CONTENTS March - April 2011
machinerylubrication.com Features in Detail
As I See It The Power of the Patch Jim Fitch explains the decades-old practice of transferring suspended particles to the surface of a membrane for analysis.
The Exponent Integrating Oil Analysis and Vibration Analysis Drew Troyer shares several philosophies for pairing oil analysis and vibration analysis for managing the reliability of common mechanical equipment in your plant.
20 Hydraulics at Work The Holy Grail of Hydraulics Brendan Casey explains how hydraulic troubleshooting can be challenging at times, but in the majority of cases it’s usually straightforward.
24 Get to Know… 8
Cover Story Lubrication Lifesaver Stephen Summerlin offers 10 ways to help improve lubricant storage and handling. Proper lubrication isn’t just about the right amount at the right time at the right place, it’s also about keeping lubricants clean, cool and identified.
On the Front Line Meet ConAgra employees John Adam and Jodie PrietoSalazar: they are just a portion of their company’s lube team that is helping to implement a lubrication plan designed to lengthen the life of their company’s equipment.
28 Lube-Tips Readers Supply Super Solutions and Sound Suggestions Our readers provide excellent advice on a host of lubrication-related issues.
30 Practicing Oil Analysis How to Select Machine-Specific Oil Analysis Tests Ashley Mayer examines the typical classes of oil-lubricated industrial machinery and the tests that are most commonly available.
36 In the Trenches
Editorial Features 2 6 20 24 28
As I See It The Exponent Hydraulics at Work Get to Know ... Lube-Tips
Departments 30 Practicing Oil Analysis 38 Test Your Knowledge 40 Certification News 44 Back Page Basics
18 22 27 39
Product News Product Supermarket Bookstore Crossword Puzzler
Proper Lubrication Means Less Visits from Your Parts Vendor Clopay Plastics lube tech Scotty Lippert explains how proper lubrication techniques have helped slow down parts replacement.
44 Back Page Basics The Real Story on Automotive Filters Jeremy Wright explains the anatomy of an automotive oil filter. March - April 2011 1
AS I SEE IT
The Power of the Patch Comparing Particle Analysis Methods Using Membranes JIM FITCH NORIA CORPORATION
he practice of transferring suspended particles to the surface of a membrane for analysis has been around for decades. It is perhaps the earliest method for inspecting solid contaminants and wear debris in a used sample of oil. It is of no surprise that these methods have enduring use today. In fact, some are the basis of recently adopted standardized methods by ASTM and ISO. While membrane-based procedures for preparing particles for analysis can be time consuming and messy (usually involving the use of glassware and solvents), the benefits can be substantial compared to alternative methods. The main advantage is the ability to both quantitatively and qualitatively describe particle contamination, depending on the method used. As in the case of microscopic particle counting, you see what you’re counting and can confirm visually what appears to be a particle. You can also characterize particle type (e.g., dirt, wear debris, rust, fibers, etc.). Because of the importance of these techniques to a modern and well-engineered oil analysis program, it seemed like a good time to review the options. There are actually eight different methods that are worth mentioning. Most have previously been covered in Noria publications, but a couple have not. We’ve used all but one of these methods in our failure investigation work here at Noria. A narrative of the methods is provided below and a summary that compares and contrasts them is shown in Table 1.
Patch Test One of the main benefits of this method is its low cost, simplicity and portability. An aliquot of oil is pushed through a 4-5 micron membrane by positive pressure or pulled by vacuum (syringe, sample pump or vacuum pump) after the sample is diluted in solvent. Particles larger than the pore size remain on the membrane’s surface for later inspection. Low power microscopes can be used for this, but often the patch is simply examined without magnification using patch comparators. An excellent comparator with a convenient scale is sold for use with fuel samples based on ASTM D2276. This comparator can be used for oils as well. Because of the amount of fluid filtered in patch testing, the debris is typically too dense on the patch to attempt to count or characterize individual particles. 2 March - April 2011
A comparator with a convenient scale is sold for use with fuel samples based on ASTM D2276. It can also be used for oils.
Microscopic Particle Count This method predates today’s popular automatic particle counters by decades and is still supported by standards organizations today (e.g., ISO 4407). Unlike the patch test, far less fluid is pushed through the membrane to enable sufficient spacing between particles so that they can be more easily sized and counted. Typically, particles are sized by the longest cord (longest projected dimension of an irregularshaped particle). On average, the longest cord is dimensionally about 1.3 times larger than particles measured using the equivalent spherical diameter (optical methods). Understandably, the procedure is unpopular among technicians who are asked to perform the tedious task of counting particles one at a time. However, the ability to obtain both a particle count (including ISO Codes) and a photomicrograph of the particles is inarguably a comprehensive assessment of total solids. Some labs run microscopic particle counts on exception, i.e., only after a high reading from an automatic particle counter.
Patch Ferrography This method is almost identical to microscopic particle counting, but combines various particle identification and characterization techniques. These include the use of bi-chromatic microscopy, magnetism and assessment of particle color, texture, shape and size. In this sense, it is very similar to analytical ferrography, where particles are magnetically and gravitationally deposited on a glass slide called a
ferrogram. However, with patch ferrography, a cellulose nitrate membrane is used, called a filtergram. A clarifying solution is applied to enable both bottom and top lighting to be used during examination. Unlike ferrograms, heat treatment of the particles and chemical microscopy are not practical options. Patch ferrography is particularly popular for samples having non-ferromagnetic wear particles (brass, aluminum, Babbitt for instance). Additionally, unlike ferrograms, particles don’t generally pile or clump (obscuring them from view).
Gravimetric Analysis Just as the name implies, gravimetric analysis uses a laboratory scale to weigh particles and sediment on a membrane (typically 0.45 microns). No attempt is made to count, size or visibly characterize the particles. Often, the particles on the membrane are dominated by organic “soft” particles such as resins from oxidation, sludge and additive degradation. Some laboratories use a series of solvent washes of various polarities to extract soluble fractions from the membrane in an effort to approximate composition. Common solvents used for this purpose include pet ether, toluene, trichloromethane and methanol.
