CONTENTS

November - December 2010

Features machinerylubrication.com
Features in Detail
4 As I See It
Increasing Demands Bring
Advancements in Oil Filtration
Demand for high-performance filter and related prod-
ucts has never been more active. In response to these
needs, many new products have emerged that have raised
the bar in the filtration market. Jim Fitch highlights some
of the most promising ones.

6 The Exponent
A Balanced Approach to
Lubrication Effectiveness
This is the second in a series of articles that illustrate the
importance of a holistic effort to manage the root causes
of failure and the interaction between non-lubrication-
related root causes and lubrication effectiveness.

20 Hydraulics at Work
8 Cover Story How to Care for Your Hydraulic Inventory
Battle Plans Hydraulic components are expensive, so you want to make
An INVISTA chemical facility’s documented path to lubrication excellence has won sure that your inventory isn’t deteriorating in the warehouse.
the site praise from corporate management, the admiration of its sister plants and the This article provides pointers for effective long-term storage.
ICML’s John R. Battle Award. ML’s Paul V. Arnold provides all of the details in this in-
depth case study. (Pictured on cover [left to right]: Stephen Hilscher, Gary Rybak, Paul 22 From the Field
Bonorden and David Griffith.) Look Both Ways Before
Lubricating That Machine!
40 28 Stephen Sumerlin describes how to set up a world-class
lubrication identification system and shows how a proper
LIS aids your lubricant consolidation and awareness
efforts.

40 Lubricant Application
Is Closed Oil Mist Lubrication
the Best Available Technology?
Oil mist systems are simple and more dependable than
22 traditional oil application methods. Still, the practice of
allowing excess oil mist to escape into the atmosphere has
come under scrutiny.

48 Certification News
Be Like INVISTA;
Apply for a Prestigious ICML Award
As the cover story in this issue shows, a strong commit-
ment to machinery lubrication pays off in many ways.
Editorial Features Departments
2 Editor’s column 24 News and Analysis 18 Product News
52 Back Page Basics
4 As I See It 28 Get to Know ... 26 Product Supermarket Here’s the Skinny on
6 The Exponent 44 Lube-Tips 32 Product Spotlight Picking Compressor Lubricants
20 Hydraulics at Work 48 Certification News 46 Crossword Puzzler Jeremy Wright outlines the lubrication of dynamic, recipro-
22 From the Field 52 Back Page Basics 47 Web Preview cating and rotary compressors.

Machinery Lubrication www.machinerylubrication.com November - December 2010 1

EDITOR
Unpacking What’s in Store
for Noria and ML in 2011
PAUL V. ARNOLD
NORIA CORPORATION
2 010 has been a great year for Noria Corporation and its Machinery
Lubrication magazine. Industrial professionals from 44 states and
21 countries attended our RELIABLE PLANT 2010 conference and exhi-
bition in Nashville. Machinery Lubrication received an award for editorial
excellence in the American Society for Business Publication Editors
competition. And, the ML Web site (www.machinerylubrication.com)
achieved record traffic, averaging more than 100,000 visits and more
than 200,000 page views per month through November.
All of that is important and noteworthy, but we are focused
firmly on what’s in store for 2011. Here’s a sneak peek.
RELIABLE PLANT 2011: Our annual information, education and
networking extravaganza returns to Columbus, Ohio, and to its
traditional spring format. The event will be held April 19-21 at the
Greater Columbus Convention Center. Watch for more case studies
from world-class plants, a phenomenal opening session and an even
stronger focus on lubrication and oil analysis best practices. Visit
http://conference.reliableplant.com in the weeks to come to get
additional details and to register. You can contact me via e-mail
(parnold@noria.com) if you are interested in presenting a case
study for the Lubrication Excellence, Reliability World or Lean
Manufacturing tracks.
Salary Survey: Very soon, we will be soliciting your input for our
inaugural salary survey of lubrication professionals. The results and
data analysis will appear in the May/June issue of Machinery
Lubrication. Are you getting financially compensated by your
employer at a fair and appropriate rate, or are you getting the shaft?
Does attaining professional certification through the International
Council for Machinery Lubrication and/or other entities have a
bearing on your wages? You’ll learn the answers to these and other
questions by reading this article.
Lube Room Challenge: Has your lubrication storage facility
undergone an extreme makeover, an amazing transformation? If so,
make sure that you enter our upcoming Lube Room Challenge. ML
has run this popular contest in the past, and in 2011, we’re bringing
it back! Tell your before-and-after story and share some photos,
and you and your team could be among those featured in our
September/October issue.
Other Magazine Features: As a result of your feedback,
Machinery Lubrication will evolve in other ways during the new year.
Watch for more in-depth cover stories on best-in-class companies,
additional articles on oil analysis topics and expanded personality
profiles in our “Get to Know ...” section.
2 November - December 2010 www.machinerylubrication.com
RELIABLE PLANT 2011 will be held in Columbus, Ohio.
Photo Slide Shows: Your crew works hard to ensure mechanical
reliability at your facility, so they deserve a little recognition and face
time. We will debut a photo section on the ML Web site in 2011. You
will be able to send us your plant “family” photos. We’ll post them.
E-mail Newsletters: You will see some changes to our popular
slate of e-newsletters. Lube-Tips has absorbed Filtration Tips,
leading to one weekly e-mail publication that covers the full range of
lubrication-related topics. And, Reliable Plant Mail has absorbed
the Lean Manufacturing Journal, creating one publication whose
content educates you on attaining reliability, uptime and overall
plant efficiency. If you aren’t currently a subscriber to our e-newslet-
ters, sign up by visiting www.machinerylubrication.com (or
www.reliableplant.com) and clicking on the Newsletters link at the
top of the home page.
Noria Book Store: Watch for some neat changes to Noria
Corporation’s Book Store Web site (visit www.noria.com and click
on the link). New Web functionality, which will be rolled out in
multiple phases, will definitely enhance the shopping experience for
industrial professionals.
Everyone here at Noria Corporation and Machinery Lubrication
magazine is excited about these and other events, features and
products coming up in 2011. We look forward to continually
growing and improving to meet your needs and expectations. Let me
know how we can be even more relevant to you and your organiza-
tion in the new year and beyond.
P.S. – Thank you to the ML readers who pointed out that the
quote that I referenced in my September/October column should
have been attributed to Patrick Henry, not John Paul Jones. Your
knowledge of American history is admirable and appreciated.
- Paul V. Arnold, editor-in-chief
Machinery Lubrication
AS I SEE IT
Increasing Demands
Bring Advancements
JIM FITCH
NORIA CORPORATION in Oil Filtration
F iltration has two primary objectives. The first objective is
“protective”. This refers to creating a barrier to protect
particle-sensitive machine components from the invasion of
contaminants capable of causing sudden-death machine failure.
Machines that have high mission criticality from the standpoint of
safety, lost production and/or repair cost are good candidates for
protective filtration. Such filters are located just upstream of sensi-
tive components. Many components don’t require wear in order to
fail, but they can experience critical loss of performance due to
motion impediment and/or flow blockage caused by the intrusion
of particles of a particular size and composition. Servo-controlled
electro-hydraulic valves are examples of such components that
benefit from protective filtration.
The second objective of oil filtration is to mitigate the slow and
progressive wear from abrasion, surface fatigue and other particle-
induced wear modes. Here is the goal to extend the life expectancy
of the machine through the strategy known as proactive mainte-
nance. Many machines release wear metal little by little over time,
like tread wearing from the surface on tires. These machines have
only so much wear metal to liberate, after which a repair/rebuild is
required. Aggressive proactive maintenance tactics using enhanced
4 November - December 2010 www.machinerylubrication.com
filtration and ingression control often can extend machine life by
two to tenfold.
Changing Landscape
While there have clearly been technological enhancements in the
field of oil filtration, what’s driving change mostly are user- and
application-specific demands needed to reliably achieve one or
both of the above filtration objectives at the lowest possible cost.
This is amplified by an increasingly competitive filter supplier envi-
ronment. Some examples of user- and application-specific
demands that have increased in importance in recent years include
the following:
Purposeful Filtration – Just having a filter is no longer good
enough. Now the filter or filters have to achieve a well-defined
objective of attaining quantifiable cleanliness goals. These target
cleanliness levels are typically measured and monitored routinely.
User-Engineered Filtration – OEMs and users often have sharply
different objectives when it comes to machine reliability and
contamination control. Too often, users are forced to take matters
into their own hands by adding a filter where there was none. In
other cases, users are changing the location and/or enhancing the
performance of the filter. Sadly, in many cases, OEMs are far less
sophisticated than end-users when it comes to filter selection and
the deployment of contaminant-exclusion methods/products.
New Application Requirements – Changing lubricant formulations
are putting new demands on filters. One example is the widespread
use of highly pure base oils (API base oil groups II & III), which has
contributed to electrostatic-discharge problems with filters, causing
localized thermal damage from electrical arcing. New filters are now
manufactured to solve these problems. These fluids also have inten-
sified varnish-related problems in fluids and machines. Other
filtration systems have been designed to remove soft insolubles from
oil and help remove deposits from internal machine surfaces. User
demand for portable and off-line filters has brought on a wide range
of instrumentation and performance features in these products that
were non-existent just a few years ago. The list goes on.
Ancillary Filtration – Contamination control is no longer just
about a single machine-mounted filtration device. It also includes
Machinery Lubrication
filters to remove particles and moisture from
incoming air to a machine’s headspace (breathers
and instrument air purge systems). Quality filters
are now needed on transfer equipment, including
storage tank pumps, drum pumps, lube-
dispensing rack pumps, etc. Of course, high-flow
filters also are found on flushing and oil reclama-
tion equipment.
The Non-Particle Filter – Contaminants include
particles and many other foreign suspensions, as
well. These include air, water, sludge/varnish,
bacteria, soot and acids. Suppliers have devised
filters and separators to remove these contami-
nants. They include dry-air sparging, dialysis
dehydrators, vacuum dehydrators, centrifugal
separators, charged-particle separators, degassi-
fiers, compressed-cellulose filters, etc.
The Best Filter of All
Undeniably, the best filter of all is the invisible
filter. This is the filter that doesn’t have to be
purchased, doesn’t have to be installed, doesn’t
have to be changed and doesn’t have to be moni-
tored. This is the filter that gets the oil clean
simply by a change in human conduct and
behavior. It’s the countless little actions by people PUBLISHER
who work with lubricants and machinery that Mike Ramsey - mramsey@noria.com
prevent oil from becoming dirty in the first place. GROUP PUBLISHER
These are the things that humans do to expose oil Brett O’Kelley - bretto@noria.com
to contamination (knowingly or unknowingly).
EDITOR-IN-CHIEF
The invisible filter is the conspicuous aware- Paul V. Arnold - parnold@noria.com
ness that cleanliness is virtuous toward achieving
machine reliability and that every critical machine SENIOR EDITOR
Jim Fitch - jfitch@noria.com
has an assigned cleanliness target and is moni-
tored religiously. TECHNICAL WRITERS
Awareness and measurement bring about Jeremy Wright - jwright@noria.com
Stephen Sumerlin - ssumerlin@noria.com
human behavioral change. Be cleanliness wise
and cleanliness conscious. CREATIVE DIRECTOR
Ryan Kiker - rkiker@noria.com
About the Author GRAPHIC ARTIST
Jim Fitch has a wealth of “in the trenches” experience Kam Stinnett - kstinnett@noria.com
in lubrication, oil analysis, tribology and machinery
failure investigations. Over the past two decades, he has ADVERTISING SALES
sales@noria.com
presented hundreds of lectures on these subjects. Jim has
Phone: 800-597-5460
published more than 200 technical articles, papers and
publications. He serves as a U.S. delegate to the ISO MEDIA PRODUCTION MANAGER
tribology and oil analysis working group. Since 2002, he Rhonda Johnson - rjohnson@noria.com
has been director and board member of the
International Council for Machinery Lubrication. He is CORRESPONDENCE
You may address articles, case studies,
the CEO and a co-founder of Noria Corporation.
special requests and other correspondence to:
Contact Jim at jfitch@noria.com. Paul V. Arnold - Editor-in-chief
MACHINERY LUBRICATION
Noria Corporation
P.O. Box 87 Fort Atkinson, WI 53538
Phone: 920-568-9768 Fax: 920-568-9769
E-mail address: parnold@noria.com
SUBSCRIBER SERVICES: The publisher reserves the right to accept or reject any
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MACHINERY LUBRICATION USPS #021-695 is published bimonthly by Noria
Corporation, 1328 E. 43rd Court, Tulsa, OK 74105. Periodical postage paid at
Tulsa, OK and additional mailing offices.
Copyright © 2010 Noria Corporation. Noria, Machinery Lubrication and asso-
ciated logos are trademarks of Noria Corporation. All rights reserved.
Reproduction in whole or in part in any form or medium without express written
permission of Noria Corporation is prohibited. Machinery Lubrication is an
independently produced publication of Noria Corporation. Noria Corporation
reserves the right, with respect to submissions, to revise, republish and authorize
its readers to use the tips and articles submitted for personal and commercial
use. The opinions of those interviewed and those who write articles for this
magazine are not necessarily shared by Noria Corporation.
CONTENT NOTICE: The recommendations and information provided in
Machinery Lubrication and its related information properties do not purport to
address all of the safety concerns that may exist. It is the responsibility of the user
to follow appropriate safety and health practices. Further, Noria does not make
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POSTMASTER: Send address changes and form 3579 to Machinery
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Award Winner, 2008 and 2010
VOLUME 10 - NUMBER 6
THE EXPONENT

A Balanced Approach to
Lubrication Effectiveness
DREW TROYER

impeller or other rotating element is Changing speed has a geometric effect on

T his is the second in a series of articles
that illustrate the importance of a
holistic effort to manage the root causes of
failure and, moreover, the interaction
between non-lubrication-related root causes
and lubrication effectiveness. For most
mechanical equipment, if the machine is
aligned, balanced, fastened down tight and
well lubricated, it has a pretty good chance
of running a long and dependable life. In my
last column, I discussed the relationship
between alignment and lubrication. Now, I
will focus on balance.
In a nutshell, a rotating element is
balanced when the distribution of mass is
equal around the circumference of the
element. It’s unbalanced when the distri-
bution is uneven. Because the fan, pump
Boundary Mixed Film
Lubrication Lubrication
Coefficient of
turning, a mass imbalance produces rela-
tive centrifugal force (RCF). RCF is
calculated using the following equation:
RCF = 1.77 x W x D x (RPM/1,000)2
Where: RCF = relative centrifugal force
W = unbalanced force in ounces
D = distance from centerline
RPM = rotations per minute
In essence, if a machine has a five-ounce
mass unbalance at some point around the
circumference of the rotating elements, and
the position of the unbalance is 20 inches
from the centerline, the resultant relative
centrifugal force is 2,294 pounds of load.
Doubling the unbalanced load or the
distance from the centerline doubles the RCF.
Hydrodynamic
Lubrication
the RCF. Just a small amount of unbalanced
force can significantly increase the load on
the machine and the lubricant film.
Utilizing Stribeck’s
Equation
Let’s consider Stribeck’s equation:
ZN/P
Where: Z = the oil’s viscosity
N = speed
P = load on the lubricant film
Figure 1 illustrates, according to
Stribeck’s equation, that as the viscosity or
speed increases, the lubricant film
increases, which in turn reduces friction –
at least up to the point that boundary
lubrication is overcome and any further
increases in viscosity and/or speed results
in fluid friction and energy losses.
But increasing load reduces the lubricant
film. Unbalance effectively increases the

W
ith load, thus decreasing the lubricant film,
Friction

ou
tE
Po which increases the likelihood of boundary
r AW
With EP or AW
contact and wear. While it may appear
obvious to those familiar with Stribeck’s
famous equation and model that increasing
X axis = ZN
Ideal P load as a result of unbalance increases the
Thickness

risk of boundary contact and wear, let us

Film

Z = Viscosity
No film due to N = Shaft Rotational Speed probe a little deeper.
inadequate speed P = Load What if the unbalance problem isn’t bad
or viscosity
enough to produce boundary lubrication?
No X axis = ZN Are you OK? Not really. For mechanical
E Po P
rA Wear controlled by both
W systems, research suggests that particles are
Wear

add viscosity and boundary

itive lubrication film Wear controlled by
viscous separation
the wearing agent in 70 to 80 percent of all
Wear controlled by
AW and EP additives Ideal failures. But the particles don’t act alone.
Suppose you have a machine that in a
Starts, stops, shockloads, direction changes Full Speed Conditions balanced state operates with a 10-micron
film. A little mass unbalance reduces the
Figure 1. The Stribeck Equation and Curve lubricant film, per the Stribeck curve, to

