States and the
MLA I Jason Jensen, MLT I Steven Chada, MLT I
Lilly del Caribe world. Upcoming dates
Bayer CropScience Kyle Maack, MLT I Glencore Jorge Arroyo, MLA I and locations for ICML
Paul Manock, MLT I Josef Dopsa, MLA I Juan Marquez, MLA I exams can be found at
Jeffrey Levin, MLT I
Scott Erickson, MLT I Barnard Jimenez, MLT I Samuel Barreto, MLA I www.lubecouncil.org.
Boehringer Ingelheim Stephanie Wyum, MLT I
Gary Helmink, MLA I Glucovil
Tyler Roberts, MLT I
John Adams, MLT I Sebastián Lombardi, MLT II
Duke-Energy
Bunge Ryan McKillip, MLA I
Green Country ICML Certifications
Carlos Oliveira, MLT I Energy LLC
E&J Gallo Winery LLA I = Laboratory Lubricant Analyst Level I
Edivaldo Junior, MLT I Lee Garell, MLT I
Everett Young, MLT I MLA I = Machine Lubricant Analyst Level I
Joel Fernandes, MLT I Hankook MLA II = Machine Lubricant Analyst Level II
Josinaldo de Melo, MLT I Eastman Chemical Yangseok Son, MLA II MLA III = Machine Lubricant Analyst Level III
Ricardo Romao, MLT I Travis Bledsoe, MLT I Harley Davidson MLT I = Machine Lubrication Technician Level I
Bureau of Reclamation EcoElectrica Motor Co. MLT II = Machine Lubrication Technician Level II
Keith Cooper, MLT I Julio Colon, MLT I Gregory Coligan, MLT I
58 | November - December 2013 | www.machinerylubrication.com
NV Energy MLT I Kenneth Puckett, MLT I Sang Chul Park, MLT I Tractors India
Kasey Davis, MLT I David Story, MLA I & MLT I Larry Orethun, MLT I Suk Yoong Jung, MLT I Saugata Roy, MLA I
Oil Filtration Systems Jamie Marquis, MLA I & Raymond Grissom, MLT I SunCoke Energy Transportadora de Gas
MLT I Richard Reeves, MLT I Jack McCoy, MLT I
John Bonner, MLA I del Sur
Kenneth Roberts II, MLA I Steven Foster, MLT I
Pall Corp. Alan Lindner, MLT I Travis Berney, MLT I T.E. Laboratories Diego Ramborger, MLA II
Ki Kook Yoon, MLT I James Vencill, MLT I Edward Elder, MLA II Julián Zottola, MLA II
Young Min Lee, MLT I Shell
Mark Stone, MLT I Jong Lok, MLA I Tamko Building Universidad del Turabo
Pattison Sand Co. Robert Garcia, MLT I Products Juan Marquez, MLA I
Steven Janes, MLT I Troy White, MLT I SIL Michael Hoover, MLT I
Claudinei Gabriel Gabriel, US Lubricants
Petro-Canada Samsung Techwin Co. MLT I Tampa Electric David Kemps , MLT I
Neil Buchanan, MLA III Seongjun Kim, MLT I Teal Trombetta, MLT I Kyle Redjinski, MLT I
Sinto Inc.
Petrolabs Sappi Daniel Laflamme, MLA II Tata Steel Vedanta Aluminum
Rajinder Negi, MLT I Seth Washburn, MLT I Ajit Verma, MLT I Ipsita Hota, MLA I
Venkata Suresh Skanska
Sarawak Energy Jaime Torres Huamani, TECO Westinghouse Weyerhaeuser
Pedasingu, MLT I Motor Co.
Berhad MLT I Paul Watson, MLA I
Petroleum Nurfaizal Wahi, MLT I David Wilson, MLA I
Development SKF Wolf Creek Nuclear
Schaeffler Group Tekfor
Mohammad Uddin, MLA II Paul Doherty, MLT I Operating Corp.
Seemant Joshi, MLA I Christopher Lawrence,
Prüftechnik Canada Southern Gardens MLT I Crettion Taylor, MLT I
Benoit Marcotte, MLT II Schreiber Foods Citrus YCRT
Brent Page, MLT I Total Austral
Brendon Russ, MLA II Juan May, MLA I
Reliability Technology Bret Morris, MLT I Gastón Delgado, MLT I
Services Chad Williams, MLT I Sugar Australia Pty. Nicolas Gatto, MLT I Manuel Gerez, MLA I
Stephen Pianka, MLT I Gary Burgess, MLA I Raúl Choque, MLA I
Gerard Curti, MLT I Total Lubrication
Rock Tenn Co. Joe Anderson, MLT I Jai Cavka, MLA I Management Co. Yemen LNG Co.