In Loving Memory Dr. Ernest C. Fitch, Ph.D., a pioneer in developing hundreds of test procedures relating to tribology, contamination control and fluid power, died March 16, 2011, at the age of 86 at his home in Stillwater, Okla. His son, Jim Fitch, is the CEO and co-founder of Noria Corporation. Dr. Fitch received his Bachelor of Science in engineering in 1950 and Master of Science in mechanical engineering in 1951, both from Oklahoma State University. He received his Ph.D. in Engineering Science in 1964 from the University of Oklahoma. He began his engineering career as a journeyman machinist before entering the military in World War II. After receiving his master’s degree he set out to gain practical experience by taking jobs with Jersey Production Research, Boeing Aircraft, Deere and Company, Cincinnati Milacron and Cessna Fluid Power. During his 35 years on the faculty of Oklahoma State University, he advised more than 100 doctoral and master degree students and countless undergraduate students. In order to provide a hands-on research opportunity for his students, he started a contract research center in 1956 that became the Fluid Power Research Center (FPRC). At least 160 industrial companies and governmental agencies sponsored research that provided financial support for his students. For 18 years Dr. Fitch headed teams of research engineers in developing hundreds of test procedures relating
Particle Micro Patch Imaging (PMPI) Optical imaging methods have been developed that rapidly scan and digitize particles on a membrane for analysis by computer algorithms. As of this writing, there are three such products that are commercially available with varying degrees of capability. These instruments are based on ISO 16232 7/8 and can size particles either by longest cord or equivalent spherical diameter. Additionally, because each particle is individually imaged, they can be categorized by shape and further inspected visually by the analyst if needed. Basically, the PMPI offers the benefits of both microscopic particle count and patch ferrography without the hassles of having to count, size and categorize individual particles manually.
Filterability Some lubricant formulations have been found to restrict flow through fine filters (one to three microns), leading to premature plugging. The problem most commonly associated with insoluble additives include degraded additives from in-service exposures such as heat and water (hydrolysis). To gauge this characteristic, filterability testing is to tribology, contamination control, and fluid power. Many of these procedures have since become national and international standards. He served as a member and chairman of half a dozen standards committees including SAE, ANSI, NFPA and ISO. During his career, Dr. Fitch co-founded several companies providing services relating to hydraulics, tribology and contamination control. He also served on more than 250 consulting projects, nearly 200 court cases and has written more than 210 technical articles and 20 books. He was been awarded 16 U.S. and 15 foreign patents and from the 1960s through the 1980s, he has served as editor-in-chief of three international technical journals. Dr. Fitch was Emeritus Professor of Mechanical and Aerospace Engineering at OSU. He has received 15 major honors and awards from state, national and international professional organizations.
PUBLISHER Mike Ramsey - email@example.com GROUP PUBLISHER Brett O’Kelley - firstname.lastname@example.org EDITOR-IN-CHIEF Jeff Billington - email@example.com SENIOR EDITOR Jim Fitch - firstname.lastname@example.org TECHNICAL WRITERS Jeremy Wright - email@example.com Stephen Sumerlin - firstname.lastname@example.org CREATIVE DIRECTOR Ryan Kiker - email@example.com GRAPHIC ARTIST Kam Stinnett - firstname.lastname@example.org Gustavo Cervantes - email@example.com Julia Backus - firstname.lastname@example.org ADVERTISING SALES email@example.com Phone: 800-597-5460 MEDIA PRODUCTION MANAGER Rhonda Johnson - firstname.lastname@example.org CORRESPONDENCE You may address articles, case studies, special requests and other correspondence to: Editor-in-chief MACHINERY LUBRICATION Noria Corporation 1328 E. 43rd Court • Tulsa, Oklahoma 74105 Phone: 918-749-1400 Fax: 918-746-0925 E-mail address: email@example.com
SUBSCRIBER SERVICES: The publisher reserves the right to accept or reject any subscription. Send subscription orders, change of address and all subscription related correspondence to: Noria Corporation, P.O. Box 47702, Plymouth, MN 55447. 800-869-6882 or Fax: 866-658-6156. 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 © 2011 Noria Corporation. Noria, Machinery Lubrication and associated 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 any representations, warranties, express or implied, regarding the accuracy, completeness or suitability, of the information or recommendations provided herewith. Noria shall not be liable for any injuries, loss of profits, business, goodwill, data, interruption of business, nor for incidental or consequential merchantability or fitness of purpose, or damages related to the use of information or recommendations provided. POSTMASTER: Send address changes and form 3579 to Machinery Lubrication, P.O. Box 47702, Plymouth, MN 55447. Canada Post International Publications Mail Product (Canadian Distribution) Publications Mail Agreement #40612608. Send returns (Canada) to BleuChip International, P.O. Box 25542, London, Ontario, N6C 6B2.
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VOLUME 11 - NUMBER 2
AS I SEE IT
sometimes performed on the new oil. The test is conducted by passing dry or wet oil through a membrane until a certain terminal pressure drop is reached. The volume of oil that passed relative to the surface area and micron size of the membrane quantifies the filterability rating (there are several variations of the method).
Pore Blockage Automatic Particle Counter There are three particle counters on the market that estimate particle size and concentration based on membrane pore blockage. The instruments use either constant pressure oil flow through the membrane and measure flow decay or use constant flow and measure pressure rise. The profile of the flow decay or pressure rise is used to estimate particle counts. The membranes used by these instruments can be used over and over. As with optical particle counters, no information is provided on the shape or composition of the particles. However, unlike optical counters, pore blockage instruments can be used with dark oils and oils with emulsified water. They have performance limitations as well.
Membrane Patch Colorimetry (MPC) Often called a varnish potential test, MPC uses a 0.45 micron membrane to collect organic and inorganic insoluble oil suspensions.