6 November - December 2010 www.machinerylubrication.com Machinery Lubrication

about 3 microns, but it’s not bad enough to produce boundary contact
conditions. If the oil cleanliness is ISO 17/15/12, there are approxi-
mately 70 particles per milliliter that are 10 microns or larger. In a typical
distribution of particles, there are approximately six times as many parti-
cles greater than 3 microns than there are particles greater than 10
microns. So, the number of potential wearing particle contacts
increases from 70 to about 400 particles per milliliter of fluid. This slight
unbalance problem produces a net effect that’s equivalent to increasing
your ISO Code from 17/15/12 to 19/17/14 or more than 20/18/15,
which can reduce the life of your machine by as much as half!
Moreover, smaller particles, for a given hardness value, are tougher.
For a particle to yield in the contact zone, it must fracture. As parti-
cles get smaller, there are fewer cleave lines at which the rupture can
occur, so the particle’s friability, or crushability, diminishes.
The Damaging Effects of Water
What about water contamination? Water contamination affects the
lubricant film in many ways. First, one element of the somewhat diffi-
cult-to-define concept of “lubricant film strength” is the fact that as
load applied to oil increases, viscosity increases (to a substantial degree,
really). Water doesn’t possess that same quality, which is one of the
reasons why water contamination has such a dramatic influence on the
rate of wear, especially in rolling-contact, elastohydrodynamic (EHD)
lubrication films where the unit loads are so high. Naturally, increasing
the contact forces as a result of unbalance will exacerbate the problem.
Water also causes plenty of erosive damage in machines as a result
of vaporous cavitation. Cavitation occurs where pressure transitions
Machinery Lubrication www.machinerylubrication.com
quickly from a vacuum to high pressure. In the low-pressure regions, a
gas or vapor bubble expands, collecting potential energy – much the
same as stretching a rubber band. When the pressure quickly transi-
tions to high pressure, the implosion force is released onto the surface
of the machine with great velocity, causing erosion.
Think of the release as the snap that occurs when you release
one end of the stretched-out rubber band. When the cavitation is
caused by water vapor, the effect is particularly damaging because
the vapor changes to a liquid in the process. Unbalance in rotating
shafts can exacerbate the pressure differentials around the circum-
ference of a rotating element.
It is important when implementing proactive maintenance that
we attend to all of the root causes of failure. They’re all bad
enough on their own. When they team up, the situation can really
get ugly!
About the Author
Drew Troyer is a seasoned and certified reliability engineer and MBA. A
noted author and thought leader with 20 years of “in the trenches” experi-
ence, he’s figured out how to put you on the fast track and execute a
reliability strategy that produces results. Senior-level and non-technical
managers gain an understanding about how a framework of reliability
management can positively influence the business. Reliability engineers
and technical managers learn how to present their initiatives and accom-
plishments in economic terms that are familiar and important to senior
managers, the investment community and company shareholders. Troyer is
a co-founder of Noria and is now the president of Sigma Reliability
Solutions. Contact Drew at drew.troyer@sigma-reliability.com.
November - December 2010 7
COVER STORY

8 November - December 2010 www.machinerylubrication.com Machinery Lubrication

A Texas Facility’s Documented Path to Lubrication Excellence Won INVISTA
the John R. Battle Award. The Company’s Other Sites are Learning From
the Plan, and So Can You!
BY PAUL V. ARNOLD
T wenty-two typeset pages of
text. More than 7,000 words
and 40,000 characters housed in 14 chap-
ters spanning from a “Preamble” to an
“Appendix”. Twenty-three photos, and three charts
and graphics.
Equal parts history book, non-fiction novel and how-to
manual, this is the essay created by the maintenance and reliability
team at INVISTA’s chemical production facility in Victoria, Texas, to
document their path to lubrication excellence. It has won the team
praise from the corporate offices at INVISTA and parent company Koch
Industries, the admiration of sister plants around the world, and, most
recently, the International Council for Machinery Lubrication’s John R.
Battle Award for Excellence in Machinery Lubrication.
“I don’t know how long an essay normally is or should be, but we
wanted to supply the details and tell the whole story,” says reliability
engineer Paul Bonorden, who wrote the text along with rotating
equipment inspection supervisor Stephen Hilscher.
The two are members of the reliability group at the Victoria site,
which manufactures the nylon 6,6 intermediate chemicals adiponi-
trile (ADN), hexamethylenediamine (HMD) and adipic acid that are
used to create STAINMASTER carpet, ANTRON carpet fiber and
CORDURA fabric, as well as a variety of other nylon fiber, resins and
specialty products.
The purpose of penning the guidebook, titled “Building a
Lubrication Program”, was two-fold. First and foremost, it satisfied
Machinery Lubrication www.machinerylubrication.com
a 2007 commitment to corporate management to fashion a working
template for other INVISTA plants to follow.
“We had to have a communication tool to give to the rest of the
sites to say, ‘Here is what you need to do to upgrade your lubrica-
tion program,’” says Bonorden. “This is what we were asked to do.
‘If you do this program, keep track of what you did so that we can
copy it.’ That way, what took us years to do could be accomplished
elsewhere in a year or in months.”
Second, the information closely mirrored the materials ICML
seeks for consideration for the Battle Award, one of two honors
(along with the Augustus H. Gill Award for Excellence in Oil
Analysis) available each year through this standards-development
and professional certification organization.
“Applying gave us the incentive to hurry up and finish that essay,”
he says. “The questions that they were asking for the Battle Award
were good, valid questions that people from the INVISTA side would
want to know. When the first few people read the essay internally,
we felt like we had succeeded. When we found out that we had won
the Battle, that was icing on the cake.”
This case study details a portion of the Victoria site’s battle plans
for lubrication excellence. By reading it, you will learn strategies to:
• Separate truth from assumptions
• Focus on the right things
• Set the stage for success
• Select an “owner” for the program
• Determine best practices and correct actions
• Measure performance
November - December 2010 9
 COVER STORY
Lubrication mechanic Gary Rybak (below, at left) provides a
filled oil transfer container to a maintenance mechanic.

Stephen Hilscher (right) is the site’s rotating equipment inspection Color-coded filter carts are stored in the facility’s
supervisor, while Paul Bonorden is a reliability engineer. ultra-clean lubrication room.

A Formula for Success
Company: INVISTA is an independently managed,
wholly owned subsidiary of Koch Industries. In 2004,
subsidiaries of Koch acquired INVISTA from DuPont.
INVISTA, formerly DuPont Textiles and Interiors, was
combined with KoSa, a producer of commodity and
specialty polyester fibers, polymers and intermedi-
ates. KoSa had been a Koch affiliate since 1998.
INVISTA operates in more than 20 countries across
North America, South America, Europe and the Asia-
Pacific region.
Plant: INVISTA, located in Victoria, Texas (130 miles
southwest of Houston). The site was built in the late
1940s and early 1950s, and today features five busi-
ness units. It currently runs 24/7/365 with two shifts
– 6 a.m. to 6 p.m. and 6 p.m. to 6 a.m.
Facility footprint: 4,500 acres.
Plant employment: Approximately 1,000 INVISTA
employees and contractors work on site. The main-
tenance staff has around 200 INVISTA employees
and contractors.
Products: The site produces adipic acid, adiponitrile
(ADN), hexamethylenediamine (HMD) and other
nylon specialty intermediates, which are used in
industrial, textile resin and carpet applications. The
facility manufactures roughly 2 billion pounds of
product per year.
When You Assume ...
The Victoria facility had the reputa-
tion of being proficient at maintenance
for many years, going back to its days as
a DuPont plant. It was an early propo-
nent and adopter of predictive
technologies, including oil analysis and
vibration analysis. It extensively used
preventive maintenance (PM) tactics
and involved operators in basic lubrica-
tion. And, the maintenance crew could
quickly bring out-of-service equipment
back to life.
When Koch Industries purchased
INVISTA in May 2004 and stated that
future success would depend on devel-
oping and maintaining reliable plants,
some in Victoria wondered to what
degree the bar could be raised. A relia-
bility group eventually formed at this
plant, which spawned focused programs
for mechanical categories such as fixed
equipment and rotating equipment. But
when the anticipated results were slow to
materialize, the team reached some
strong conclusions.
1) Sheer manpower had been driving
reliability.
2) A sizeable percentage of PM tasks
added little to no value.
3) “We fix it fast” wasn’t a motto to
promote.
4) And, perhaps most importantly ...
“The mechanical reliability programs
made one assumption – that the correct
lubricant was used and it was clean per
OEM specification,” says Bonorden.
“That was just an assumption and
nothing was addressing it.”
Correct oil? At the time, the facility
housed 79 different oils and greases
from 26 different vendors. Drums
weren’t always labeled. Transfer
containers weren’t identified and speci-
fied for a given lubricant. The oil code
system was complex. And, employees
knowledgeable about lube applications
were retiring and less-experienced
workers were taking on their roles.
“People wanted to do the right thing,
but mistakes did happen,” says Hilscher.

10 November - December 2010 www.machinerylubrication.com Machinery Lubrication

 COVER STORY

All oil is directed through a header system via a capped

and labeled 2-inch cam-lock connection. Each label is
color-coded and engraved with the lubricant name. The
oil flows through a filter on its way to the bulk tanks.

Transfer containers are filled in the lube room and then

moved to one of 22 lubrication cabinets.

Clean oil? New drums were not filtered after receipt from a impact to the program. If there was an opportunity that didn’t
vendor. Drums were stored outside at various locations on the focus on those two principles, we tabled it. We feel that by doing
property. It wasn’t uncommon for these containers and transfer those two things and getting it done right, we will solve 95 percent
containers to be open and exposed to contaminants. Plastic of our issues.”
funnels were convenient but enabled additional opportunities for Adds Hilscher: “Clean oil. The correct oil. The equipment is
contamination. labeled. The staff is knowledgeable and trained on best practices.
In 2007, reliability manager David Griffith called to wipe the That’s all part of lubrication excellence.”
slate clean and create a lubrication program grounded on two
elementary principles: Setting the Stage
1) Put the right oil in the right equipment. This INVISTA facility took several actions in 2007 which laid the
2) Keep that oil clean. groundwork for success.
“That became our mantra,” says Bonorden. “We realized that Finding a partner: Purchasing lubricants from 26 vendors
there were so many things to address that we couldn’t do it all. So, proved to be unruly, redundant, and an inefficient use of time and
we had to go after the key components that had the greatest money. So, reliability group members developed a critical-needs
matrix which served to rate the supply base. The selection criteria
included: overall availability, lubrication engineer technical
Criteria for John R. Battle Award Consideration support, comprehensive product line, distributor facilities, avail-
According to the International Council • Lubrication program metrics and able training, quality assurance/control of products, ability to
for Machinery Lubrication, recipients of the overall performance tracking assist with the lubrication program, fully functional oil analysis
John R. Battle Award demonstrate a solid • Lubricant storage, handling, safety and program and price. Finalists were invited to give a presentation on
lubrication program, backed up by multi- conservation their abilities to fulfill the criteria. A single supplier, ExxonMobil,
disciplinary efforts and approaches, with was picked to handle nearly all of the site’s lubrication needs.
• Lubrication PM optimization, work
sustainable results and continued improve-
plan management, scheduling and “Our corporate purchasing department was impressed with our
ments. Among other factors, the criteria for
documentation methodology,” says Bonorden. “They eventually developed a
the award includes:
• Oil analysis program design, test slates, purchasing agreement for not only the Victoria site, but for all of
• Commitment to education and skills INVISTA.”
lab selection and setting of alarms
competencies
• Oil analysis sampling frequency,
Oils and greases are now ordered through a single cost center
• Maintenance culture and management instead of individual business units.
sampling hardware and procedures
support Creating a database: Afterward, a survey and database exercise
• Contamination exclusion and removal
• Lubricant selection, performance stan- was employed to standardize and consolidate lubricants at the site.
dards and consolidation • Oil and grease application methods Reliability group members and representatives from the oil
and hardware deployed vendor developed a spreadsheet to collect data from equipment
• Preventive, predictive and proactive
To learn more about the John R. Battle files, field walkthroughs and personnel knowledge. This data
program design and effectiveness
Award, visit the ICML Web site at consisted of: equipment number, equipment description, location,
• Continuous improvement www.lubecouncil.org.
manufacturer, model, vertical or horizontal orientation, process

12 November - December 2010 www.machinerylubrication.com Machinery Lubrication

 COVER STORY
temperature, rpm, current oil code, current oil description, oil
change interval, oil volume, filtration system, number of lube
points, input horsepower and any unique information discovered.
A site team (predictive/preventive maintenance coordinators,
reliability engineers and experienced mechanics) and vendor
personnel used this information to develop a list of recommended
oils for all 3,116 pieces of equipment.
The effort has helped Victoria reduce on-site lubricants down to
13 bulk oils and 28 application-specific lubes.
Tagging machines: Stemming from the database work, 99
percent of the equipment had a change in lubricant type. To make
that change visible and permanent, 3,116 colored lube identifica-
tion tags were produced and installed on equipment baseplates.
Each tag denotes a specific type of oil or grease, such as SHC 526,
DTE 732 or XHP 222.
“We wanted to make sure that we didn’t have a single mistake
and put in the wrong lubricant to cause unexpected downtime,”
says Bonorden.
Since the system went into operation, a mechanical failure has
not occurred due to an error in the database or type of lubricant
selected.
Constructing a lube room: The next step was to design a central
storage room that would literally and figuratively bring most of the
lubricant inventory under one roof. This would serve as the hub of
the clean and correct initiative.
Oil is delivered via a bulk tank truck or an enclosed truck where
barrels of oil are pumped off. All oil coming from either method is
directed through a header system via a capped and labeled 2-inch
cam-lock connection. Labels are color-coded and engraved with the
lubricant name. The oil flows through a Pall filter (rated Beta 1000
at 3 to 7 microns, depending on product) on its way to the bulk
tanks. The bulk tanks are labeled and range in size from 80 to 240
gallons. The label on the tank is identical in color and description
to the one on the 2-inch cam-lock connection. Each tank has a
desiccant breather installed to keep moisture from the oil. Each
dispensing spout is labeled and has a plastic cap to prevent dirt
from collecting on the spout end. All of the tanks reside in a spill
containment area with individual catch pans under each spout.
Oil is dispensed into a labeled plastic transfer container. Filled
containers are moved to one of 22 lubrication cabinets placed in the
field. Inside the cabinet are oils needed for that specific area.
14 November - December 2010 www.machinerylubrication.com
They Won the Battle,
But the War is Far From Over
The INVISTA facility in Victoria, Texas, is the most recent recipient of
the ICML John R. Battle Award for Machinery Lubrication.
The site won the Battle ...
“That wasn’t the goal of this improvement program,” says rotating
equipment inspection supervisor Stephen Hilscher. “After we went
through all of the work, it was more of ‘let’s put in an application for
the award and see what happens.’”
“We aren’t trying to brag about winning, but word of mouth has
gotten around,” says reliability engineer Paul Bonorden.
... But the war for lubrication excellence is far from over.
“We still have a lot of work left to do,” says Hilscher. “I don’t know
if you can ever be ‘done’. There’s always a way that you can improve on
what you have done or are currently doing.”
The next steps include:
• changing the methods in which greases are specified and applied;
• taking best practices into the mobile equipment garage and the
machine shop;
• further enhancing filtration of oil.
In addition to the oil, there are two sizes of disposable paper funnels
and disposable lint-free paper towels for wiping down the fill ports.
The Face of the Program
The Victoria facility recognized early in the process that all of the
foundational work would not be sustainable without someone to
lead the effort on a daily basis. It obtained company approval to
create the position of lubrication mechanic, and selected long-time
maintenance veteran Gary Rybak to fill that role in early 2009.
“We had to have a dedicated employee, someone to own it,”
says Hilscher. “We put out a posting and had many good candi-
dates apply. We wanted someone who was knowledgeable,
self-sufficient and a self-starter. It was desirable for the person to
have years of mechanical experience because they could bring much
more to the table from a technical perspective.”
Bonorden says the public perception of Rybak also was an asset.
“Gary was very personable. He’s been around here for 38 years.
He’s a mechanic. And, he was well respected throughout the
Machinery Lubrication
 COVER STORY