Barry Smith, MLA I & MLT I Josh Behrendt, MLT I Paul Roddy, MLA I Lloyd Funchess, MLT I Venkatesan Narayanan,
Brian Mounce, MLA I & Kenneth Kanc, MLT I Sun Up Co. Michael Dougay, MLT I MLA II
Become an
Expert through
Certification
I In today’s highly competitive manufacturing and service envi-
ronment, machine and equipment uptime is critical. More often
than not, it is a determinant of a company’s success and surviv-
ability. Downtime is the death knell of profitability. Perhaps the
most important people in this metric are the mechanics and
technicians. The wide range of skills required from the individual
to keep a machine operational or to get it running after a break-
down is significant. This person must have an understanding of
mechanics, hydraulics, pneumatics, and increasingly, electric
and electronic controls. That is a tall order by any standard.
Some of the best engineers are those who have an extensive
background or started their careers in troubleshooting and
repair. They have seen what works, what doesn’t and what to do
about it. They have a keen understanding of what it means to
design and package an energy-efficient and safe system for
minimal maintenance, reduced downtime and repair with the fewest tools. They understand firsthand the need for and the
value of proper and thorough documentation.
In other words, the engineer designs, the test technician tests
and troubleshoots, and the mechanic fixes. All of these skill sets
are critical. In the context of the overall success of the project,
none is exclusive or more important than the other. Experts must
be knowledgeable in the many aspects of fluid power: hydraulic,
pneumatic, and basic electric and electronic controls.
Becoming a well-rounded fluid power expert does not end at
a particular destination; it is a continuing, career-long journey. It
requires the self-challenge to constantly seek out the opportunity
to learn by engaging others with more or different knowledge
and skills than your own. It demands stepping outside of your
comfort zone and taking on the challenges that others may
avoid. It involves extra time and effort that perhaps you would
rather spend doing something else. You must read from text-
books, fluid power periodicals and component manufacturer
catalogs to gain knowledge of the types of hydraulic and pneu-
matic hardware in the marketplace, how they work and how they
do not. To gain additional knowledge, consider taking a commu-
nity-college course or attending a technical seminar in a discipline
studies address the savings in lubricants, bearings, downtime and explain the “why” of oil analysis, he began to come around and
many other areas that you can use to form a sound argument. see the benefits.
Secondly, you must get other team members onboard. In my This leads us from the “conscious incompetence” stage to the
experience, explaining the “why” is the most effective method to “conscious competence” stage. Now you know the proper proce-
accomplish this. Why are we doing this? Talking about saving the dures, quantities, frequencies, etc., and are putting this information
organization money may or may not be your best approach. to use. This is when the magic happens and the organization begins
Detailing the benefits of keeping the oil clean, cool and dry in terms to change. You as the champion have made an impression, and the
of reduced downtime and workload may help. staff is following your example. When you start seeing evidence of
I recently conducted a training course where one of the this transformation taking place, you should take a moment to
students was skeptical of the advantages of oil analysis. He was congratulate yourself and your team. Many organizations don’t
a fan of vibration analysis and thermography but questioned the make it this far.
benefits of oil analysis. I explained that in order for vibration and Keep striving to make improvements and eventually you will reach
thermography technologies to be used, you must either have the fourth and final stage, “unconscious competence.” In this stage,
personnel perform procedures correctly and aren’t even sure why.
67%
When asked why things are done a certain way, they might answer, “I
of lubrication professionals say
don’t know; we’ve always done it that way.” Better yet, perhaps they
their facility has attempted to
change its lubrication culture, can explain why everything is done the way it is. If so, you are well on
based on a recent poll at your way to having a world-class lubrication program.
MachineryLubrication.com
About the Author
Loren Green is a technical consultant with Noria Corporation, focusing
vibration or a higher than normal temperature condition. On the on machinery lubrication and maintenance in support of Noria’s Lubrica-
other hand, with a good oil analysis program, you can detect tion Program Development (LPD). He is a mechanical engineer who holds a
potential issues before they get to the point of registering on Machine Lubrication Technician (MLT) Level II certification and a Machine
either vibration or thermography equipment. The ideal situation Lubricant Analyst (MLA) Level II certification through the International Council
is to match all of these technologies. After taking the time to for Machinery Lubrication (ICML). Contact Loren at lgreen@noria.com.
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