Particle Count/ISO Code Particle Shape and Characterization Overall Color and Concentration Submicron Particles Quantification of Total Insolubles Soft Insolubles Characterization Soft Insolubles Quantification Wear Debris Analysis Membrane Diameter (mm) Membrane Pore Size (μm) Fluid Volume (ml) Instrument Cost
The apparatus is identical to a patch test kit, but the sample preparation is different. Afterwards, the membrane is analyzed by spectrophotometry to get a CIE LAB E value (color scale). Optionally, the membrane can be weighed and the gravimetric value reported. Additive floc, oxide-insolubles, carbon resins and similar soft contaminants all contribute to the MPC reading. The procedure is gaining popularity with the proliferation of varnish and sludge problems in recent years. An ASTM standard is pending approval. So that’s a short summary of membrane-based particle analysis methods. Many of these methods can be used onsite in addition to commercial laboratories. The basic patch test kit is small and inexpensive enough to be brought to the field. When used in the correct application, they can all enhance value from a condition monitoring program.
About the Author Jim Fitch has a wealth of “in the trenches” experience in lubrication, oil analysis, tribology and machinery failure investigations. Over the past two decades, he has presented hundreds of courses on these subjects. Jim has published more than 200 technical articles, papers and publications. He serves as a U.S. delegate to the ISO tribology and oil analysis working group. Since 2002, he has been director and board member of the International Council for Machinery Lubrication. He is the CEO and a co-founder of Noria Corporation. Contact Jim at firstname.lastname@example.org.
Microscopic Particle Count
Particle Micro Patch Imaging (PMPI)
SAE ARP 4285
Pending ASTM standard
ASTM F312-08 ASTM D4898 - 90 FTM-3009 ISO 4405 Yes No
Pore Blockage Particle Count
Membrane Patch Colorimetry (MPC)
ASTM D7670 FTM 3012/3 Estimate
Table 1. Several particle analysis techniques can be used to maintain a modern and well-engineered oil analysis program. 4 March - April 2011
Integrating Oil Analysis and Vibration Analysis – Machine By Machine
il analysis and vibration analysis are natural partners for machine condition monitoring. This, unfortunately, hasn’t always been the perception. In the early days of the modern condition monitoring era, these two powerful technologies were viewed to be in competition with one another – vying for the same condition monitoring resources. Time has allowed most people and organizations to see the value of integrating vibe and oil. For root cause management, they team up to provide control over the “big five” root causes of machine failure. Vibration analysis enables the control of balance, alignment and looseness. Oil analysis enables control over lubricant quality and contamination. They are also a great pairing on the predictive side of condition monitoring. The strengths of vibration analysis counteract the limitations of oil analysis and vice versa in managing the health of specific machine types. In this issue, I’m going to share some philosophies for pairing oil analysis and vibration analysis for managing the reliability of common mechanical equipment in your plant. These short vignettes are by no means comprehensive, but rather are intended to make you think so you can start to formulate your integrated condition monitoring solution for mechanical plant equipment. I’m covering enough types to ensure that you get the idea and can think through your specific applications.
Gearboxes Just about every plant in the world employs gearboxes. A gearing application is a rough application for most lubricants because of the high heat, aeration and the presence of chemically active particles, such as brass and steel. Also, contaminants are always present that weaken the lubricating film strengths and interfere with critical lubricant film clearances. Likewise, misalignment, unbalance and looseness are a risk to a greater or lesser degree depending upon the configuration of the machine train and what the gearbox is coupled to and the coupling mechanism. As with most machines, vibration analysis and oil analysis are required for proactive control over the root causes of mechanical wear and failure. As previously mentioned, the proactive aspects of integrated condition monitoring apply to most of the machine types discussed herein – gearboxes are our example and are certainly no exception to the rule. Occasionally, gears go bad. The most common failure modes are gear tooth wear and gear tooth fracture. Detecting wear-related gear faults with vibration analysis can be challenging because there 6 March - April 2011
are so many competing vibration signals – particularly at slow speed, where the amplitude of the vibration signal may not be strong enough to overcome the noise factor. However, oil analysis provides excellent resolution in detecting contact fatigue, abrasion and adhesive wear, making it a great choice for the early detection of these failure modes. If a gear tooth breaks away from the shaft, it is unlikely that the failure will produce a detectable concentration of wear particles – particularly if the failure is caused by a sudden impact or defective material. However, monitoring the gear mesh frequency with vibration analysis will nail a broken tooth each time. Together, vibe and oil analysis make a powerful combination for managing the health of gearboxes.
Paper Machines Having cut my teeth in oil analysis, I have always struggled with paper machines. We like to collect return line samples where we get a high concentration of information about the bearings before the oil goes to the tank. The problem is that a paper machine has hundreds of these bearings. If you collect a sample from the common return line header, the information generated from any single bearing gets lost. And, it’s impractical to set up 200 bearings for routine individual return line sampling. Paper machines employ rolling element bearings – a real strength for vibration analysis. My approach - I like to sample the oil going to the bearings to make sure the oil is clean, dry and healthy. Then, I rely on vibration analysis to monitor the condition of the individual bearings themselves. The advanced player installs sampling valves on the individual return lines from each bearing, but only samples them on-condition – when vibration analysis or some other condition monitoring technology points to a problem. We typically analyze these samples qualitatively using particle microscopy to evaluate the nature and severity of the event. This helps with planning and scheduling, prioritization and cause analysis.
Oil Lubricated Centrifugal Pumps Like paper machines, pumps have rolling element bearings – making them a natural for vibration analysis. However, because they are small-sump systems, they get a great concentration of wear
debris. For sump lubricated systems, sampling often constitutes an oil drain, which can be tricky when the pump is operating. For these systems, I prefer to employ a statistical sampling approach to time oil drains and manage contamination and rely on vibration analysis for primary machine condition monitoring. Much like paper machines, we can install valves on pumps to sample on-condition to aid in troubleshooting.
Grease Lubricated Electric Motor Again, these are usually rolling element bearing applications – a strength for vibration analysis. Traditionally, I would rely solely on vibration analysis to monitor a motor’s mechanical condition. However, with the advent of “Grease Thief” sampling devices, we can now extract a reasonably representative sample of grease to detect mixing, grease degradation and wear particles.