Machinery Lubrication Initiative Follows Corporation’s Guiding Principles

Market-Based Management is the engine that
powers Koch Industries and its subsidiary firms.
Developed by Charles Koch over the past 40 years,
MBM is a holistic approach to management that inte-
grates theory and practice and prepares organizations
to deal successfully with the challenges of growth and
change. MBM requires a culture centered around
specific attributes. These set standards for evaluating
policies, practices and conduct, establishing norms of
behavior, and building the shared values that guide
actions. The MBM Guiding Principles articulate Koch
companies’ rules of just conduct along with shared
values and beliefs.
“After Koch bought INVISTA, I spent three days in a
class going over these principles and why they were so
important to the company,” says Paul Bonorden, a reli-
ability engineer at INVISTA’s facility in Victoria, Texas.
“This is how we want everybody to think and behave.
These aren’t marketing materials. This is something to
apply on a daily basis.”
The MBM Guiding Principles are as follows:
Integrity: Conduct all affairs lawfully and with
integrity.
Compliance: Strive for 10,000 percent compliance,
with 100 percent of employees fully complying 100
percent of the time. Ensure excellence in environ-
mental, safety and all other areas of compliance. Stop,
think and ask.
Value creation: Create real, long-term value by
economic means. Understand, develop and apply
MBM to achieve superior results. Eliminate waste.
Principled entrepreneurship: Demonstrate the sense
of urgency, discipline, accountability, judgment, initia-
tive, economic and critical thinking skills, and the
risk-taking mentality necessary to generate the greatest
contribution to the company and society.
Customer focus: Understand and develop relation-
ships with customers to profitably anticipate and
satisfy their needs.
Knowledge: Seek and use the best knowledge and
proactively share your knowledge while embracing a
challenge process. Measure profitability wherever prac-
tical.
Change: Embrace change. Envision what could be,
challenge the status quo and drive creative destruction.
Humility: Practice humility and intellectual honesty.
Constantly seek to understand and constructively deal
with reality to create real value and achieve personal
improvement.
Respect: Treat others with dignity, respect, honesty
and sensitivity. Appreciate the value of diversity.
Encourage and practice teamwork.
Fulfillment: Produce results that create value to
realize your full potential and find fulfillment in your
work.
“If you look at what this team did in Victoria and
the way that it approached lubrication and reliability
improvement, the efforts really did represent those
guiding principles,” says INVISTA public affairs
manager Amy Hodges.

facility,” he says. “When we made Gary the lubrication mechanic,
that gave credibility to that role and to the program. When Gary
was hired, I told him, ‘You are the face of the program. I’m not out
there. You are the guy.’”
Rybak presently oversees the lube room and the satellite cabi-
nets. His goal is to provide operators and maintenance technicians
the products and materials they need to correctly perform their
lubrication tasks. He serves as an inventory manager, technical
resource, logistics professional, stockboy, bottle washer and
program auditor. In that latter role, he monitors how operators
and mechanics in 22 plant areas comply to a list of quality control
expectations for their particular cabinet.
“I know that they appreciate everything that I do, and that’s
fulfilling,” says Rybak. “It’s instant gratification.”
That level of fulfillment and gratification increased earlier this
year when, after attending a training seminar through Noria
Corporation, Rybak obtained his ICML Machine Lubrication
Technician Level I certification.
“Working in this field, you have to be continually learning,” he
says. “This is an evergreen process.”
Following Best Practices
Education is a consistent theme in this INVISTA facility’s push to
determine best practices and the path forward.
The site takes advantage of training from its vendor representa-
tives, and sends employees to Noria’s machinery lubrication and oil
analysis seminars and annual RELIABLE PLANT conferences.
“After each one, we step back and look at our lubrication
program and say, ‘OK, how can we take what we learned and utilize
this to our best advantage?’” says Bonorden.
Lessons are passed on to as many people as possible. In 2009,
Bonorden, Rybak, Hilscher and ExxonMobil engineer Marianne
Duncanson led a two-hour class on lubrication practices for 450
operators, mechanics, engineers and managers.
“Operators and mechanics with 30-plus years at the plant
stated that they weren’t aware that their current practices could

16 November - December 2010 www.machinerylubrication.com Machinery Lubrication

have such a negative impact on equipment relia-
bility,” says Bonorden. “We stressed during the
training that all of our efforts were primarily
focusing on two primary principles: Keep it clean
and put the correct lubricant in the equipment.
We emphasized how each item that we covered
related to these two principles.”
An interactive, computer-based training
module, slated to debut in 2011, will serve as a
follow-up to the class.
Learnings and strategy sessions aren’t
confined to the classroom. They also occur
around the machinery. Reliability-Centered
Maintenance has been critical to developing
lubrication and overall asset care plans for the
past two years.
In the RCM process, a team representing oper-
ations, maintenance and engineering examines a
piece of equipment to determine all possible
failure modes and assign it a criticality ranking.
With this information, the best course of action is
determined to mitigate the risks of each failure
mode. The actions to mitigate the risks of a
failure mode may include vibration analysis,
infrared thermography, oil sampling, oil change
intervals, grease intervals and quantities, preven-
tive maintenance, spare parts strategy, visual
inspections or a system redesign.
By taking into account all failure modes and
assigning PM tasks according to risk and severity,
RCM is an effective method of directing lubrication
activities and optimizing the lubrication program.
Analyzing Oil Condition
Clean and correct is confirmed through oil
sampling and analysis. A total of 210 pieces of
equipment are regularly sampled (either monthly
or quarterly) by predictive maintenance techni-
cians Mike Stastny and Bobby Gallardo.
Equipment inclusion in the program is based on
criticality rating.
Test slates are based on equipment type. Each
piece of equipment is categorized to ensure that
the proper tests are performed on the oil samples.
Specific test slates utilized include separate pack-
ages designed for each application, such as
engine, turbine, hydraulic, compressor, gear drive
and circulating system. Test slate selection is
adjusted as needed based on discussions with the
testing laboratory and the lubricant supplier.
Specialized testing (RPVOT, RULER, QSA and
ultracentrifuge) also is performed on large oil
reservoirs to help determine remaining oil life.
In addition, lube room oil totes are sampled
on a regular basis to confirm that cleanliness
Machinery Lubrication
goals continue to be met. Bulk oil deliveries are
quality-checked on the spot by comparing the
new oil viscosity and color to baseline samples.
Pass It On
In analyzing the overall success of this INVISTA
site’s lubrication improvement initiative, you can
go with the numbers, but that can be difficult to
quantity.
“Look at the oil analysis abnormal readings –
levels are going down, the counts per month …
things are getting better,” says Hilscher. “We
know our lubrication efforts have improved.
Other key indicators of reliability improvement
are our mean time between failure figures on
pumps and seals. The MTBF on our pumps has
increased 50 percent and the seal life has gone up
25 percent in the last couple of years. Lubrication
is an important part to any mechanical reliability
program, as is RCM, the pump seal program,
precision maintenance standards and employee
training, to name a few. Lubrication is one of the
building blocks of all of these other programs.”
The true indications of success are found in
words and deeds.
The corporate leaders at INVISTA and Koch
Industries believe in lubrication excellence so
much that they don’t require Victoria to supply
reams of data.
“In the beginning, we knew what we were
spending on lubricants but did not have lubrica-
tion failure data to generate cost avoidance
savings,” says Bonorden. “We promoted the
initial benefits of this program as fewer purchase
orders and reduced oil stocks. The longer-term
benefits would be the reliability improvements.
Since the program’s inception, we have had the
full support of management.”
They believe in it so much that they want that
7,000-word, 22-page essay in the hands of opera-
tions and maintenance managers at company
facilities around the world.
“We are giving them the essay, a copy of our
database, our SAP ordering chart. They are going
to get our training program,” says Bonorden.
“They can use it all as their template because we
know it worked. They can take it and customize it
to their site. They appreciate that.”
Who knows? By following the template,
another INVISTA or Koch plant may be a future
winner of ICML’s John R. Battle Award and be
featured in Machinery Lubrication magazine.
Or, by following this battle plan, maybe that
facility will be yours.
www.machinerylubrication.com November - December 2010 17
PRODUCT NEWS

One-drum Containment Unit Condition Monitoring Software

The new Ultra-HardTop P1 Plus from UltraTech International SpectroTrack from Spectro Inc. is a computerized maintenance management
is the only one-drum containment unit with a conven- system optimized for real-time machine condition monitoring. The software
ient “roll-top” cover. Tall headspace allows its use provides you with data to make maintenance decisions
with drum pumps or conical based on machine condition, increasing the availability
funnels. Simply lift the cover of key assets, reducing unscheduled maintenance by
from waist level to pour detecting and correcting prob-
waste or pump fluids. The lems before major failures
forkliftable unit’s all-poly- occur, and extending oil drain
ethylene construction will intervals and equipment life.
not rust or corrode, and it is This product runs as a Web-
lockable for added security. based application.
Its 70-gallon capacity meets
EPA Container Storage Spectro Inc., a subsidiary of
Regulation 40 CFR 264.175. QinetiQ North America
www.spectroinc.com
UltraTech International 978-486-0123
www.spillcontainment.com
800-764-9563
Compact Oil Cooler
For oil cooling applications, the new DOC30 (dedicated oil cooler) copper
Silicone-enhanced Lubricant brazed plate heat exchanger from Alfa Laval offers higher efficiency with a
Sili Kroil from Kano Laboratories is the result of the successful smaller heat transfer area, resulting in an increase in performance capacity. The
blending of Kroil and dymethyl silicones. Sili Kroil penetrates to DOC30 offers less pressure drop,
one-millionth-inch spaces, dissolves rust, and lubricates to loosen reducing power consump-
frozen metal parts and keep them moving. tion. It maintains the same
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enhanced lubrication.
Alfa Laval
Kano Laboratories Inc. www.alfalaval.com
www.kanolaboratories.com 866-253-2528
866-638-1565

Portable Hand Tool Sets

Food-grade Grease Portable Mechanics’ Service Sets from Snap-on Industrial put large and small
hand tools – including screwdrivers, wrenches and pliers along with multimeters
with MICROL and other specialty equipment – at easy reach for plant professionals looking for
PURIT Y FG2 with MICROL MAX maximum protection of their tools and equipment. A hard-sided Pelican 0450
grease from Petro-Canada contains case houses a choice of two comprehensive tool offerings. The cases are
MICROL, an antimicrobial preserva- resistant to water, temperature, drops and impact.
tive registered by the EPA for use in
food-grade lubricants. This grease fits Snap-on Industrial
perfectly in HACCP and Good www.snapon.com/industrial
Manufacturing Practice plans. It main- 877-740-1900
tains consistency and lubrication in
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washout during cleaning applications.

Petro-Canada
www.petro-canada.ca/en/lubricants
888-284-4572

18 November - December 2010 www.machinerylubrication.com Machinery Lubrication

 Spill Response Caddy ASTM D86 Distillation Tester
Packaged in a sturdy, recyclable cardboard container for indoor storage The MINIDIS ADXpert analyzer from
and one-time spill response, the PIG GoBox Universal Spill Caddy offers an Grabner Instruments is the new benchmark
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AMETEK Petrolab Company
New Pig Corporation www.petrolab.com
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Online Viscometers
Online viscometers from Cambridge Viscosity are widely
used to monitor real-time changes in lubricant viscosity that can
Machine Alignment Tool happen between regular oil laboratory analysis intervals. This
ROTALIGN Ultra Live Trend, a short-term continuous monitoring is particularly prevalent in high-value equipment, in
application, helps to accurately determine the relative positional processes where the costs of failure are high. In the case
changes between coupled machines during run-up or shutdown. It of refinery gas compressors, replacement parts and
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these measured values, 781-393-6500
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Ludeca Inc.
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Lockout Procedure Design Tool
Brady launched a new Web application, the Brady Lockout Procedure Online Design
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Side Mount Series Reels
Coxreels expanded the capabilities of its existing
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Brady Corporation
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Machinery Lubrication www.machinerylubrication.com November - December 2010 19

HYDRAULICS AT WORK
How to Care for Your
Hydraulic Inventory
BRENDAN CASEY
H ydraulic components are expensive and, so, regardless of the
amount of spares that you carry, one thing you want to make
sure of is that your inventory is not deteriorating in storage. With
this in mind, here are a few pointers for the effective long-term
storage of hydraulic components:
Store them indoors in a clean, dry area. This is stating the
obvious and is easy enough to do for more compact components
like pumps, motor and valves. But in the case of large or long cylin-
ders, the warehouse department may find it more convenient to
store them outdoors. This should be avoided if at all possible.
Protect all exposed metal parts. Smear the internal surfaces of
cylinder eye/clevis bushes or bearings with grease. Pump and motor
drive shafts should be wrapped in oil-impregnated tape such as
Denso tape. The same goes for exposed chrome on cylinder rods.
Before applying Denso tape or a similar product to a cylinder rod,
make sure that the rod is fully retracted. If a product like Denso
tape is applied to the rod when the rod is not fully retracted, subse-
quent retraction can result in damage to the rod seal.
Plug the component’s port connections with steel (not plastic)
plugs or blanking plates. Plastic plugs don’t provide the same
sealing integrity as their metal counterparts and are easily
dislodged – both of which can result in contaminant ingression.
Consider filling the component with clean hydraulic oil through its
service and/or case drain ports – particularly if it is an expensive, large-
diameter or high-pressure pump, motor or cylinder. I say “consider”
because there are a few issues to understand before doing this.
Directions on Filling
Components with Oil
If the component – a cylinder, for example – is not filled with oil,
it will obviously be filled with air. If this air is not perfectly dry, then
as the ambient temperature decreases, the air can reach the dew
point. This results in moisture forming on the inside of the cylinder
tube. This can cause spot-rusting and pitting of the tube surface,
which will reduce the volumetric efficiency of the cylinder and the
service life of the piston seal.
Completely filling the component with clean hydraulic fluid
prevents this from occurring; however, there is a major caution,
which is best illustrated by an example. Say a cylinder is prepared
for storage during the winter months. When the cylinder is filled
20 November - December 2010 www.machinerylubrication.com
with oil, the ambient temperature is 10 degrees Celsius. A year and
a half later, during the middle of summer, the same cylinder is set
down beside the machine to which it is to be installed. In the heat
of the mid-day sun, the temperature of the cylinder rises to 40
degrees C. Assuming an infinitely stiff cylinder, the pressure of the
oil in the cylinder resulting from the rise in temperature can be
approximated by the formula:
p (bar) = 11.8 x ΔT
So, the theoretical pressure of the oil in the cylinder is now: 11.8 x
(40 – 10) = 354 bar, or 5,134 psi! When it comes time for the unsus-
pecting mechanic to crack loose the blanks on the service ports …
well, let’s just say that’s more excitement than he is expecting.
That said, cylinders (and other hydraulic components) CAN be
safely filled with oil for storage provided that you:
1) Check that the worst-case temperature rise in storage won’t
result in a static pressure that exceeds the cylinder’s safe
working pressure.
2) Use port plugs or blanking plates that are rated for the
cylinder’s working pressure.
3) Attach appropriate warning tags to each of the service ports.
4) Provide a means to check and vent any pressure before the
service port blank is removed. A simple way to do this is to fit
each port blank with a pressure test point. This enables the
quick attachment of a pressure gauge to check the pressure in
the cylinder. And, if necessary, the pressure can be safely vented
into a drum using a test-gauge hose.
The flip side to all of this is, if you get involved in installing
hydraulic components, when it comes time to remove blanking plates
or plugs, always assume the possibility that the component may
contain oil under pressure. And, take the necessary precautions.
How Should Cylinders Be Stored?
Another storage issue peculiar to large cylinders is the question
of orientation – that long-term horizontal storage can permanently
distort the seals due to the weight of the rod “resting” on them.
Based on my experience, the argument that large hydraulic cylin-
ders need to be stored vertically to prevent this is a myth. Two cases
I was directly involved in come to mind. In both cases, the cylinders
in question were off 400-ton, mining-size hydraulic excavators. We
Machinery Lubrication
are talking about cylinders that weigh between two and three tons.
The piston rod typically weighs more than a ton by itself.
These big, expensive, high-pressure cylinders were suffering
premature seal failures. In both cases, the machine owners sought
the advice of “seal experts”. Their recommendation was to store the
cylinders vertically.
Let’s consider the reality of doing this:
Someone drops a three-ton cylinder with a closed length of four
meters at your feet and tells you to store it vertically – so it doesn’t
fall over and destroy itself or, worse still, kill someone. Not a five-
minute job, but it’s possible, I suppose.
Next, a truck arrives to transport the cylinder to a remote mine
site. The route consists of 1,000 miles of rough, unsealed road. Given
that you have gone to the trouble of storing the cylinder vertically in
the warehouse, surely you must insist that it is transported in the
same orientation? I mean, if it can’t be stored horizontally in a shed,
then surely the pounding it is going to get if it’s laid down on the back
of a truck will turn the seals into mush, right? The truck driver thinks
you’re crazy, but he doubles his rate and obliges anyway.
The cylinder arrives at the mine site in the mandated vertical posi-
tion. Trouble is, it’s a “stick” cylinder, so it’s orientation on the machine
is horizontal. If the bearing (wear) bands on the piston and in the gland
can’t adequately support the piston rod and prevent it from distorting
the seals when the cylinder is sitting in the shed or bouncing around on
the back of a truck, how on earth will it cope with the thrust developed
when it goes into service on a 400-ton excavator?
Machinery Lubrication
Common sense would tend to suggest that if the bearing bands
have sufficient area and are correctly tolerenced to adequately
support load-induced thrust without distorting the seals, then
surely they will cope with the static weight of the piston rod in
storage and any dynamic loading that may occur during transport?
Whether you agree with this assessment or not, troubleshooting
is a process of elimination. And in both cases, when the seal failures
continued to occur even after the cylinders had been stored verti-
cally, it became clear to all concerned that this was not the root
cause of the problem. No surprise to me. That said, if your spare
hydraulic cylinders can be stored vertically – safely and inexpen-
sively – then there’s certainly no harm in doing so. On the other
hand, think twice before going to a lot of effort and expense to
facilitate this.
It’s a Logical Process
In the final analysis, taking proper care of your spare hydraulic
components is very similar to caring for the ones on your machines:
Keep them clean, dry and cool!
About the Author
Brendan Casey has more than 20 years experience in the maintenance,
repair and overhaul of mobile and industrial hydraulic equipment.
For more information on reducing the operating cost and increasing
the uptime of your hydraulic equipment, visit his Web site,
www.HydraulicSupermarket.com.
www.machinerylubrication.com November - December 2010 21
FROM THE FIELD
Look Both Ways Before
Lubricating That Machine!
STEPHEN SUMERLIN
NORIA CORPORATION
I n today’s fast-paced industrial world, few people believe that
they have time to correctly mark and identify where various lubri-
cants should go and be stored. But, this is an important task! A
good lubricant identification system (LIS) spans from the lube
room to the application without any missing links. This means that
you must label your lubricants, not just in the lube room and appli-
cation but everything in between, such as grease guns, top-up
containers, filter carts, etc. All must be labeled to correspond. If
there is a single break in labeling communication, the risk of cross-
contamination or wrong product usage increases. This article will
describe, demonstrate and provide guidance on setting up a world-
class lubricant identification system and show how a proper LIS will
help in your lubricant consolidation and awareness efforts.
When establishing a proper LIS, there are many variables to
consider, but three primary ones have the most impact: designing
the labels, corresponding lubricant properties with label designs
and implementation.
Design
There are many ways to design a label, whether it is using specific
shapes, colors, icons, etc. But whichever method is used, it should
remain consistent with every label. Using specific shapes is a great
way to denote lubricant type (oil or grease). For example, use a
square for oil and a circle for grease. This allows everyone to quickly
identify which type of lubricant is used or stored in an application.
Use specific colors to denote different base oil types or perform-
ance properties. You could use a red border for a mineral base oil
and a green border for a synthetic base oil, or a red border for non-
food-grade lubricants and a green border for food-grade
lubricants.
Figure 1. LIS Labels for Oil and Grease
22 November - December 2010 www.machinerylubrication.com
Using icons is a great way to denote lubricant usage. A leading
contributor of cross-contamination and wrong lubricant usage
comes from not knowing the application for which the product is
used. Many times, gear oil is added to a hydraulic system or vice
versa. An example of using shapes to denote lubricant usage by
type is to use a gear to denote gear oil and a cylinder to denote
hydraulic oil. This way, there’s no question as to the application
for a lubricant.
You can use shapes and colors in combination, such as a
colored border or fill, to denote certain performance properties.
For example, extreme-pressure (EP) oil could have a solid blue fill
and anti-wear (AW) oil could have a solid white fill. Shapes and
colors are only limited by your imagination and available printing
software.
Lubricant Properties
Denoting all of the lubricant properties with one label is chal-
lenging, but this typically can be handled in the design phase of the
label. To properly denote the lubricant properties, you must first
know what properties to denote. These properties are: lubricant type
(oil or grease: if oil – hydraulic, gear, etc.; if grease – lithium complex,
aluminum complex, etc.); NLGI grade (grease only); base oil
viscosity; base oil type (mineral or synthetic); base oil classification
(G1, G2, G3, etc.); and, performance properties (AW, EP, H1, etc.).
Properties are the essence of the lubricant and the first things
that should be looked at when deciding which product to use in an
application. Remember that viscosity is the most important phys-
ical property of a lubricant; therefore, it should be readily visible on
your label design. The next most important is the performance
properties – EP or AW. These establish the physical performance of
the lubricant and how they relate to machine component protec-
tion; as a result, they also should be readily visible on the label.
The last vital property is base oil type. This is where cross-contam-
ination issues can arise and have big consequences. Ensure that you
aren’t mixing base oil types, especially if you know they are incom-
patible. Therefore, the label design should denote base oil type.
Implementation
The implementation phase is where most mistakes are made.
Such mistakes can have the greatest impact on the success or
failure of the LIS. Many times, the design and lubricant property
Machinery Lubrication
 Figure 2. LIS Labels in Lube Room Implementation
correlation have been well thought out and
executed, but the thoughts of where to use and
how to use the labels are not. Use the labels,
from receiving to application and everything in
between. Create labels for your lube room to
use on bulk containers, cabinets, shelves, etc.
Put corresponding labels on filter carts, grease
guns, top-up containers, funnels, etc. And,
match these labels to labels on the actual appli-
cation. For instance, ensure that the label on the
gearbox matches the label on the filter cart and
bulk storage container. This way, the technician
is sure that the right product is going in the
right place.
A complete and correct LIS label should
denote all available properties, usage and type of
lubricant without sacrificing readability, which
can be difficult to accomplish. You don’t want a
label that is too information intensive, but you
don’t want a label that is information poor, which
could lead to costly mistakes. (See Figure 1.)
As stated previously, the implementation
phase is just as important as (if not more impor-
tant than) the actual label design phase.
Implementation isn’t just about labeling the
equipment; it’s about labeling everything from
Would You Like to Contribute?
Are you a technical expert? If so, we want to
publish your lubrication article in Machinery
Lubrication. To submit a technical article, please
send it to editor-in-chief Paul V. Arnold via e-mail
at parnold@noria.com.
Machinery Lubrication
storage to application. Figure 2 shows a good
example of label implementation within a lube
room.
Lubricant Consolidation
A good LIS also can help with consolidation
efforts simply based on denoting the lubricant’s
performance properties in a generic alphanu-
meric code. By doing this, you allow for a more
complete viewing of current lubes and their prop-
erties, which allows for easy cross-referencing and
consolidating. It’s difficult to consolidate lubes
based solely on their names, but when consid-
ering their performance properties, the
consolidation efforts are clearer and easier.
As you can see, there are many variables and
options to think about and include in a complete
LIS. Think of all affected variables – from lubri-
cant type to layout and design. With a little
research, knowledge and time, a world-class LIS is
within your reach.
About the Author
Stephen Sumerlin is a senior technical consultant
with Noria Corporation, providing Lubrication Process
Design Phase I and II consulting and general lubrica-
tion excellence training. His client list includes Holcim,
Alcoa, Goodyear, H.J. Heinz, Bemis, Molson,
International Paper, Cargill and E.J. Gallo. He is a
mechanical engineer who holds Machine Lubrication
Technician Level II and Machine Lubricant Analyst Level
III certifications through the International Council for
Machinery Lubrication. Contact Stephen at
ssumerlin@noria.com.
www.machinerylubrication.com November - December 2010 23
NEWS AND ANALYSIS

Study: Re-refined Basestocks

on Par with Virgin Basestocks
BY KLINE & COMPANY

about 12 percent is sent to re-refining. It is considerably cheaper

G lobally, approximately 69 percent of the finished lubricant
demand is converted into used oil. Of the total used oil
collected, 78 percent is consumed as industrial fuel and 16 percent
is re-refined, finds the recently released study “Global Used Oil
2009: Market Analysis and Opportunities” from global consulting
and research firm Kline & Company.
Following significant technological advances in the last 10 years,
the re-refining industry has reached a stage where it can produce
re-refined basestocks on par with virgin basestocks. Awareness of
the quality of re-refined lubricants is spreading among a growing
band of end-users; however, this perception is not nearly universal
and customer hesitance due to perceptions of poor quality and
inconsistent supply still prevents a larger-scale industry growth.
Used-oil collection and disposal rates differ significantly across
countries, and even by states and municipalities. Although used oil
collection regulations exist in most countries, varying levels of
enforcement and incentives mean that, globally, of the total used
oil generated, only about 74 percent is collected. The remaining 26
percent is combusted, re-used without appropriate treatment or
discarded.
The front runner of the re-refining industry is Europe. Thanks to
strong regulation and enforcement, nearly 90 percent of all used oil
is collected, and 50 percent of this is sent to re-refining. As a result,
re-refined basestocks at present account for 13 to 15 percent of the
overall basestock supply in the region.
Influencing the utilization of used oil are the economic values of
different disposal options. North America’s collection rates are
comparable to those of Europe; however, more than 80 percent of
the used oil collected is used in various fuel applications, while only
and less complicated to prepare used oil for fuel applications.
With the exception of Brazil, where strong regulation favors re-
refining, collection rates are low in other parts of the world –
approximately 60 to 70 percent of the total, in comparison to 85 to
90 percent in Europe and North America. Furthermore, of the total
oil collected, a significant portion is used as fuel, whereas re-
refining accounts for a small percentage.
There are three key drivers for growth in the re-refining industry.
First, growing virgin basestock prices due to high costs of crude oil
have increased interest in re-refined basestocks. Second, improve-
ments in re-refining technology have dramatically improved the
quality of re-refined basestocks, allowing them to be used in
blending of a growing range of lubricants. Third, regulation in
Europe, and increasingly in North America, favors re-refining.
However, to achieve its potential, the re-refining industry will
have to deal with a number of challenges. Chief among these are
negative customer perceptions. End-users who have no experience
with re-refined basestocks equate them with poor-quality, substan-
dard and adulterated products. They also tend to clump all
re-refining technologies and re-refined basestocks into one cate-
gory. This hurts re-refiners who use advanced technologies to
produce high-quality basestocks.
About the Author
Kline & Company is a consulting and research firm serving the manage-
ment consulting and market research needs of organizations in the
chemicals, materials, energy, life sciences and consumer products indus-
tries. For more information, visit www.klinegroup.com.

Shell Continues to Pace Global Market for Finished Lubricants

Despite the negative impact of the 2008-
2009 recession on the global consumption of
lubricants, Shell managed to retain its position
as the global market share leader for the fourth
consecutive year. Shell accounted for 13.4
percent of all finished lubricant sales in 2009,
according to a report published in September
by Kline & Company.
Shell outperformed ExxonMobil and BP,
which ranked second (11 percent) and third (7
percent), respectively, in global market share.
Chevron, Total and Petro-China rounded out
the top six.
Kline’s report estimated global lubricant
demand in 2009 at 35 million tonnes. This signif-
icant decline of 8.4 percent over the previous year
followed the 2.6 percent decline that the industry
experienced between 2007 and 2008.
As predicted by Kline, the impact of the
global recession has been less severe in the
Asia-Pacific region. This region continued to
show the most robust growth on a volumetric
basis, and now accounts for 39 percent of the
total global market. This trend, which has seen
Asia-Pacific become an increasingly significant
global market player, is likely to prevail as
China and India are expected to continue to be
the growth engines for the lubricants industry
in the future.
On the other hand, the United States is among
those markets most severely curtailed by the
economic downturn, and experienced a double-
digit decline in 2009.