Reciprocating Combustion Engines Vibration analysis is the primary condition monitoring tool for grease lubricated electric motors, but oil analysis owns condition monitoring for reciprocating combustion engines, irrespective of fuel type. Engines simply create too many different vibrations for traditional vibration analysis to be effective. Oil analysis, on the other hand, is ideal for the application for several reasons. First, the combustion process itself must be monitored to detect excessive soot generation and fuel dilution of the lubricant. Also, we must always be watching for coolant contamination, which severely compromises lubrication. Because engines are enclosed, wet-sump lubrication systems oil analysis effectively identifies ring, liner, bearing and other sources of wear with a high degree of effectiveness. For mobile plants, oil analysis is the primary condition monitoring tool for the entire drive train. For fixed equipment, vibration is useful for monitoring the health of other parts of the machine train (e.g., generators and pumps).
Hydraulic Systems Hydraulics systems are the most difficult to typify because they can take so many different forms. Some have gear pumps, others employ vane pumps and still others are equipped with axial piston pumps. Speeds and load vary as a function of the application and
the machine’s duty cycle. Some are equipped with cylinders, while others utilize motors. It’s really all over the board. Oil analysis is generally the lead technology for hydraulic systems, assuming we can obtain a return-line sample before the filter. However, vibration analysis is useful for vane pumps, gear pumps, drive motors and hydraulic motors, assuming we can fix speed and load during the sampling process over time. Vibration analysis is not useful for monitoring cylinder health or axial piston pumps. A note on piston pumps, a case-drain sample is often preferred for monitoring the health of the pump because debris shelled out by the pump tends to concentrate there.
Slow-Speed, Grease-Lubricated Pillow Block Bearings Pillow block bearings are a challenge all the way around. While they are typically rolling element bearings, the low speed makes it difficult to detect problems with vibration analysis until very late in the failure process. Likewise, because they’re grease-lubricated, the challenge in gathering a representative sample creates a challenge for oil analysis. The new Grease-Thief sampling method helps to overcome some of these challenges. Once considered enemies in the battle for scarce condition monitoring resources, we now view oil analysis and vibration analysis as essential complementary condition monitoring methods for managing the reliability of the entire plant. Both are required to manage the “big five” root causes of machine failure. And on the predictive side of condition monitoring, the strengths of oil analysis help to overcome the limitations of vibration analysis and vice versa. It’s truly a match made in engineering heaven! 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” experience, 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 accomplishments in economic terms that are familiar and important to senior managers, the investment community and company shareholders. Troyer is the president of Sigma Reliability Solutions. Contact Drew at email@example.com.
March - April 2011 7
ways to improve lubricant storage and handling
BY: STEPHEN SUMERLIN, NORIA CORPORATION
or a complete and proper lubrication program to work effectively and provide the most return on investment, the entire gamut of lubrication must be considered, ranging from receiving to application. Through this gamut there are missed opportunities to increase equipment productivity and reliability and to maximize the returns of investing in a professionally designed lubrication program. One of the biggest and most costly missed opportunities is proper lubricant storage and handling. Many facilities are unaware of the danger improper lubricant storage and handling practices create and what inevitable fate it can lead to in terms of equipment reliability and lifecycles. Proper lubrication is not only about the right amount-at the right time-at the right place, it is also about keeping lubricants clean, cool and properly identified. Here are some tips to help outline the best practices for proper lubrication storage and handling:
1. Lube Room Design and Requirements A properly designed lube room must be functional, safe and expandable, and provide all necessary storage and handling requirements for the facility. Lube room designs should allow the maximum storage capacity without allowing for too much bulk oil and grease
Illustrated by: Gustavo Cervantes
8 March - April 2011
March - April 2011 9
Above, proper design and functionality are a must when designing a lubrication storage and handling room.
storage. Limiting the amount of bulk oil and grease storage will allow the oils that are stored to be used in a timely manner. Some key features to consider are a limited access door, which will allow for logging of who and when a lube technician enters and leaves the room; visible landing area for new lubricants; log all new lubricant deliveries; make filtration of stored lubricants easy; provide proper safety devices; designate enough floor space for fire proof storage cabinets to store top-up containers, grease guns, etc.; and include a desk and computer to track inventory, sampling, filtration, receiving, etc. It also is a smart idea to have a separate storage area to store bulk totes, drums, buckets, etc.
2. Bulk Oil Storage The first area of a lubricant storage and handling system that requires attention is bulk storage. Whether storing lubricants in a 10,000-gallon tank or 55-gallon drums, it is very important to ensure the lubricantsâ€™ quality is not tainted by contamination or additive settling. To help ensure lubricants stay in an optimal condition, one must determine how much lubricant should be stored at one time. To aid in this process, certain steps can be employed, such as: A. Determine lubricant consumption rate. Consumption will vary greatly depending on industry and equipment type. To ensure the right quantities of lubricants are being stored at a facility, the consumption rate must be determined. There are many factors that contribute to consumption, ranging from leaks to excessive drain and fills. 10 March - April 2011
A large bulk storage area must require the same attention as smaller areas, constructed to ensure the lubricant is not tainted by contamination or additive settling.
B. Determine lubricant storage capacity. The required lubricant storage capacity depends on consumption, but often there are too little or too many lubricants stored at one time. The proper storage capacity should maximize shelf life but allow for a certain percent excess of critical lubricants to be stored for emergency situations. C. Determine lubricant supplier turnaround time. A lubricant supplierâ€™s turnaround time should be a metric used to aid in determining the quantity of lubricants stored. If there is a short time interval between deliveries, fewer lubricants can be stored onsite, but if there is a lengthy time interval between deliveries, the quantity of lubricants stored onsite should account for this. Once the consumption rate and storage capacity have been determined, one should decide what type of storage containers will be used. The correct size storage container is a direct reflection of the consumption rate and storage capacity. If a large consumption rate is determined, a large bulk storage tank may yield the best results, but if a low consumption rate is determined, a rack mounted storage system or 55-gallon drums may yield the best results. For smaller facilities that have a small consumption rate, the use of drum storage may be the best option.
3. New Oil Receiving Oftentimes, improper receiving techniques do nothing but promote higher risks of contamination ingression, mixing of lubricants, etc. Proper written receiving procedures should be in place to
ensure the highest level of consistency and cleanliness is maintained. Proper receiving techniques should include filtration of incoming oils. Many times new oils may be dirtier than your defined particle target cleanliness level. Meaning, if you define your particle target cleanliness level and spend time, money, manpower, etc., to achieve these levels of in-service lubricant cleanliness, the last thing you want to do is contaminate it with â€œdirtyâ€? new oils.
4. Quality Control Quality control of lubricants delivered from lube suppliers must be verified to ensure the correct product is being delivered and that the cleanliness of the delivered lubricant are up to current target particle and moisture cleanliness levels.
To help ensure your lubricants are meeting their standards, the use of oil analysis is a powerful tool and will reveal the following: 1. Quality of base stocks 2. Additive quality and concentration 3. Lubricant performance properties 4. Thickener performance properties (grease)
5. Presence of Mixed or Contaminated Lubricants Oil analysis results and other quality assurance variables, such as damaged containers, rusted containers and any other quality issue, should be well documented and cataloged. Items to note in the documentation phase are: 1. Delivery date and date of oil sample taken 2. Inspection results of storage containers 3. Labels depicting results of oil analysis test 4. Itemized checklist for sampling test 5. Periodic decontamination with filtration Whichever storage container is chosen, it is best to filter the new oil while filling the storage container. Doing so will reduce the amount of contamination that is delivered with the new oil, but periodic filtration and agitation should be performed to maintain certain ISO cleanliness levels and prevent additive settling. Periodic filtration is a good practice to ensure clean, fresh oil will be used to perform top-ups and drain and fills. There are two primary methods for filtration of bulk stored oils: hard plumbed filtration system or filter cart. The hard plumbed filtration system works best in conjunction with a rack mounted system. Each container should be fitted with a breather, sight glass, filter, lubricant label, quick connect fittings and dedicated dispensing line. This system will help ensure the lubricants are at optimal condition when they are needed and the right product for the application is dispensed. Periodic filtration for drum storage also is easy with the use of a filter cart once the drums are equipped with quick couplers. No matter how large or small the storage container, periodic decontamination should be a priority to maintain the quality of the stored lubricant.
6. Dispensing Options for Stored Oils
Common ways oil can become contaminated 12 March - April 2011
When stored oil is transferred from the bulk storage system to the top-up container, it is best to filter the dispensing oil. This can be made very easy with the use of a hard plumbed filtration system and a rack mounted storage system fitted with dedicated dispensing nozzles. If using 55-gallon drums, they can be fitted with quick connect fittings, a hand pump, an inline filter manifold breather and sight glass to achieve the same goal. Improper dispensing of new oils into top-up containers is a primary cause of self-induced contamination. Proper techniques and tools must be used to ensure your new, filtered oil is transferred to the top-up container with minimal exposure to atmospheric conditions. Not using proper techniques here could be a waste of time to the filtration efforts, storage and in-service lubriation cleanliness.
7. Precision Top-Ups and Drain and Fills Once the bulk storage system is properly set up, one should consider the method for transporting oil and filling machines. The best top-up method utilizes a proper top-up container, one that is sealed from the environment, has a built in spout, hand pump, etc. If short cuts are taken at this stage, all of the time and effort spent building and designing the bulk storage system and ensuring the quality of the bulk oil with filtration will have been wasted. Too many times oil is highly contaminated from the time it is dispensed into the top-up container to the time it is added to the machine. Using washable and re-usable top-up containers allow for easy cleaning and maintenance. Typically, non-sealable top-up containers that are re-used introduce large amounts of containments to the system, which could counteract any effort of removing or excluding contaminants, and also can have a slight lubricant cross-contamination effect. For top-ups of larger sump volumes, such as large gearboxes, circulating system reservoirs, etc., the use of filter carts is the preferred method for transferring the new oil from the storage container to the machine.
8. Proper Top-Up Container and Grease Gun Storage Storage for top-up containers, grease guns, rags, etc., is another important step to ensure contaminants are not introduced to the lubricants as a result of poor housekeeping. These tools should
have their own dedicated fire-proof storage cabinets for easy access and organization. Grease storage is simpler than oil storage but also must not go overlooked. Open grease tubes and drums are magnets for attracting airborne contaminants such as lint and dust. Securing used grease tubes that will be re-used in sealable washable containers is considered the best practice. The containers will hold one tube of grease and allow for great contaminant exclusion. Used drums of grease are at an even higher risk of contamination. These drums are often opened and used over a greater period of time, leading to more and more opportunities for contaminants to enter. If not using a sealed air style grease dispensing unit for drums of grease to fill grease guns, some of the best methods for contaminant exclusion are to use Velcro style covers or snap-on caps. Using these types of contaminant exclusion devices will keep the grease cleaner and prolong its life. Grease guns should be stored in a clean, dry and controlled environment. They are precision tools that must be taken care of in order for them to provide the maximum degree of accuracy and reliability. Grease guns should be regularly cleaned and inspected for proper function and an annual calibration should be performed. This calibration will ensure the same volume of grease is still being dispensed with one shot as when the gun was new. The best method for grease gun calibration is to use a postal scale to measure how much grease is dispensed with one pump.