24 November - December 2010 www.machinerylubrication.com Machinery Lubrication

PRODUCT SUPERMARKET
The Donaldson Filter Buddy™ is a 2 gpm hand-
held portable filtration system. Two models are
available: a standard version for fluids up to 900 SUS
and a high viscosity version for fluids up to 8000
SUS. For more information, contact:
Donaldson Company Inc.
800-846-1846
www.donaldson.com/en/ih
Keep your hands free and your lubricant spot-on
with perma® automatic lubricators. Preloaded with
premium LE lubricants, they provide continuous,
precise application. The result: reliability, efficiency,
safety and savings.
Lubrication Engineers Inc.
www.le-inc.com 800-537-7683
Webleads@le-inc.com
CONTROL WATER CONTAMINATION. Remove
100% free water and 95% dissolved water with C.C.
JENSEN Desorbers. Proven, effective and reliable.
Suitable for oil systems with small or large volumes.
Guaranteed performance. Contact us today for
information or purchase.
C.C. Jensen Inc.
www.ccjensen.com 800-221-1430
ccjensen@ccjensen.com
26 November - December 2010
PAID ADVERTISING SECTION
VIBXPERT II Color Display Fast Vibration Analyzer.
Easy-to-use menu-driven setups help resolve simple and
complex machinery issues. Fast data collection, cross-
channel, transient analysis, modal/ODS, balancing and
more. OMNITREND software for analysis, reporting
and trending.
LUDECA Inc.
www.ludeca.com/vibxpert 305-591-8935
In addition to particle counting and automatic
type of wear classification into non-metallic,
cutting, fatigue, sliding, fibers, water droplets
offering images and trending, the new SpectroLNF
Q200 also reports dynamic viscosity.
Spectro Inc.
www.SpectroInc.com 978-431-1120
sales@SpectroInc.com
Quickly monitor the remaining useful life of
lubricants. The RULER provides an easy on-site
method for monitoring antioxidants and identi-
fying problems like lube oil varnish. Maximize
lubricant life with the RULER.
Fluitec
www.fluitec.com 888-557-9575
info@fluitec.com
www.machinerylubrication.com
The Easylube RFID Patrol Management
Automatic Lubrication System provides precision
bearing lubrication and condition monitoring in
one system. Easily calculate and manage greasing
quantities and intervals using our software.
Hornche Corporation
www.easylube.com
service@easylube.com
Actively filtering lubricants can prevent contami-
nation-related problems. The Des-Case FlowGuard™
Drum Filter Cart is a customizable, all-in-one cart
that filters and transfers oil from a conveniently
attachable, secured drum.
Des-Case Corporation
www.descase.com 615-672-8800
sales@descase.com
Because viscosity measurement should be
simple, CANNON is excited to introduce the
SimpleVIS™ portable viscometer. Everything is
included to get you started, minus your sample and
solvent. Contact us for more information.
Cannon Instrument Company
www.cannoninstrument.com 800-676-6232
sales@cannoninstrument.com
Machinery Lubrication
 MEMOLUB® Lubrication Systems – Precise,
Reliable. Lube up to 12 points with the reusable
MEMOLUB®. Available in 3 sizes and 4 power
options, MEMOLUB® uses low-cost replaceable lube
cartridges with customer-specified grease or oil.
PLI LLC
www.memolub.com 800-635-8170
sales@memolub.com
A new full-color 104-page catalog is available on
Oil-Rite’s lubrication equipment, featuring PurgeX®
Centralized Lubrication Systems. Complete turnkey
systems are available for immediate delivery, liquid
or grease delivery, air or electric motor-operated.
The catalog also features an entire line of level
gauges, lubricators, valves, vent plugs and filters.
www.oilrite.com 920-682-6173
Harvard’s filter systems are designed and built
with quality materials and craftsmanship to provide
years of trouble-free service. Filter elements for
viscosity ranges from fuels to gear oils (ISO 1000).
Customers report clean fluids to ISO 13/12/8 in
operation. Contaminant capacity per element is
about four pounds. The product has demonstrated
the ability to remove one gallon of water from oil.
Harvard Corporation
www.harvardcorp.com 800-523-1327
Machinery Lubrication
Simple and cost-effective, LE’s Clear Grease Gun
will make an immediate impact on your reliability
efforts. No more mistakes or cross-contamination.
Be confident in knowing you are using the right
grease, time after time.
Lubrication Engineers Inc.
www.cleargreaseguns.com 800-537-7683
Webleads@le-inc.com
REMOVE VARNISH, PARTICLES AND WATER.
Three problems, one solution. C.C. JENSEN is
focused on supplying highly efficient and reliable
offline filters and filter carts. Guaranteed
performance. Contact us today for more informa-
tion or to purchase.
C.C. Jensen Inc.
www.ccjensen.com 800-221-1430
ccjensen@ccjensen.com
Inolex Chemical Company synthesizes premium
ester base oils for high-performance lubricant applica-
tions such as chain formulations for oven temperatures
up to 550°C. HX-1 food grade oils for baking chains
are available.
Inolex Chemical Company
www.inolex.com
1-800-521-9891
lubeinfo@inolex.com
www.machinerylubrication.com
Summit EnviroTech FGPL is a bio-based, NSF H1
registered food-grade spray penetrating lubricant
for use in the food processing industry. It is
biodegradable, odorless, tasteless and rapidly pene-
trates corrosion or carbon residue on equipment.
Summit Industrial Products
www.klsummit.com 800-749-5823
info@klsummit.com
Easy Vac Inc. provides the right tool for an
important job! Vampire fluid sampling pumps ...
small, hand-operated vacuum pumps accept any
size sampling tube (with an OD of 3/16 inch to
5/16 inch) without changing fittings. “Super
Clean” sampling containers, tubing and acces-
sories are also available.
Easy Vac Inc.
www.easyvac.com 865-691-7510
An EP grease for extended, heavy-duty service, LE’s
Almagard Vari-Purpose Lubricant stays put – even in
severe conditions. It lengthens intervals, will not
harden with age, and extends bearing life by up to
threefold.
Lubrication Engineers Inc.
www.le-inc.com 800-537-7683
Webleads@le-inc.com
November - December 2010 27
GET TO KNOW…
Ex-Navy Mechanic Got Program
Off the Ground at Temple-Inland
R andy Hall, a predictive maintenance
technician at Temple-Inland’s wall-
board plant in Cumberland City, Tenn., is
one of the subjects of this issue’s “Get to
Know ...” feature. He has worked 11 years
for this company after spending 20 years
performing aviation maintenance for the
U.S. Navy. Let’s learn more about Randy.
What types of training have you
taken to get you to your current posi-
tion?: The training and experience I received
in the military have been invaluable. I use
many of the ideas, principles and practices
learned in the aviation field on a daily basis
in my current position. Also, I went to several
Noria seminars and vibration classes, and
spent a lot of time reading books on indus-
trial lubrication and predictive maintenance.
Attending conferences and talking with other
people doing the same type of work also
have been very helpful.
What certifications do you hold?: I am
a Machine Lubrication Technician Level II and
a Machine Lubricant Analyst Level III through
ICML, a Certified Lubrication Specialist
through STLE, and a Category III Vibration
Analyst through the Vibration Institute.
When did you get your start in
machinery lubrication, and how did
it happen?: If you can count changing the
oil in your own vehicles, I started around 15
when I changed the oil in my dad’s car for the
first time. In the Navy, I had to change oil
and filters in aircraft engines, gearboxes and
hydraulic systems, and took oil samples on
engines and gearboxes. Additionally, I took
oil samples on the hydraulic systems and ran
patch tests on them. At the time, I didn’t
realize the significance of what I was doing.
After becoming a Class A mechanic at
Temple-Inland in 2000, I was asked by the
mechanical supervisor if I’d be interested in
28 November - December 2010
Randy Hall is a PdM technician at
Temple-Inland in Tennessee.
helping the mechanic that was tasked with
starting the vibration program. I had been
involved with a little vibration in the service
and liked it, so I said yes. Later that year, the
maintenance superintendent called us both
into his office and told us that the plant was
going to start a lubrication program. He said
that since the other mechanic had more
experience in vibration, he would continue to
do that, and I would start the lubrication
program. I’m glad he did because I really
enjoy working in this field.
What’s a normal work day like for
you?: Since we have a small maintenance
department, I might be assigned to do
lubrication PMs, take and process oil
samples, work on rolling stock, collect and
analyze vibration data, review PMs, help
with a root cause analysis, or help with
upset conditions on the production line. It’s
always something new, which is one of the
things I love about my job.
What is the amount and range of
equipment that you help service
through lubrication/oil analysis
tasks?: There are approximately 900 pieces
of equipment at the plant, consisting of
www.machinerylubrication.com
gearboxes with half-gallon oil sumps to ones
with 14-gallon oil sumps, hydraulic power
units, fans with 1-inch-diameter to 4-inch-
diameter shafts, electric motors ranging from
1 to 300 horsepower, and various sizes of
valves and pumps. I routinely take and analyze
oil samples on 100 pieces of critical equip-
ment and 36 pieces of essential equipment.
What lubrication-related projects
are you currently working on?: One
ongoing project is to increase the cleanli-
ness in bulk and operating oils. Also, I’ve
been experimenting with ultrasonics and
using high-frequency vibration data to fine-
tune the amount of grease needed to
relubricate fan and motor bearings. We
also are going through all of the lubrication
PMs to make sure they are up to date.
What have been some of the biggest
project successes for which you’ve
played a part?: I am most proud of the
changes I made to the lube storage areas. That
includes the addition of air-powered pumps
with filtration, desiccant breathers, quick-
disconnects and sample points, and setting up
the pumps to kidney-loop the oil in the drum.
How does your company view
machinery lubrication in terms of
importance, strategy, etc.?:
Management has been very supportive of all
the changes that I have made. Without
them, it would have been almost impossible
to do the things I have done.
“Get to Know …” features a brief question-
and-answer session with a Machinery
Lubrication reader. These articles put the spot-
light on industry professionals and detail some
of the lubrication-related projects they are
working on. If you know of an ML reader who
deserves to be profiled, e-mail editor-in-chief
Paul V. Arnold at parnold@noria.com.
Machinery Lubrication
GET TO KNOW…
Lab Background Helps Peterson
in Latest Alabama Power Role
J ames “Pete” Peterson, a senior condition-based maintenance
specialist at Alabama Power Company’s Gorgas Steam Plant in
Parrish, Ala., is our other “Get to Know ...” subject. He has worked
32 years at Alabama Power (a subsidiary of the Southern
Company), first starting in 1978 as a chemical technician. He also
has been a laboratory foreman (from 1983 to 1994), a special proj-
ects coordinator (1994-1995) and a training team leader/employee
development coordinator (1996-2002). Let’s get to know Pete.
Tell us a bit about your educational background: I earned
a bachelor’s of science degree in biology/math from the University
of Alabama (1969). Afterward, I was a research technician (1972-
1976) and laboratory coordinator (1976-1977) in the university
system. Years later, I became Level II certified in lubrication through
the Southern Company.
When did you get your start in machinery lubrication,
and how did it happen?: In 2002, I was asked by management
to return to technical work at the plant. I had been the training team
leader at Gorgas since 1996, and as they were looking to expand the
site’s condition-based maintenance team, they felt that my previous
work experience would serve me well as a lubrication specialist.
What’s a normal work day like for you?: I like to plan my
work by the week, with Tuesdays being my normal “sample collec-
tion” day. I prepare on Monday by labeling bottles, getting my
equipment ready, etc. As I normally sample, test, analyze and
report on 175 to 200 samples per month, it takes most of the day
on Wednesday and Thursday to finish testing the samples and
writing my reports. On Friday, I do rechecks and work on oil-related
issues that we are having with the equipment. When I include
motors, which occurs every four months, it doubles my workload.
What is the amount and range of equipment that you
help service through lubrication/oil analysis tasks?: We
have the type of equipment – turbines, fans, pumps, pulverizers and
associated motors – that you’d expect to find in a coal-fired power
plant. We have five units and more than 250 pieces of critical
equipment. Each piece of critical equipment has multiple – usually
four to five – sample points.
What lubrication-related projects are you currently
working on?: We are currently investigating the use of perma-
nently placed filtration equipment on our smaller boiler feed
30 November - December 2010 www.machinerylubrication.com
“Pete” Peterson takes an oil sample at the Gorgas Steam Plant.
pumps; we have vacuum dehydrators on our large-unit versions.
Also, we are attempting to upgrade the plant’s oil storage facilities,
which is necessary considering Gorgas is the oldest coal-fired plant
in Alabama Power’s fleet.
What have been some of the biggest project
successes for which you’ve played a part?: It would be
getting our newer operations folks trained and helping to educate
them as to the critical role that they have in taking our lubrication
program to the next level.
How does your company view machinery lubrication?:
The entire Southern Company has demonstrated a renewed
commitment to a fully functional CBM program, encompassing the
use of vibration monitoring, motor diagnostics, infrared, ultra-
sonics and machinery lubrication. That has really been exciting.
Management is on board with the cost savings that can be realized,
both at the plant level and system-wide, through the use of things
like cost benefit analysis (CBA). The company facilitates sharing of
best practices among the plants, which has enabled us to help each
other learn and grow.
What do you see as some of the more important trends
taking place in the lubrication and analysis field?:
Though I’m relatively new to lubrication, it seems to me that this
field is gaining in importance as it relates to the overall strategy to
operate any industrial plant at peak efficiency. Whether you
monitor oil condition in-house or have a commercial lab do it, the
oil that flows through your machines must be attended to properly
if you wish to be successful.
Machinery Lubrication
PRODUCT SPOTLIGHT

Portable Filtration System Fluid Filtration Station

The Donaldson Filter Buddy is a 2 gpm (7.6 l/min) handheld The Filtration Station from Schroeder Industries flushes, filters and
portable system that allows you to kidney-loop reservoirs that you monitors ISO cleanliness with user-defined, automatic features. The
normally cannot with larger filter carts. Its small size and light weight FS transfers fluid through two Schroeder K9 filters in series for staged
(approximately 45 pounds) allows carrying it up and down stairs and particulate or water/particulate removal. Both filters are top-
into tight or confined spaces. It also fits on top of a drum for conven- loading and include element indicators in the cap. A
ient transferring and filtering from a drum to a reservoir. The Filter particle monitor samples discharged
Buddy features dual filtration, which utilizes fluid from the pump and displays
Donaldson’s exclusive high-eff iciency ISO cleanliness codes for the fluid.
Synteq media. The filters are plumbed In auto mode, the system runs until
in series, giving you the option of the desired cleanliness codes are
coarse/f ine particle removal or achieved. Upon reaching the
install a water-absorbing codes, the pump will stop and
element for water/particle the completion indicator light
removal. There are two models will come on. In manual mode,
available: a standard (low- the system runs continuously
viscosity) version for fluids up and displays the ISO codes. A
to 900 SUS and a high- water sensor is available for
viscosity version for f luids providing the water saturation
up to 8000 SUS. and temperature of the fluid.

Schroeder Industries
Donaldson Corporation
www.schroederindustries.com
www.donaldson.com/en/ih
800-722-4810
800-846-1846

Filter Separators Drum Filter Cart

CJC Filter Separators from C.C. Jensen are off-line oil filtration
systems / oil separators, combining fine filtration with water separa-
tion in one unit, with an integrated circulating pump. They are
designed for use in applications containing hydraulic oil, diesel fuel,
lubricating oil, etc., in which water ingress is a constant or recurrent
problem. CJC Filter Separators remove water by coalescence and at
the same time minimize oil contamination levels of particles and oil
degradation products (oxidation resin/sludge, varnish). The CJC
depth filters have a filtration degree of 3 microns absolute and a
large dirt-holding capacity. This, combined with efficient and contin-
uous water removal from the oil, enables reduced maintenance,
increased productivity, and maximum life of system components, in-
line filters and oil.
The FlowGuard Drum Filter Cart from Des-Case is a customizable,
all-in-one filtration system built upon a rugged powder-coated dolly.
The cart filters and transfers oil from a drum secured to the cart with
adjustable, heavy-duty straps, while a removable plastic drip pan
prevents filter changes from contaminating the work area. With dual-
stage filtration to customer specifications, a filter bypass, 12-foot
hose assemblies with a variety of hose-end connections and a remote-
mounted power switch, it’s easy to build the perfect solution for any
application. FlowGuard fluid handling systems incorporate smart
technology to make fluid handling a simple task, requiring less equip-
ment and labor while reducing
system contamination.

C.C. Jensen
www.ccjensen.com
800-221-1430

Des-Case Corporation
http://descase.com/flowguard/
615-672-8800

32 November - December 2010 www.machinerylubrication.com Machinery Lubrication

 Includes Level I MLT and MLA
Certification Preparation

Learn Precision Lubrication Skills

for Maximizing Machine Reliability
Here’s a Sample of What You’ll Learn:
• How to build a safe and effective lubricant storage and handling program
• How to rate filters and select the right filtration for the job
• Lubricant labeling and coding systems – what works and what doesn’t
• Industry’s best procedures for greasing electric motor bearings
• How to get the right lubricant, in the right place, at the right time,
and in the right amount

Presented by

Enroll today!
Visit Noria.com or call 800-597-5460 © Noria Corporation
You’ll gain practical new skills that you
can use right away:
1
The secrets of lubricant selection.
This course will empower you with the knowledge to understand important lubricant proper-
ties and strategies to select the correct lubricant for each machine application.
Who Should Attend?
• All Maintenance Professionals 2
• Lubrication Technicians The best practices for lubricant storage,
• Craftsmen or Millwrights handling and dispensing.
• Equipment Operators Learn how award-winning maintenance programs design lube storage areas, dispensing sta-
• Laboratory Analysts tions and transfer carts.
• Lubrication Engineers
• Maintenance Managers 3
• Maintenance Supervisors The four Rs of lubrication.
Right lubricant, right time, right quantity and right place. If these four basic elements aren’t
• Manufacturing and Industrial Engineers
properly addressed, you could be doing your equipment more harm than good. Learn the
• Operations Managers newest methods for implementing the best lubrication practices.
• Predictive Maintenance Technicians
• Reliability Engineers
4
Grease gun or lethal weapon?
What Industries Will Benefit? In the hands of an untrained operator, a grease gun can deliver pressure up to 15,000 psi.
That’s 30 times what a typical bearing seal can handle. Once the bearing seal is broken, the
• Aerospace bearing is on its way to early failure. This course will teach you proper grease gun practices.
• Automotive Manufacturing
• Earthmoving
• Food and Beverage 5
Effective oil analysis with precision oil sampling.
• General Manufacturing Learn how to get data-rich oil samples, exactly where to install oil sampling ports, and what
• Lumber and Wood sampling equipment should and shouldn’t be used.
• Municipal Utilities
• Petrochemical
• Pharmaceuticals Apply What You Learn and Reap
• Power Generation
• Primary Metals the Benefits:
• Process Manufacturing • An organized, safe, world-class lubricant • Stop early bearing failures
• Pulp and Paper storage area • Compare and select the best lubricants
• Rubber and Plastic • Extend machine life by up to 10X for the job
• Textile • Solve water-in-oil problems • Reduce energy and fuel costs
• Transportation • Squeeze maximum life from lubricants • Create more effective lubrication PMs
• Reduce electric motor failures and replace- • Solve annoying hydraulic system problems
ment costs • Spend less on lubricants and filters
If You Use Any of These Machines, • Improve health and safety issues – not more
This Training is a Must: • Stop pesky oil and hydraulic fluid leaks • Improve equipment mean time between
• Electric Motors • A more effective oil analysis program failures
• Compressors • Effectively troubleshoot lubricant-related
• Diesel Engines machine failures
• Final Drives
• Gas Turbines
• Gearboxes
Comprehensive Course
• Hydraulic Systems Manual is Included
• Hydrostatic Transmissions You’ll receive a course manual to use as your textbook during the
• Paper Machines course and then take home for future reference. It’s packed with
guidelines, worksheets, right/wrong examples, reminders, look-
• Process Pumps Course Manu
• Rolling Mills
up charts, additional references and much more. You’ll consider al
it an indispensable on-the-job reference for years to come.
• Steam Turbines
• Blowers/Fans

2 Enroll today! Call toll free 800-597-5460 or visit www.noria.com

A special note from Noria’s President

Satisfied Customers Say it Best…

“The information from this course could
nal, save my company as much as $20,000 in
Dear Industry Professio su cce ss (and your own career su
ccess) de-
an iza tio n’s monthly oil costs.”
To a large degree, your org desired result.
ab ility to ge t thi ng s do ne – on time and with the es , Jeff Smith, Maintenance Planner, Mueller Copper Tubes
pends on your e – to bri ng you the proven techniqu
valuable cours
This is the focus of this ns rely on to stay comp
eti-
es an d str ate gie s tha t world-class organizatio d str ate gic “Packed with powerful information that
guidelin rposeful an
hig hly de ma nd ing ma rket. This course is a pu can be applied with measureable results.
tive in today’s excellence practices.
um to tea ch you ho w to implement lubrication This course provides the right training to
for
ining cours e: influence a cultural change in mainte-
sa mp le of wh at you ’ll learn in this powerful tra nance and operation organizations.”
Here’s just a an t storage and handling sys
tem
wo rld -cla ss lub ric Brian Baldwin, Reliability Engineering Manager, Dynergy
• How to set up a lub ric ation excellence
fro m ac hie vin g
• The financial benefits
extend oil drain intervals
• How to optimize and res “ABSOLUTELY AWESOME! Should reduce
ompatible grease mixtu
• 7 tips for avoiding inc downtime 25 to 50 percent.”
w to ove rco me lea ka ge stability problems Scott Gilreath, Lube Tech, UNICCO
• Ho d fittings
cti ce s for the ma int en ance of grease guns an
• Best pra ance
hance lubricant perform
• Key additives that en d ref illin g “I believe the knowledge I have now will
for oil draining an
• The best procedures reduce downtime 50 percent.”
chart your road Johnny Dominquez, Mechanic, Freeport-McMoran
oth er tip s, tec hn iqu es and strategies to help you
Plus, dozens of
map to success. how to help organiza-
sig ne d to pre sent practical advice on “I think the information I learned can
This traini ng is de
n. We ’ll giv e you the proven tools you need to improve our hydraulic systems by 40
competitio
tions get the edge on the wo rk arm ed wit h the most up-to-date in- percent.”
job. You’ll return to
face challenges on the re productive and more Vernon Player, PDM Tech, International Paper
in the ind us try , ma kin g you more confident, mo
formation
valuable than ever. ble insights
en d. Th at’ s all it tak es to benefit from the valua “This course has provided me an in-
Register now and att er. Do n’t miss this opportunity to att
end.
rful tra inin g ha s to off depth view on how to create a world-
and new skills this powe class lubrication program.”
Dennis Hill, Facility Engineer, Alcoa
Sincerely,

Jim Fitch
Noria Corporation “Vendor-neutral
e in increased produc- makes a difference!”
idends for years to com
r inve stm ent in this training will pay you div today by calling 800-597-5460, by visiting
P.S. - You your place
effectiveness. Reserve Alfredo Romaro,
tivity and professional iling in the registration form on Page 7.
www.noria.com or by ma Maintenance Technician,
Kawneer Company