9. Lifecycles and Lubricant Shelf Life For both oil and grease, one should be aware of their respective shelf life. Exceeding their OEM shelf life may render the product useless or severely hamper its performance. For this reason it is best to use the First-In, First-Out (FIFO) method. This method simply requires the maintenance professional to use the oldest lubricants that were put into the storage system first and the newest lubricants put into the storage system last. This will help ensure lubricants do not accidentally exceed their recommended shelf life. As previously mentioned, OEM storage limits should be considered when storing greases and oils. Table 1 outlines maximum storage limits for different grease types and oils. NLGI recommends the following steps for best practice of grease storage: 1. Store the grease in a cool, dry indoor area where airborne debris is at a minimum 2. Use the oldest container first 3. Keep containers tightly covered 4. Wipe off the edges of a container before opening it to avoid intrusion of dirt 5. Where necessary, grease should be brought to a satisfactory dispensing temperature just before being put into service 6. Clean grease-handling tools (such as spatulas, drum pumps, etc.) 7. When a container has been partially emptied and the remainder will not be immediately used, all void spaces within the remaining grease should be filled with grease, and the surface leveled and smoothed 8. Store grease cartridges (tubes) vertically with the removable cap up (ref. NLGI)
14 March - April 2011
10. Labeling and Identification Lubricant labeling is one aspect of storage and handling that is often overlooked. Labeling is just as critical as periodic filtration
Lubrication tools should be stored in a fire-proof storage cabinet for easy access and organization.
Maximum Recommended Storage Time (Months)
Product Lithium Greases Calcium Complex Greases Lubricating Oils Emulsion-type Fire-resistant Fluids Soluble Oils Custom-blended Soluble Oils Wax Emulsions
Table 1. Maximum Storage Limits
16 March - April 2011
12 6 12 6 6 3 6
and without proper labeling it is very easy for lubricant cross contamination to occur. Lubricant cross contamination is a result of mixing two lubricants together and can yield a devastating result. This happens more often in the dispensing equipment rather than the bulk storage equipment. A labeling system can be a simple concept but could prove to be difficult to implement and maintain. Decide how to label each corresponding lubricant from bulk storage to the equipment it will be used in. It can be a color coded system, an alphanumeric code system that depicts important performance data about the lubricant, or a combination of both. Any labeling system can efficiently ensure the right lubricant is used at the right location and prevent cross contamination, but in order to do this, the labeling system must be kept consistent and up to date with current lubricants that are in use and being stored. For example, Noriaâ€™s LIS system is a technical recommendation that denotes a lubricantâ€™s key performance properties and compiles them into an alpha-numeric code. Each performance property gets its own section of the alpha-numeric code. Once these alpha-numeric codes are determined, they can then be easily printed and incorporated in a labeling scheme. There are hundreds of possibilities for the alpha-numeric codes, so a system that is easy to read and maintain is preferred. Matching stored lubricants to the machines in which they are used should be a primary focus of your labeling system. We must be able to correctly identify lubricants in storage and also correctly identify their applications in the field. Applying the labels to top-up containers, grease storage containers, totes, drums, etc., is the only way to ensure correct product delivery to application. About the Author Stephen Sumerlin is a senior technical consultant with Noria Corporation, providing Lubrication Process Design Phase I and II consulting and general lubrication 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 firstname.lastname@example.org.
PRODUCT NEWS Coulometric Karl Fischer Titrator JM Science’s AQUACOUNTER® Coulometric Karl Fischer Titrator (AQ-300) is a reliable, easy-to-use coulometric titrator that has six builtin calculation modes to accommodate solid, liquid and gas samples. Laboratories with limited budgets will benefit from this low-cost, highly productive unit, according to the manufacturer. It has one-touch calculations – including a statistics package. Four files with preset conditions can be stored in memory and allows instant recall of data for up to 20 samples. A built-in detector monitors titration status. The unit has balance and computer interfaces for GLP and ISO documentation. Choice of ion exchange or fritless cell system and thermal printer or impact printer also are available. Printout contents include date, sample number, measurement value (μgH20), sample quantity, moisture content, mean value, standard deviation, CV, moisture quantity-time curve, and other preset titration parameters. The unit is CE approved, has an international voltage input (100-240V) and results may be printed on an optional printer or downloaded to a PC. The AQ-300 comes with DVD training movie, plasticized Quick-Start guide for use in the lab, paper and PDF manual. Also included are complete accessories, downloadable software for transferring results to a laptop or PC, RS-232 cable, and an AQUACOUNTER® KF Reagent starter kit. JM Science (800)495-1678 www.jmscience.com
Uncover Oil-based Fluid Leaks with Leak Detection Kit Spectronics Corporation has introduced the OPK-341 Industrial Leak Detection Kit, an effective and efficient way to pinpoint the exact source of all fluid leaks in hydraulic equipment, compressors, engines, gearboxes, fuel and other synthetic and petroleum-based industrial systems. At the core of the kit is the OPTIMAX™ 3000, a cordless, rechargeable, super-powerful blue light LED inspection flashlight. It’s 15 times brighter than regular LED flashlights and has an inspection range of up to 20 feet (6.1 m). Powered by a rechargeable NiMH battery, the flashlight has an LED life of 50,000 hours. Also included in the kit are two 16 oz., twin-neck bottles of patented OIL-GLO™ 44 concentrated fluorescent oil dye, which is compatible with all synthetic and petroleum-based fluids. When a leaking industrial system is scanned with the OPTIMAX™ 3000 flashlight, the dye glows brightly to reveal the precise location of the leaks each time. Rounding out the kit is an 8 oz. spray bottle of GLO-AWAY™ dye cleaner, smart AC and DC chargers, and fluorescence-enhancing glasses. All components are packed in a rugged carrying case. Spectroline (516)333-4840 www.spectroline.com
Oil Skimmers for Hydroelectric Power Plants Abanaki has announced a full range of oil skimmers and emergency oil spill systems for the special challenges facing hydroelectric power generation facilities, who must protect water resources from spills of hydraulic fluid. Although hydroelectric-generated electricity is considered clean, small leaks of hydraulic oil from turbines at hydroelectric plants are not uncommon. The oil can end up in the facility's sump and spill into its water resource. Oil skimming cost-effectively removes the oil before the water is discharged into the environment. Utilities may employ absorbents and other manual methods of oil skimming. These methods are messy and inefficient, and take maintenance personnel away from more important work. In contrast, Abanaki oil skimmers are proven in thousands of applications to be the lowest maintenance and most reliable means of removing oil from water, according to the manufacturer.