Enroll today! Call toll free 800-597-5460 or visit www.noria.com 3

Fundamentals of

Machinery Lubrication
• What you need to know about food-grade addi-
Course Outline tives, base oils and grease thickeners
How Lubrication Affects • Guidelines for food-grade lubricants
Machine Reliability
Join this list of world-class • Financial benefits from achieving
Lubricating Grease Application
companies who have benefited lubrication excellence Methods
from Noria training • Four equipment maintenance strategies, and • How to protect against incompatible grease
when each applies mixtures
3M Heinz • Advantages and disadvantages of centralized
• Important implementation steps to lubrication
Alabama Power Houston Metro Transit lubrication systems
excellence
Alcoa International Paper • Best practices for greasing motor bearings
Alumax Invista
Lubrication Fundamentals • How to control pressure when greasing bearings
Ameren John Deere
• Six important functions of lubricating oils • The unique problems caused by over-greasing
American Electric Power Kinder Morgan
ArcelorMittal • How oils and greases are formulated and why it – specific steps to eliminate
Koch Industries
Archer Daniels Midland Lockheed Martin is important • 3 critical instructions to give your electric motor
Barrick Goldstrike Lukens Steel • How friction is generated in lubricated machinery rebuild shop
BHP M&M Mars • The importance of oil film thickness and critical • Comparing single- and multi-point lubrication
Boeing MillerCoors clearances options
Boise Cascade Michelin • How to calculate greasing intervals and quantity
BP Mosaic Understanding Additives, Base Oils • Best practices for ultrasonic/sonic-based greasing
Cargill Noranda Aluminum and Grease Thickeners
Castrol Nova Chemicals • How lubricant properties irreparably change Lubricating Oil Application Methods
Caterpillar Owens Corning • Seven important physical properties of a base oil • Overview of oil lubrication methods and devices
Centralia Mining OxyChem
• The importance of API’s five base oil categories • How to use oil mist and other automatic
Chevron Pacific Gas & Electric
• What causes grease to dry out and 18 ways to lubrication methods
Citgo Peabody Energy
prevent it • Using pressure spray methods for gearboxes
Clopay Pfizer
ConAgra Foods Powder River Coal • How to detect the root causes of lubricant oxidation • Best practices for the maintenance of grease
ConocoPhillips PPG Industries • When to select one of the six most commonly guns and fittings
Constellation Energy Procter & Gamble used synthetic base oils • How to protect against problems caused by con-
Dow Chemical Progress Energy • How to use temperature to determine the right stant-level oilers
Dow Corning Reliant Energy base oil for your machine • Overview of single-point direct lubrication systems
DTE Energy Rio Tinto • How to select grease thickeners for your
DuPont Seattle Times application Journal Bearing Lubricants
Dynegy Seminole Electric • The 8 most common journal bearing lubrication
Eli Lilly Shell Oil Lubricant Performance Properties problems
Entergy Southern Company • Key additives that enhance lubricant • How to select journal bearing viscosity based on
ExxonMobil Temple-Inland performance speed
First Energy Texaco • Viscosity grades, measurement and reporting
Florida Power Texas Instruments Rolling-element Bearing Lubricants
• Why Viscosity Index is important
Ford Motor Co. Toyota
• What causes oil viscosity to change and how to • The nine critical factors affecting rolling-element
Formosa Plastics TXU Energy
set monitoring limits bearing lubricant selection
General Electric Unilever
• Lubricant performance tests and reporting • How to convert required operating temperature
General Motors U.S. Army
– what you need to know viscosity to ISO viscosity grades
Geneva Steel U.S. Navy
Georgia Pacific U.S. Postal Service • How water contamination generates other
contaminants
Gear Lubricants
Georgia Power USG Corporation
Goodyear Verso Paper • 5 key requirements for gear oil
• How to control and eliminate aeration problems
Great Lakes Chemical Via Rail Canada • How to select the best viscosity for a gear lubricant
Harley-Davidson Westinghouse Food-grade and Environmentally- • Best practice guidelines for storing spare gear-
Holcim Weyerhaeuser friendly Lubricants boxes – lubrication matters!
Honeywell Whirlpool • Important USDA requirements and government • 10 conditions that may require synthetic gear
Intel Willamette Industries regulations for food-grade lubricants lubricants

4 Enroll today! Call toll free 800-597-5460 or visit www.noria.com

Fundamentals of
Machinery Lubrication
• Lubrication best practices for enclosed gears
– a 12 point checklist
• Mastering the challenges of open gear lubrication
Automotive and Mobile Equipment
Drive-line Lubricants
• How to read a motor oil label – what really matters
• The 6 critical objectives a motor oil must accomplish
• Understanding API service classifications for en-
gine and gear oils
• The #1 reason automatic transmission fluids fail
and how to protect against it
• Service classifications for automotive greases – how
to select
• Extending engine life – surprising engine oil filter
study results
Compressor Lubricants
• Steps you can take right now to combat compressor
lubricant failure
• The most common compressor lubricant stressors
• When to use synthetic compressor lubricants
and why
Steam and Gas Turbine Lubricants
• Why turbine/generator lubricants are the #1
contributor to forced outages
• Comparing steam and gas turbine oils
– how they differ
• Checklist for best practice steam turbine lubrication
Hydraulic Fluids
• How to select the ideal hydraulic fluid viscosity for
gear, vane and piston pumps
• Nine key hydraulic fluid requirements and why
they matter
• Specific conditions that may require a synthetic
hydraulic fluid
• Fire-resistant hydraulic fluids – what you need
to know
• Hydraulic system maintenance best practices
– 21-point checklist
Contamination Control
• Strategies for building reliability through
contamination control
• The seven most destructive contaminants and how
to control them
• Specific steps for managing a proactive lubricant
management program
• The ISO Solid Contaminant Code – understand it,
track it
Enroll today! Call toll free 800-597-5460 or visit www.noria.com
• 10 ways to get more mileage out of portable
filter carts
• How dirt, metal particles and soot mechanically
destroy machine surfaces
• Guidelines for controlling machine surface fatigue
and extending machine life
• The #1 cause of machine wear and how to manage it
• How to set realistic cleanliness levels for lubricants
• Effective lubricant contamination control strategies
for extending machine life
• 4 ways water contamination attacks lubricant
additives
• How to set limits for water-in-oil contamination
• Managing the root causes of foam and aeration
• Best practices for excluding and removing
contaminants
• The right way to control contamination in tanks
and sumps
• How oil filters are rated
• Calculating the clean-up rate for portable filters
• Best practices for removing water contamination
from oil
• The unique problems created by varnish
– how to remove and stop it
Oil Drains, Flushing and Reservoir
Management
• How to optimize and extend oil change intervals
• Interval vs. condition-based oil changes
– pros and cons
• Metrics for monitoring lubricant consumption
• Best practices for oil changes
• Know how and when to perform a flush
• The best procedures for oil draining and refilling
• How and when to use the bleed-and-feed strategy
for extending oil drains
• Selecting the right cleaning and flushing procedures
Storing, Handling and Managing
Lubricants
• How to set up a world-class lube room
• How to know when to reject a new oil delivery
• How to optimize your lubricant selection and
procurement process
• How to implement a lubricant consolidation
program and select suppliers
• Used lubricant storage, handling and disposal
best practices
• Bulk lubricant storage do’s and don’ts
• Guidelines for storing and handling drums
• Lubricant dispensing options and what you must
avoid
• Lubricant coding and identification systems
– what works and what doesn’t
• Portable oil transfer and filter cart selection advice
• How and where to store oil transfer and filter carts
• Understanding and managing lubricant storage life
• Keeping grease fresh – best practices for storage
Design and Inspect for Lube Excellence
• World-class strategies for accessorizing equipment
for lubrication excellence
• Seven critical accessories for lubricant inspection
and sampling
• The right machine accessories for effective
contamination control
Used Oil Sampling and Analysis
Fundamentals
• What oil analysis can tell you
• Types and categories of oil analysis
• Applications for oil analysis
• Overview of oil analysis tests
• Elements of a successful oil analysis program
• How clean should oil sample bottles be?
• How to find the best sampling locations
• Oil sampling valve and hardware recommendations
• A quick method for optimizing sampling intervals
• An oil sampling technique that ruins trending
• The importance of primary and secondary
sampling points
• Advice for sampling hard-to-reach machines
• How to properly sample circulating systems
• Safe, effective high-pressure sampling from
hydraulic systems
Essential Field Inspections
• 12 questions your oil filter will answer about your
machine
• Visual inspections you can get big results from
right now
• Quick tips for using scent, sound and touch to
inspect lubricants
5

Get Certified!
Why Certify?
Certification is an important part of the
training process because it confirms you
possess the skills to do the job. Combin-
ing training with certification creates a
knowledgeable and valuable employee.
Which Certifications?
This course is designed to help you prepare
for the following ICML certification exams:
• Level I Machine Lubricant Analyst (MLA)
• Level I Machine Lubrication Technician
(MLT)
Find out more about these ICML certifica-
tion exams at the ICML web site:
www.LubeCouncil.org
What is ICML?
The International Council for Machinery
Lubrication (ICML) is a vendor-neutral, not-
for-profit organization founded to facilitate
growth and development of machine lu-
brication as a technical field of endeavor.
Among its various activities, ICML offers
skill certification testing for individuals in
the fields of machine condition monitoring,
lubrication and oil analysis.
How to Certify
Level I MLT and Level I MLA certification
testing will be held the Friday following the
training. To register for the ICML certifica-
tion exam, go to www.LubeCouncil.org or
call 918-259-2950 for more information.
On-Site Training
We can customize Fundamentals of Ma-
chinery Lubrication – or any of our other
courses – to meet your unique needs.
We’ll provide expert instruction at a time
and place most convenient for your group.
Want to know more? Call 800-597-5460.
Whether you have 5 or 500 people to train,
Noria is the answer.
6 Enroll today! Call toll free 800-597-5460 or visit www.noria.com
Trainers
Jim Fitch
Jim Fitch, a founder and president of Noria Corporation, is a highly
sought-after consultant and trainer described by his clients as “in-
sightful, dynamic and thorough.” He has advised hundreds of
companies on developing their lubrication and oil analysis pro-
grams and has taught more than 400 training courses in more
than 20 countries.
Jeremy Wright
Jeremy Wright, a Noria senior instructor, provides a lively interac-
tive forum for learning at his courses. As a consultant, Jeremy has
helped numerous Fortune 500 companies develop lubrication
procedures, benchmark to best practices and implement world-
class lubrication programs.
Bob Scott
Bob Scott brings to his courses a wealth of “in the trenches” ex-
perience. His practical “how to” advice and engaging teaching
style consistently gets top scores from audiences. You’ll reap the
benefits from his 25+ years of experience with lubricants, lubri-
cation and oil analysis and come away from the training with solid,
practical skills.
From our Resource Center...
The Level I MLT / Level I MLA Study Packet
This Study Packet is designed to be used for both ICML Level I MLT
and Level I MLA certification.
Level I MLT/MLA Flash Cards (more than 385 flash cards) are
designed as a study aid for preparing for both ICML Level I MLT
and Level I MLA certification.
Lubricating Grease Guide is written for beginners who are starting in the grease field
or for practitioners who would like to broaden and deepen their knowledge of
lubricating grease.
Lubrication Fundamentals discusses lubricant basics, machine elements that require
lubrication, methods of application, lubrication, lubricant storage and handling, and
lubricant conservation.
Oil Analysis Basics Book is the No. 1 book in the lubrication industry and makes oil
analysis for machinery condition monitoring easy to understand.
The Practical Handbook of Machinery Lubrication is a phenomenal text. Once you
start reading this book, you probably won’t stop until you finish it. It is that easy to
read. You’ll find understandable explanations of how lubricants work, what they’re
made of and how they break-down. Topics ranging from engine lubricants to
industrial oils and hydraulic fluids are covered.
Retail Price: $410.95 Your Price: $355
Plus $12 for shipping in the U.S.
Fundamentals of

Machinery Lubrication Registration Form

4 Ways to Register
1. Training Course Online Call toll-free!
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Or 918-749-1400
Course Date: ___________________________________________ Mail the Fax your registration!
registration 918-746-0925
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Renaissance St. Louis Airport Sheraton Nashville Downtown
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5. Certification Study Packet 5353 Westheimer Rd
Quantity Houston, TX 77056
The Level I MLT/MLA Certification Study Packet - $355 ______ 713-585-2711
$12 for shipping will be added to all study packet orders. Check Noria.com for more dates and locations

6. Method of Payment Registration Information

Course: Fundamentals of Machinery Lubrication
Course Fee: $1,195
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Noria Corporation
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tute. If you cancel, we will refund your entire payment, cancel your invoice or,
7. Emergency Contact if you prefer, apply your payment to a future Noria course.