Compressed Fiber Gasket Material Has Variety of Applications Thermoseal Inc., a leading manufacturer and supplier of fluid sealing materials for a broad range of applications, has announced a new product to the market KLINGER Quantum, the first fiber-reinforced gasket material that is exclusively HNBR-bound. In addition to improved flexibility, this gasket material can be used with a much wider range of media than any other fiber reinforced gasket material that is currently available, according to the manufacturer. The HNBR (hydrogenated nitrile butadiene rubber) binder provides Quantum gaskets with exceptional temperature and chemical resistance so Quantum gaskets perform even after prolonged use at higher temperatures while other gaskets become brittle reducing the gasket’s ability to adapt to changing temperatures and pressures. Quantum gaskets adapt to conditions caused from flange irregularities and misalignments and absorb additional forces in the gasket connection. KLINGER Quantum gasket material (800)990-7325 www.thermosealinc.com
Abanaki (800)358-7546 www.abanaki.com
18 March - April 2011
HYDRAULICS AT WORK
Hydraulic Pumps and Motors: Considering Efficiency BRENDAN CASEY
n a condition-based maintenance environment, the decision to change out a hydraulic pump or motor is usually based on remaining bearing life or deteriorating efficiency, whichever occurs first. Despite recent advances in predictive maintenance technologies, the maintenance professional’s ability to determine the remaining bearing life of a pump or motor, with a high degree of accuracy, remains elusive. Deteriorating efficiency on the other hand is easy to detect, because it typically shows itself through increased cycle times. In other words, the machine slows down. When this occurs, quantification of the efficiency loss isn’t always necessary. If the machine slows to the point where its cycle time is unacceptably slow, the pump or motor is replaced. End of story. In certain situations, however, it can be helpful, even necessary, to quantify the pump or motor’s actual efficiency and compare it to the component’s native efficiency. For this, an understanding of hydraulic pump and motor efficiency ratings is essential. There are three categories of efficiency used to describe hydraulic pumps (and motors): volumetric efficiency, mechanical/hydraulic efficiency and overall efficiency. Volumetric efficiency is determined by dividing the actual flow delivered by a pump at a given pressure by its theoretical flow. Theoretical flow is calculated by multiplying the pump’s displacement per revolution by its driven speed. So if the pump has a displacement of 100 cc/rev and is being driven at 1000 RPM, its theoretical flow is 100 liters/minute. Actual flow has to be measured using a flow meter. If when tested, the above pump had an actual flow of 90 liters/minute at 207 bar (3000 PSI), we can say the pump has a volumetric efficiency of 90% at 207 bar (90 / 100 x 100 = 90%). Its volumetric efficiency used most in the field to determine the condition of a hydraulic pump - based on its increase in internal leakage through wear or damage. But without reference to theoretical flow, the actual flow measured by the flow meter would be meaningless. A pump’s mechanical/hydraulic efficiency is determined by dividing the theoretical torque required to drive it by the actual torque required to drive it. A mechanical/hydraulic efficiency of 100 percent would mean if the pump was delivering flow at zero pressure, no force or torque would be required to drive it. Intuitively, we know this is not possible, due to mechanical and fluid friction. 20 March - April 2011
Pump Type External gear Internal gear Vane Radial piston Bent axis piston Axial piston
Overall Efﬁciency % 85 90 85 90 92 91
Table 1. The typical overall efficiencies of hydraulic pumps, as shown above, are simply the product of volumetric and mechanical/hydraulic efficiency. Source: Bosch Rexroth
Like theoretical flow, theoretical drive torque can be calculated. For the above pump, in SI units: 100 cc/rev x 207 bar / 20 x π = 329 Newton meters. But like actual flow, actual drive torque must be measured and this requires the use of a dynamometer. Not something we can - or need - to do in the field. For the purposes of this example though, assume the actual drive torque was 360 Nm. Mechanical efficiency would be 91% (329 / 360 x 100 = 91%). Overall efficiency is simply the product of volumetric and mechanical/hydraulic efficiency. Continuing with the above example, the overall efficiency of the pump is 0.9 x 0.91 x 100 = 82%. Typical overall efficiencies for different types of hydraulic pumps are shown in the Table 1. System designers use the pump manufacturers’ volumetric efficiency value to calculate the actual flow a pump of a given displacement, operating at a particular pressure, will deliver. As already mentioned, volumetric efficiency is used in the field to assess the condition of a pump, based on the increase in internal leakage due to wear or damage. When calculating volumetric efficiency based on actual flow testing, it’s important to be aware that the various leakage paths within the pump are usually constant. This means if pump flow is tested at less than full displacement (or maximum RPM) this will skew the calculated efficiency - unless leakage is treated as a constant and a necessary adjustment made. For example, consider a variable displacement pump with a maximum flow rate of 100 liters/minute. If it was flow tested at full displacement and the measured flow rate was 90 liters/minute, the calculated volumetric efficiency would be 90 percent (90/100 x 100). But if the same pump was flow tested at the same pressure