Name:__________________________ Phone: ________________ Certification Exams

Certification testing is offered by the ICML the morning following this
(Please list any food allergies so that training course at the same hotel. Please contact the ICML to register for
8. Food Allergies we can better serve you.) the certification exam or register online at their web site:
International Council for Machinery Lubrication
__________________________________________________________________________ Phone: 918-259-2950 • Fax: 918-259-0177
__________________________________________________________________________ Email: info@lubecouncil.org • Online: lubecouncil.org P2763
LUBRICANT APPLICATION
Is Closed Oil Mist Lubrication
the Best Available Technology?
BY HEINZ P. BLOCH, PROCESS MACHINERY CONSULTING, AND CHRIS REHMANN, AESSEAL INC.
O il mist systems are incredibly simple and orders of magnitude
more dependable than traditional oil application methods.
Still, the practice of allowing excess oil mist to escape into the
atmosphere has come under scrutiny. As a result, it is time to revisit
closed systems that avoid polluting the air.
Some closed systems have been in highly successful service since
the mid-1980s and unquestionably represent best available tech-
nology. While the purpose of this article is to provide you with a
relevant experience update on closed oil mist systems, we wish to
first summarize the overall advantages of oil mist:
• Almost completely free of maintenance and fully self-checking.
Users don’t have to rely on operators or maintenance workers
to check and fill housings with oil.
• Better lubricant properties because the oil on the bearings is
always new.
• Lower operating temperatures are routinely obtained.
Reductions typically range from 10 to 20 degrees Fahrenheit.
• Reduced power requirements (typically 3 percent) since the
Figure 1. Old-style (Non-API Type) Oil Mist Introduced
at Midpoint of Bearing Housing
40 November - December 2010 www.machinerylubrication.com
bearings operate in a thin film of oil instead of plowing through
a pool of oil.
• Oil mist is applied without using oil rings. Oil rings are subject
to abrasive wear if the shaft system is not absolutely parallel.
Background on Oil Mist
Oil mist lubrication has been used in petrochemical plants
(ExxonMobil, Shell and many others) since the 1960s. The extended
mean time between failure (MTBF) benefits of oil mist over tradi-
tional oil sump lubrication have been well-documented, and oil
mist was included in the venerable API-610 pump standard, seventh
edition (1989).
In describing the basic oil misting process, we first note that no
liquid oil is placed in the bearing housing. Instead, an oil mist
generator with no moving parts creates the mist in a central plant
that serves all of the facility’s process pumps within approximately
a 600-foot radius. The mist is a mixture of microscopic (less than 3
microns) oil droplets combined with clean air at a ratio of about
1:200,000. The mist is moved out to the pumps via 2-inch pipe
headers at a low pressure (less than 1 psi) and at low velocity (less
than 7 feet per second). At each process pump, the oil mist passes
through a nozzle or reclassifier. Here, the mist velocity is greatly
increased; this causes the droplets to collide and coalesce into
larger liquid drops of oil. While in motion, the various bearing
components contribute to the number of collisions and aid in
doing the coalescing more efficiently.
Comparing Open and Closed Systems
In old-style, “open” oil mist systems (Figure 1), the air/oil
mixture fills the bearing housing, and much of it contacts the bear-
ings. A portion of the coalesced droplets takes a straight path
through the bearing housing; this portion of the coalesced oil and
stray mist passes through a hole near the bottom of the housing
and can be collected for disposal at the drain location in Figure 1.
With these old-style configurations, much oil mist also will escape
at the two unsealed regions where many pump shafts protrude
through the bearing housing.
Efforts to simply provide effective bearing housing seals at the
ends labeled “oil mist out” in Figure 1 had unexpected consequences
Machinery Lubrication
Machinery Lubrication www.machinerylubrication.com November - December 2010 41
 LUBRICANT APPLICATION
Figure 2. Closed Oil Mist System Supplying Continuous
Lubrication to Pumps and Drivers (Source: Lubrication Systems Company)
for inexperienced users. Oil mist functions by letting oil mist globules
coat (actually wet-out or coalesce on) the bearing components. To
provide continuous oil replenishment on bearing surfaces, the oil
mist must flow and cannot be dead-ended. Tight-sealing bearing
protector seals very often caused dead-ending.
Irrespective of prevailing or legislated clean-air requirements, an
environmentally conscious user shouldn’t allow continual releases of
oil mist into the atmosphere. It is worth mentioning that oil mist
releases are low enough to stay within the worker health guidelines of
many industrialized nations. Still, from a housekeeping viewpoint, it
is clearly advantageous not to have smudges of oil on the ground
around every pump. Also, from a wastewater processing viewpoint,
oil spills end up in an oily-water sewer, and it takes money to extract
that oil before the water can be discharged. An open oil mist system,
thus, does not represent best available technology.
The authors recommend using technology found in closed oil
mist systems (Figure 2). Such systems incorporate a collecting tank
(shown near the far left in Figure 2) to which a return header system
is connected. A small blower is provided at the top of the collecting
tank, and the suction effect of this small blower causes stray mist
to be pulled into the tank. Inserted in the blower is a coalescer
maze. Coalesced oil droplets fall out and the oil can be reused.
Virtually oil-free air is vented to the atmosphere.
Figure 3. API 610-compliant Oil Mist Application at Locations
Between the Bearings and Isolators (Source: AESSEAL plc)
42 November - December 2010 www.machinerylubrication.com
Favorable Experience Ascertained
The use of face-type bearing housing seals and oil mist routing
(per Figure 3) make closed systems possible. Forward-looking oil
mist users have discontinued “old” mist application since the mid-
1970s and have enjoyed decades of superior experience with the
routing shown in Figure 3. The API standards (starting with API
610, eighth edition, released in 2000) have recommended oil mist
introduction into the region between the bearing and the bearing
housing protector seal.
Best-technology oil-mist systems recover 99 percent of the lube
oil and best protect physical plant as well as environmental assets.
Closed systems emit no oil mist into the environment and, for years,
have been used by refineries and petrochemical plants concerned
about the environment.
In late 2003, one of the authors visited eight petroleum refineries
located in the U.S. Gulf Coast region. During these visits, it was
discovered that oil-mist lubrication was the predominant method of
lubricating pumps throughout the U.S. refining industry. An equip-
ment sales specialist with more than 20 years of experience as a
refinery reliability engineer estimated that oil mist was being used by
24 out of the 30 refineries in or near Port Arthur, Texas. He believed
that about 80 percent of the pumps in each facility were lubricated
by an oil mist system. A West Coast consulting engineer with a back-
ground in refinery engineering estimated that approximately 50
percent of all U.S. refineries are using oil mist.
Many of these refineries have now employed closed-system oil
mist technology for a few decades and are considering this applica-
tion method an unqualified success. They consider closed oil mist
systems a competitive advantage and have fully endorsed the appli-
cation routines illustrated in Figure 3. Moreover, these users are
doing their part toward achieving a cleaner environment while
imparting reliability to their rotating equipment assets.
Bibliography and Suggested Reading
Bloch, Heinz P.; “Practical Lubrication for Industrial Facilities”,
Fairmont Publishing Company, Lilburn, Ga., second edition, 2009, (ISBN
0-88173-579-5)
Bloch, Heinz P., and Alan Budris; “Pump User’s Handbook: Life
Extension,” Fairmont Publishing Company, Lilburn, Ga., first edition,
2004, ISBN 0-88173-452-7; second edition, 2006, ISBN 0-88173-517-5;
third edition, 2010, ISBN 0-88173-627-9
Bloch, Heinz P., and Abdus Shamim; “Oil Mist Lubrication: Practical
Applications”, Fairmont Publishing Company, Lilburn, Ga., 1998, ISBN 0-
88173-256-7
About the Authors
Heinz Bloch works as a consultant for Process Machinery Consulting.
He is the author of more than 400 technical papers and similar publica-
tions. He has written 17 books on practical machinery management and oil
mist lubrication published by major engineering publishers. To learn more,
e-mail Heinz at hpbloch@mchsi.com or visit www.heinzbloch.com.
Chris Rehmann is the North American operations marketing manager for
AESSEAL, a designer and manufacturer of mechanical seals and engineered
systems. He previously worked for Schlumberger, an oilfield engineering firm,
for 15 years, holding positions in field engineering, technical sales and
management in the United States, the Middle East and Asia-Pacific. He can
be reached at chris.rehmann@aesseal.com or 865-531-0192.
Machinery Lubrication
Machinery Lubrication www.machinerylubrication.com November - December 2010 43
LUBE TIPS

Readers Administer an Ample

Amount of Applicable Advice
T he “Lube-Tips” section of Machinery Lubrication magazine
features innovative ideas submitted by our readers. Additional
tips can be found in our Lube-Tips e-mail newsletter. If you have a
tip to share, send it to editor-in-chief Paul V. Arnold at
parnold@noria.com. To sign up for the Lube-Tips newsletter, visit
www.machinerylubrication.com and click on the “Newsletters” link
at the top of the home page.
Construct This Container and Save Oil
This tip was sent in by Craig Palculict, a lubrication analyst with
Georgia Pacific:
“We built a container (Figure 1) to let us filter and reuse oil when
we need to drain a reservoir, typically during an annual reservoir PM.
The unit has a pump and motor that runs on 110 volts, holds 275
gallons and was constructed to be moved with a fork truck.
Breather
“The oil in the reservoir is pumped into the container through a
filter (we use a 6-micron 40CN housing – double-length Parker filter).
While the reservoir is being cleaned, the unit’s valves are arranged so
the oil circulates through the filter. After the reservoir is cleaned, the
oil is pumped back in, through the filter. This simple unit has saved
thousands of gallons of oil since it was built 20 years ago.
“The container has a big door, and the tank interior is epoxy-
coated for easy cleaning; the residue from the oil doesn’t stick.
After use, we wash the interior with water. The drain at the bottom
is large and the water drains quickly. We then put an air hose into
the tank for about 30 minutes, change the filter and it is ready to
go again.
“If I had to rebuild this unit, I’d probably use stainless steel for
the tank and piping. I’d also use the biggest motor and pump that
would run on a 15-amp, 110-volt power supply for more gallons per
minute and, therefore, quicker turnaround.
“This unit is almost always used on hydraulic units, as the tank
is not big enough for most lube units that we have here at the paper
mill. We have eight paper machines, three power boilers, a wood-
yard, a waste fuel area and a big paper converting area. So, the
opportunities for this unit are numerous.”

Sight Glass PM May Save Bearings

This idea comes courtesy of Dave Nestman, a lubrication
mechanic at Howe Sound Pulp and Paper:
Door “One of our fan pumps lost an oil-filled bearing due to a lack of
oil in the sump. The oil level sight gauge used on this pump indi-
cated that the pump was full, but actually it was not. The pipe
Recirc Valve coming out of the side of the pump to the level gauge was plugged
with sediment and would not let oil out of the gauge to give a true
Filter level reading. To prevent this, lube technicians need to drain sight
gauges periodically to confirm proper functioning.”
Oil to Dump Valve
Reservoir
One Extra Step Improves
Oil from
Reservoir
Oil Analysis Process
Pump and Tank Valve This advice comes from Randy Hardin, a reliability analyst with
Motor ConocoPhillips:
Figure 1. Here is a schematic of the container that was “When oil samples are prepared for shipping to an outside lab,
constructed at a Georgia Pacific facility. the labels often won’t stick to the bottles. Consider using an

44 November - December 2010 www.machinerylubrication.com Machinery Lubrication

eyeglass cleaner towelette to wipe off any unwanted film from your
bottles, allowing the bottle to arrive appropriately labeled.”

Advice for Small Pump Oil Changes

This neat trick was supplied by Eddie McCay, a reliability tech-
nician at Sun Chemical Corporation:
“Changing oil in small pumps can be challenging due to the
design of the pump housing. There is a cavity in the bottom of the
housing that traps water and contaminants. We have started using
a small handheld vacuum pump to completely remove the water
and/or old oil from this cavity, resulting in much cleaner oil with
each changeout. We get 10 extra ounces or more out of the pump
using this method vs. only opening the drain plug.”

Magnets Enable Clean Oil,

Handy Inspections
This tip was supplied by David Towle and Jason Frankiewicz,
reliability team members with Holcim (US):
“Filtering oil with a filter cart has been useful for maintaining
target ISO contaminant cleanliness codes. We’ve found that
placing a magnet in the filter cart and/or unit, near the inlet before
the pump, also is beneficial for removing wear debris and for
routine inspections.
“Place the magnet in a location where it can’t interrupt oil flow
and ensure that the magnet is strong enough to remain in place.
Magnet inspections should be compared to oil samples because oil
analysis results may be better due to the magnet capturing metal.
If multiple pumps/bearings feed into one lube unit, use a magnet
for each return line to determine which one may be wearing out.
Figures 2-3. Magnets make a difference in a four-roll vertical
Wear leather gloves to protect your hands from sharp metal frag- mill at a Holcim facility.
ments when cleaning the magnet.
“The two pictures (Figures 2-3) are from a four-roll vertical mill
with a 1,000-gallon reservoir. The magnets are in the sight glasses
Hungry For More Information?
for the return pumps for each of the four rolls. They are approxi- The Machinery Lubrication Web site is the home for
mately the size of a quarter, three-eighths of an inch thick and silver hundreds of technical articles, columns and reports related
in color. They appear black due to the metal built-up. The sight to lubrication research, solutions and best practices. Check
glasses can be opened, and the magnet can be removed and out www.machinerylubrication.com and learn more.
cleaned.”

Machinery Lubrication Statement of Ownership, Management and Circulation 2010

1. Publication Title: Machinery Lubrication
2. Publication Number: 021-695
3. Filing Date: September 30, 2010
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14. Issue Date for Circulation Data Below: SEP/OCT 2010
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Legitimate Paid and/or Requested Distribution (By Mail and Outside the Mail) (1) Outside County Paid/Requested
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Requested Circulation 53%
16. Publication of Statement of Ownership for a Requester Publication is required and will be printed in the NOV/DEC
2010 issue of this publication.
17. Signature and Title of Editor, Publisher, Business Manager, or Owner: Mike Ramsey, September 30, 2010. I certify
that all information furnished on this form is true and complete. I understand that anyone who furnishes false or
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Machinery Lubrication www.machinerylubrication.com November - December 2010 45


CROSSWORD PUZZLER
2 3
8 9
13
15
16
18
19
ACROSS
2 Noria recently revised and published this popular book
(visit http://store.noria.com/ for a hint).
6 A device which removes the inherent or introduced
impurities from the oil that lubricates an internal-
combustion engine.
8 The International Council for Machinery Lubrication’s
annual prize for excellence in machinery lubrication.
14 The plant featured in this issue’s cover story is located
in this Texas city.
15 Filter performance test in which contaminated fluid is
allowed to recirculate through the filter for the duration
of the test. It is used to determine the Beta Ratio (q.v.)
of an element.
16 A unit of work, energy or heat.
17 When an oil oxidizes, will that typically raise or lower its
viscosity?
18 A type of fluid with a constant viscosity at a given
temperature regardless of the rate of shear.
19 The Oklahoma city where the International Council for
Machinery Lubrication is headquartered.
Get the solution on Page 49.
46 November - December 2010 www.machinerylubrication.com
Get a Printable Version
of This Puzzle Online at:
MachineryLubrication.com/puzzle
4
10 11
12
14
17
DOWN
1 The lowest temperature at which an oil or distillate fuel
is observed to flow, when cooled under conditions
prescribed by test method ASTM D 97.
3 Water, glycol, fuel oxidation, nitration, additive depletion
and soot are oil properties that can be analyzed by this.
4 The month that the RELIABLE PLANT 2011 conference
and exhibition will be held.
5 The term for compounds that repel water.
7 Company featured in this issue’s cover story.
9 A container for storage of liquid in a fluid power system.
10 Group III hydrocracked mineral oil and Group IV PAO
synthetic are considered this type of oil.
11 The term for compounds that have an affinity for water.
12 An imaginary line that divides the upper and lower
halves of gear teeth while in the contact area.
13 This staple of Machinery Lubrication magazine features
personality profiles of our readers.
Machinery Lubrication
WEB PREVIEW
Get More Information on
Our Publication Web Sites
E very day, thousands of industrial professionals
from around the world visit Noria Corporation
Web sites. See what makes these sites so popular
and so informative. Visit us today and every
day at www.machinerylubrication.com and
www.reliableplant.com.
Articles & White Papers
Lubricant Container Modification
Reduces Contamination Risk
Temple-Inland outlines how it reduced
contamination during refilling of oil top-up
containers by adding male quick-disconnects to
the lids and female quick-disconnects to the hose
coming from all the bulk oil drums. Find this
article in the Web Exclusives section on the
Machinery Lubrication site or type in “Lids” in the
ML Search bar.
Grease Analysis in the Field
Improves Plant Lubrication
If it is widely accepted that machinery lubrica-
tion is important, why are 50 percent of
premature bearing failures the result of bad lubri-
cation practices? Why spend time, effort and
money on high-quality bearings and sophisticated
mounting tools and then neglect lubrication? This
white paper presents some bad practices
commonly encountered in the field and explores
how monitoring of grease degradation can
improve overall lubrication efficiency. Find this
article in the White Papers section on the ML site.
Creating a Lean but
Effective Oil Analysis Program
This article explores alternatives to expensive
in-house test equipment, good utilization of
outside labs, oil storage solutions, methods of
reporting findings to further the program, and
selling the program to upper management as well
as to operations and maintenance. Find this
article in the Web Exclusives section on the
Reliable Plant site or type in “Saybolt” in the RP
Search bar.
Machinery Lubrication
Also
Education on the Road
Get all the details on Noria’s industry confer-
ences, seminars and other educational events,
including our RELIABLE PLANT 2011 conference
and exhibition (April 19-21 in Columbus, Ohio).
Click on the “Events” link at the top of the ML and
RP home pages.
Term Glossaries
Nearly 100 lubrication and oil analysis terms
are defined in the Glossary on the ML Web site.
Maintenance, reliability and lean terms are
defined on the RP Web site. Just click on the
“Glossary” link on the top of each home page.
Watch Videos
More than 175 free videos, vodcasts and
slideshows on lubrication and oil analysis topics
are available for viewing on the ML Web site.
Simply click on the “Videos” box on the ML home
page. Nearly 2,000 videos on maintenance, relia-
bility, lean, safety and manufacturing topics can
be found on the RP site.
Industry News
Stay informed by reading news stories posted
most every day. Check out the “Industry News”
box on each site’s home page. The RP Web site
features more than 22,000 news articles.
E-mail Newsletter
Sign up for Lube-Tips, Noria’s free lubrication-
related e-mail newsletter, which contains helpful
articles, tips, trivia and more. Just click on the
“Newsletters” link at the top of the ML home page
or visit www.lube-tips.com. Additional newsletters
are available via the “Newsletters” link on the RP
home page.
Subscription Services
Ensure that you will continue to receive award-
winning Machinery Lubrication magazine by filling
out the free subscription form. Click on the
“Subscribe” link at the top of the ML home page.
www.machinerylubrication.com November - December 2010 47
CERTIFICATION NEWS
Be Like INVISTA; Apply for
a Prestigious ICML Award
BY SUZY JAMIESON
A s the cover story in this issue of Machinery Lubrication maga-
zine shows, a strong commitment to machinery lubrication
pays off in many ways. For INVISTA, one particular way was being
recognized by the International Council for Machinery Lubrication
as the latest recipient of the John R. Battle Award. INVISTA joins
other industry visionaries such as Clopay Plastics, Valero Energy,
Cargill Corn Milling and Eli Lilly Company as a winner of this pres-
tigious award, which honors excellence in machinery lubrication.
The Battle Award – like its counterpart, the Augustus H. Gill
Award for Excellence in Oil Analysis – was developed by ICML for
the betterment of industry in a number of ways.
1)The awards criteria outlines critical areas in which companies
need to focus when developing or improving their machinery
lubrication and/or industrial oil analysis programs.
2) It benchmarks industry by identifying role model companies
that have exhibited excellence in applying machinery lubrication
or oil analysis in machine and lubricant condition monitoring.
3) It further recognizes champion organizations and their staffs,
which naturally become mentors for other companies and
staffs looking to improve the quality of their maintenance
organizations, and consequently their machines’ reliability and
overall asset management.
4) By focusing on facilities that have achieved this through the
application of machinery lubrication and oil analysis, it high-
lights the direct impact of such programs on the bottom line.
What’s in it for You
and Your Company?
The ICML awards bring to light what’s in it for companies that
elevate the profile of lubrication and analysis personnel.
The awards recognize lubrication and oil analysis as not only
required, but a valid and important technical field. They demon-
strate the need and the benefits associated with disposing of “oiler”
roles and installing skilled, educated professionals who are
supported by their companies in technical development.
Trained and certified technicians are respected and recognized by
these employers for their (and lubrication’s) crucial roles in the main-
tenance organization and the company at large. Such companies
48 November - December 2010 www.machinerylubrication.com
recognize that maintenance technicians (lubrication and oil analysis
ones included) are the walking, talking human factor of reliability
and asset management, ultimately holding the key to cost savings
that directly hit the bottom line. These firms have achieved by
dignifying the role of personnel involved in lubrication and oil
analysis and, as a result, have committed professional, capable
technical staff with buy-in (and the required skills) to elevate their
organizations to a best-in-class level. That means rewards to the
individual, the maintenance department, the company and to
society as a whole.
Here’s Your Call to Action
ICML hopes its mission will bring about the “retirement” of
oilers, lubricators and lubies and the advent worldwide of valued,
respected, supported, trained, certified and fairly compensated
lubrication technicians and oil analysts. It believes in the power this
has to not only better industry, but to better the careers and lives of
lubrication and oil analysis practitioners around the globe.
The awards are open to companies worldwide, independent of
any involvement with ICML. There is no fee to apply for the awards.
However, it is imperative to note that ICML cannot nominate a
company. ICML instead requires that the nominations come from
industry, with plant personnel nominating their facilities by submit-
ting an application.
If you know of someone doing a great job in the areas of
machinery lubrication and/or oil analysis – be it your own team,
peers, customers or industry in general – let them know about the
ICML awards and encourage them to get this most deserved pat on
the back. Also, let us know who they are so we can follow up with
them. ICML can only facilitate the betterment of our industry to the
extent that we all participate, so do get the word out and help the
council recognize worthy programs.
For more information on ICML or the awards and criteria, or to
download an awards application, visit www.lubecouncil.org or
e-mail info@lubecouncil.org.
John R. Battle Award Criteria
• Commitment to education
• Maintenance culture and management support
• Lubrication selection
Machinery Lubrication
 • Preventive, predictive and proactive maintenance effectiveness • Lube analysis strategies
• Metrics and performance tracking • Use of information technology
• Lubricant storage and handling • Plan for continuous improvement
• Routing sensory inspection for lubrication effectiveness
• Sampling for oil analysis Gill Award Recipients
• Contamination exclusion and removal • Palo Verde Nuclear Generating Station – Arizona Public Service
• Application systems of oil and grease (Wintersburg, Ariz.)
• Continuous improvement • J.R. Simplot Smoky Canyon Mine (Afton, Wyo.)
• Georgia Power – Southern Company (Branch, Ga.)
Battle Award Recipients • Kennecott Energy Maintenance & Reliability Group – Rio Tinto
• Clopay Plastic Products Company (Augusta, Ky.) (Meeker, Colo.)
• Valero Energy Corporation (Port Arthur, Texas) • Clopay Plastic Products Company (Augusta, Ky.)
• Cargill Corn Milling (Wahpeton, N.D.) • Great River Energy Coal Creek Station (Underwood, N.D.)
• Eli Lilly & Company (Indianapolis) • Energizer Battery (Maryville, Mo.)
• INVISTA (Victoria, Texas)
About ICML
Augustus H. Gill Award Criteria The International Council for Machinery Lubrication (ICML) is a vendor-
• Commitment to education neutral, not-for-profit organization founded to facilitate growth and
• Maintenance culture and management support development of machine lubrication as a technical field of endeavor. Among
its various activities, ICML offers skill certification testing for individuals in
• Performance measurements
the fields of machine condition monitoring, lubrication and oil analysis.
• Proactive/predictive maintenance ICML is an independently chartered organization consisting of both paid
• Standardized procedures professional staff members and volunteer advisors. It provides lubrication
• Integration of condition monitoring and oil analysis standard development support, scholarship, skill-based
• Contamination control testing and certification, and recognition of excellence. For more informa-
• Lubricant management tion about ICML, visit www.lubecouncil.org.

From Page 46

P
O O I L A N A L Y S I S B A S I C S
U H N P
R Y F I L T E R R
P D R I I
J O H N R B A T T L E A W A R D L N
I O R E V
N P E S W H I
T H D E H Y S
O A P R I D T
B N G I V I C T O R I A
M U L T I P A S S T E S T O E O
C L T C I P
Y T H R H
S J O U L E R A I S E
N E W T O N I A N K I L
S N N I
O E C
B R O K E N A R R O W

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Machinery Lubrication www.machinerylubrication.com November - December 2010 49

 CERTIFICATION NEWS

Recent Recipients of ICML Certifications

MACHINE LUBRICANT Jean Sewell Guillermo Rela Roy Burke Charles Holtz Janos Pattantyus
ANALYST – LEVEL I Lion Oil ANCAP Georgia-Pacific Alcoa Laurentide Controls
Joe Balderas Larry Welker Steven Reynolds Justin Burke Randy Jacobs Jeffery Pesek
DuPont Cliffs Natural Resources Entergy Alcoa Southwestern Petroleum Alcoa
John Bittinger Ryan Wright Hector Ariel Sarmiento David Cairns David James Matthew Peterson
Thilmany Papers Goldcorp Canada Cargill NV Energy Southwestern Petroleum DuPont
Lance Brown Manjit Singh Kimble Callahan Howard Jamieson
MACHINE LUBRICANT Stephen Polk
Constellation Energy Group Singh Teknik Janakuasa DuPont Alcoa
ANALYST – LEVEL II Georgia-Pacific
David Buck Paul Skubal Ian Campher George Johnson Sr.
Jeffery Aaron Mark Poremba
Clearwater Paper Luminant Power Pan Pac Forest Products International Paper
Luminant Power Georgia-Pacific
Carlos Alberto Bullon Daniel Spinks Steven Carter Troy Jones
Komatsu Mitsui Maquinarias Gonzalo Abad Fisher & Paykel Appliances DuPont Joshua Reimers
Cargill
Peru ANCAP Thailand Omaha Public Power District
Daniel Castillo Ji-Yoon Jung
Kimble Callahan Carlos Alarcon Richard Sullca Korea East-West Power Plant Doug Reiter
Minera Yanacocha S.R.L.
DuPont Ferreyros S.A.A. SKF del Peru Wells Dairy
Johnny Chirinos Joe Justis
Brad Dahl Norsham bin Amin Mark Tarbet Alcoa Bob Reiter
Votorantim Metais
Goldcorp Canada Shell MDS Luminant Power Southwestern Petroleum
Will Clements Bill Kemp
Grant Donesley Hongkyun An Luis Turin Southwestern Petroleum James Reynolds
Mighty River Power
Chevron Phillips Chemical Korea Plant Service & Pluspetrol Energy S.A. PCA
Jonathan Clouser Tae Guol Kim
Engineering
William Dunbar Aidil Hilal bin Udin J.R. Simplot Hyosung Ebara Gerald Riner
Haas TCM Mauricio Aspilcueta Malakoff
Drake Compagna Tae Seung Kim Georgia-Pacific
Yura S.A.
Wayne Feazel Pedro Villena Cargill Hannam Techno Mitchell Roberts
Lion Oil Juneyoung Bae Spectro SA
Charles Connell Myeong-Su Kim Southwestern Petroleum
Solge Corporation
Eder Gago Anthony Wilson Firscomp
Pablo Guillermo Bazán PCA Kirk Ross
SKF del Peru Entergy Matt Krommenhoek
Pluspetrol Energy S.A. Anthony Conte DuPont
Steve Garner Kang-il Yun Wells Dairy
John Bonner Southwestern Petroleum Eads Russ
Clearwater Paper LG Chem Robert Lauer
Luminant Power Randy Counce Holcim
Michael Gilbert PCA Southwestern Petroleum
Jordan Cortes MACHINE LUBRICANT Francisco Saldivia
DuPont Kye-Hong Lee
Minera Esperanza ANALYST – LEVEL III Shane Coyle Unexpo Venezuela
Richard Hassebrock Wells Dairy Korea East-West Power Plant
Jesus Cruz Kurt Bittner Roy Alfredo Sanchez
BP Lubricants USA Myung-Ha Lee
Organizacion Terpel S.A. PSEG Nuclear Jessica Daily Minera Yanacocha
Keith Haukereid
American Electric Power Korea East-West Power Plant
Justin Draughn Danny Franklin Kelly Schatz
Peabody Energy Chun Ho Lee
Entergy PSEG Nuclear Phil Dawson Cargill
Phillip Hicks Korea East-West Power Plant
Ernesson Fernandez Andrea Kousal PCA
DuPont James Leonard Randy Seaton
Holcim Philippines Kousal SA Bruce Delainey
Ken Hicks J.R. Simplot PCA
Ronnie Guarin Mike Johnson Cargill
Holcim Ryan Maes Adam Serwinski
Petron Corporation AMRRI Gary DeLashmutt
Russ Holindrake Cargill Lubrication Engineers
Sergio Gutierrez Daryl Kelly Wells Dairy
Wheeler Caterpillar Matthew Malone Jean Sewell
Minera Esperanza Dalrymple Bay Coal Terminal Christopher Diener
Frank Karr Buzzi Unicem Lion Oil
Kyoung Hun Han Jeff Tucker Southwestern Petroleum
American Electric Power Serge Marsan Jack Short
Korea Plant Service & International Paper Greg Dinger
Rafael Lainez Engineering Rotating Equipment DuPont
Southwestern Petroleum
Cementos del Norte S.A. MACHINE LUBRICATION Consultant
Ronald Henderson Jerremy Donoho Alan Sine
Justin Lewis Entergy TECHNICIAN – LEVEL I Donald Marsh Southwestern Petroleum
PCA
ConAgra Foods Richard Altizer Mirant
Bo-Yon Jo William Dunbar Craig Smith
Georgina Leyte Korea East-West Power Plant Southwestern Petroleum Bruno Massari
Haas TCM Georgia-Pacific
Holcim Tyler Angell Minera Yanacocha
Min Chul Kim Darrin Earis Michael Smith
Adam Marshall Korea East-West Power Plant Cargill Daniel McArdle
Cargill PCA
Cyclone Drilling William Anson Rio Tinto
Jounghyum Lee Alan Fariss
Marvin McCoy Scott McCarley Pablo Solano
Korea Plant Service & Southwestern Petroleum
PSEG Nuclear PCA International Paper Wells Dairy
Engineering Talmadge Austin
Michael McLagan Wayne Feazel Victor Mendoza Hamish Speedy
Robert Luetge DuPont
Peabody Energy Lion Oil Alcoa Pan Pac Forest Products
Luminant Power Fernando Balboa
William Miller III Andre Gagnon William Messer Eric Straub
Jacob Meyer Alcoa
Cashman Equipment Southwestern Petroleum International Paper MRG Labs
Luminant Power Joe Balderas
Aaron Murphee Patrick Garrett James Miller Kenne Talley
Towny Mosley DuPont
Lubrication Engineers Alcoa Southwestern Petroleum PCA
Entergy Donald Barksdale
Kent Olivier Southwestern Petroleum Michael Gilbert Kevin Miller
Leonel Nardoni Mickey Thornton
Cargill DuPont J.R. Simplot
Ternium Siderar Brian Baros International Paper
Larry Owens Van Pajo Alcoa Jeff Gonsoulin Todd Moody Richard Troxclair
International Paper Holcim Philippines Southwestern Petroleum Georgia-Pacific
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Matthew Peterson René Paredes Alcoa V. Gonsoulin Michael Morris
Southwestern Petroleum Scott Wendel
DuPont Hidro San Joaquin Trent Beebe PCA
Southwestern Petroleum
Hugh Piercy Jin-Kyung Park J.R. Simplot Bruce Graham Aaron Murphee
Alcoa Wilbur Wimberly
Chevron Phillips Chemical Solge Thad Beebe Lubrication Engineers
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Sabic Innovative Plastics PCA Georgia-Pacific Kevin Yelle
Luminant Power Bruce Benson
Brian Hafeman Laurentide Controls
Kyle Richardson Walter Pedro Lubrication Technologies James Nelson
Unicco Lanxess William Bittner SFK Pulp Cargill
MACHINE LUBRICATION
Frank Rogers Javier Omar Piazza Georgia-Pacific Todd Hanson Brian Nelson
Southwestern Petroleum TECHNICIAN – LEVEL II
Luminant Power Ternium Siderar William Boyd Lubrication Engineers
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Georgia-Pacific Cargill Alcoa Laurentide Controls
Lanxess Bryan Breland
Eads Russ Ralph Pollan Georgia-Pacific James Herring Lee Oakley David Piangerelli
Holcim Entergy Georgia-Pacific PCA Lubrication Technologies
Darryn Brown
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Southern California Edison CEMEX Solid Cement America (PCA) Holcim Alcoa Wells Dairy
Adam Serwinski Jayson Ray Chris Bumphus Lee Sang Ho Sam Patronella Jeff Tucker
Lubrication Engineers Luminant Power PCA GS Caltex DuPont International Paper

50 November - December 2010 www.machinerylubrication.com Machinery Lubrication

BACK PAGE BASICS
Here’s the Skinny on Picking
Compressor Lubricants
JEREMY WRIGHT
NORIA CORPORATION
N early all compressors require a form of lubricant to either
cool, seal or lubricate their internal components. Only static
jet compressors (ejectors) and late-20th-century and early-21st-
century oil-free machines with rotors suspended in magnetic or air
bearings are exempt from the need for some type of lubrication.
This article deals with the lubrication of dynamic, reciprocating and
rotary compressors. These three types are the most prevalent in
industry today.
Compressors are manufactured in several types and for a variety
of purposes. In addition to being used to compress gas, many
compressors serve as blowers or can be used as vacuum pumps.
Lubrication requirements vary considerably, depending not only on
the type of compressor but also the gas which is being compressed.
In general, air and gas compressors are mechanically similar. Thus,
the main difference is in the effect of the gas on the lubricant and
the compressor components. The lubricant plays a role in
preventing wear, sealing, minimizing reactions with the gas and
preventing corrosion. Refrigeration and air conditioning compres-
sors require special consideration because of the recirculation of
the refrigerant and mixing of the lubricant with that refrigerant.
Defense Mechanisms
To combat all of these stressors, a compressor lubricant needs
several defenses. Oxidation and thermal stability are very important
– along with corrosion inhibitors, detergents, demulsifying agents
and foam suppressors – to increase the life of the machinery.
As mentioned, not only does compressor design have an effect
on lubricant selection, so does the gas being compressed. The four
popular categories of compressed gasses are: air, hydrocarbon,
chemically active and chemically inert. Dependent upon these cate-
gories, special considerations must be made when selecting the
proper lubricant. At the very least, all should have:
• Long life without need for changeout (high oxidation stability)
• Prevention of acidity, sludge and deposit formation
• Excellent protection against rust and corrosion, even during
shutdown
• Good demulsibility to shed water that enters the lubrication
system
• Easy filterability without additive depletion
• Good foam control
52 November - December 2010 www.machinerylubrication.com
Synthetic Lubricant Options
Because of the system stressors and the quality needed to
combat them, synthetic lubricants are preferred. The three popular
synthetics are polyalkylene glycol (PAG), esters (diester and poly-
olester), and polyalphaolefin (PAO).
PAGs offer the ability to dissolve sludge and deposits, burn
without leaving residues when degraded, have a low solubility with
hydrocarbons, and have good hydrolytic stability. Their downfall is
that they absorb vast amounts of water and have very poor
compatibility with mineral and PAO oils.
Esters have a very high detergency and solvency, making them
excellent at dissolving sludge and deposits. They are compatible
with mineral and PAO oils, and most seal and gasket materials.
However, they also absorb moisture from the air and are hydrolyti-
cally unstable at high temperatures.
PAOs are most similar to minerals, so they are very compatible.
They also are generally compatible with seals and gasket materials.
They offer excellent hydrolytic stability, low water solubility and
poor solvency. Because of this poor solvency, avoid these in appli-
cations where high discharge temperatures are present. They have a
tendency to form deposits in these situations.
Making the Right Selection
There are many variables when selecting a compressor lubricant.
Even though I only skimmed the surface of these variables, I hope
you now have an appreciation of the art of lubricant selection for
compressors. It is not as easy as simply selecting the product
denoted as “compressor lubricant”.
Reference
Heinz Bloch, “Compressor Lubrication Best Practices”. Machinery
Lubrication magazine. May 2003.
About the Author
Jeremy Wright is a senior technical consultant with Noria Corporation. He
serves as a senior engineering consultant for Lubrication Process Design proj-
ects and a senior instructor for Noria’s Fundamentals of Machinery
Lubrication and Advanced Machinery Lubrication training. His client list
includes companies such as DuPont, Dow Chemical, Michelin, Pactiv, Westar
Energy, International Paper, Rio Tinto, Gerdau AmeriSteel, ExxonMobil,
CITGO and Gulf Chemical. He is a Certified Maintenance Reliability
Professional through the Society for Maintenance and Reliability Professionals,
and holds Machine Lubricant Analyst Level III and Machine Lubrication
Technician Level I certifications through the International Council for
Machinery Lubrication. Contact Jeremy at jwright@noria.com.
Machinery Lubrication