and oil temperature but at half displacement (50 L/min), the leakage losses would still be 10 liters/minute, and so the calculated volumetric efficiency would be 80 percent (40/50 x 100). The second calculation is not actually wrong, but it requires qualification: this pump is 80 percent efficient at half displacement. Because the leakage losses of 10 liters/minute are nearly constant, the same pump tested under the same conditions will be 90 percent efficient at 100 percent displacement (100 L/min) - and 0 percent efficient at 10 percent displacement (10 L/min). To help understand why pump leakage at a given pressure and temperature is virtually constant, think of the various leakage paths as fixed orifices. The rate of flow through an orifice is dependant on the diameter (and shape) of the orifice, the pressure drop across it and fluid viscosity. This means that if these variables remain constant, the rate of internal leakage remains constant, independent of the pump's displacement or shaft speed. Overall efficiency is used to calculate the drive power required by a pump at a given flow and pressure. For example, using the overall efficiencies from the table above, let us calculate the required drive power for an external gear pump and a bent axis piston pump at a flow of 90 liters/minute at 207 bar: External gear pump: 90 x 207 / 600 x 0.85 = 36.5 kW Bent axis piston pump: 90 x 207 / 600 x 0.92 = 33.75 kW As youâ€™d expect, the more efficient pump requires less drive power for the same output flow and pressure. With a little more math, we can quickly calculate the heat load of each pump: Drive power for a (non-existent) 100% efficient pump would be: 90 x 207 / 600 x 1 = 31.05 kW So at this flow and pressure, the heat load or power lost to heat of each pump is: External gear pump: 36.5 â€“ 31.05 = 5.5 kW Bent axis piston pump: 33.75 â€“ 31.05 = 2.7 kW No surprise that a system with gear pumps and motors requires a bigger heat exchanger than an equivalent (all other things equal) system comprising piston pumps and motors. About the Author Brendan Casey, a fluid power specailist with an MBA is the founder of HydraulicSupermarket.com and the author of Insider Secrets to Hydraulics, Preventing Hydraulic Failures, Hydraulics Made Easy and Advanced Hydraulic Control. He has more than 20 years experience in the design, maintenance and repair of mobile and industrial hydraulic equipment. Visit his Web site: www.HydraulicSupermarket.com Machinery Lubrication
March - April 2011 21
PRODUCT SUPERMARKET PAID ADVERTISING SECTION
With over 20 years of oil analysis experience, we know how to treat you and what you want most. At MidContinent Testing Labs Inc. we make the entire process easy and accommodating. Call for a complete range of tests available. New AND improved. Introducing the new DCHG-1 Hydroguard™ hybrid breather – your best option for low-flow applications with limited headspace. Try an HG-1 breather FREE – visit http://descase.com/sample. Des-Case Corporation http://descase.com/sample 615-672-8800 email@example.com
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
Valve reduces sampling time by 80% Plus - Unique 360° rotating spout allows easy one hand sampling. Stainless steel chain and clip. NEW higher flow for low pressure applications. NEW rugged spout design with easy to grip knurled cap. Checkfluid, Inc. www.checkfluid.com 866-652-8728 firstname.lastname@example.org 22
March - April 2011
Maximize productivity and reduce costs with the power of Castrol High Performance Products • Cutting & Grinding Fluids • Cleaners • Greases • Corrosion Inhibitors • Deformation Fluids Discover what 55 Gallons of Castrol Product can save YOU! Castrol Industrial North America Inc. www.castrol.com/industrial 877-641-1600 email@example.com
Donaldson Bulk Fuel & Lube products are designed for single pass high efficiency filtration. Our modular manifold solutions handle a wide range of flows/viscosities and spin-on filter technology makes the elements easy to change.
We know what you want and expect and we are committed to your success. MidContinent Testing Labs Inc. provides Environmental Analysis and Oil Testing. We soar above and beyond by providing not only quality results, but also practical maintenance recommendations as well. Mid Continent Testing Labs Inc. www.thechemistrylab.com 605-348-0111 firstname.lastname@example.org
Donaldson Company Inc. www.donaldson.com 800-846-1846 Bulk.Filtration@donaldson.com
Escalator Chain Lube is a synthetic lubricant; it excels in lubricating the chains of escalators, moving sidewalks & elevator doors. Its high-film strength improves equipment reliability while reducing lubricant consumption. Royal Purple, Inc. www.royal-purple-industrial.com 888-382-6300 email@example.com
Know when to lubricate with UE Systems Ultraprobe® 201 Grease Caddy. Sensing ultrasound, Grease Caddy isolates bearing sounds making it easier to listen in noisy plant environments. Wear on a holster or attach to grease gun. UE Systems, Inc. www.uesystems.com 800-223-1325 firstname.lastname@example.org
Fundamentals of Machinery Lubrication provides more than 24 hours of foundational training on best practices for machinery lubrication and oil sampling. It lays the groundwork for establishing a world-class lubrication program, and is Level I certification prep course.This online training format allows 24/7, anywhere accessibility. Noria Corporation store.noria.com 800-597-5460
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 email@example.com
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 firstname.lastname@example.org
The SureSample utilizes a patented vacuum technology that eliminates the need for sample pumps. Simply affix the length of tubing to the SureSample bottle, insert into a reservoir or sample port, and let the bottle do the rest.
Analysts, Inc. www.analystsinc.com 800-655-4473 email@example.com Machinery Lubrication
The IFH Group, Inc. www.ifhgroup.com 800-435-7003 firstname.lastname@example.org
Krytox® Fluorinated Greases and Oils are chemically inert, insoluble in common solvents. Temperatures range from -103° to 800°F. Compatible with plastics, rubber, ceramics and metals. Nonflammable, oxygen compatible, no silicones or hydrocarbons. H-1/H-2 Food Grades available. Miller-Stephenson Chemical Company, Inc. www.miller-stephenson.com 203-743-4447
Summit Varnasolv will alleviate problems from varnish and carbon in your rotary screw or rotary vane compressor. Clean your compressor while it’s running, no need to disassemble. Use Varnasolv to clean heat transfer systems, high temperature chains and gearboxes. Summit Industrial Products www.klsummit.com/varnasolv.pdf 800-749-5823 email@example.com
Inolex Chemical Company synthesizes premium ester base oils for high-performance lubricant applications 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 800-521-9891 firstname.lastname@example.org
SIMPLIFY MOTOR CHANGE-OUTS and ENSURE ELECTRICAL SAFETY. Motor Plugs allow technicians to quickly connect/disconnect motors. Safety features protect from electrical hazards and simplify NFPA 70E compliance. FREE samples available. Meltric Corporation www.meltric.com 800-433-7642 email@example.com
Very mobile and lightweight. Reduces Cross Contamination! Two sets of filters, two separate outlet hoses. Allows for flushing two different grades of fluid using a single cart. Optional onboard particle monitor Y2K Fluid Power www.y2kfluidpower.com 888-925-8882 firstname.lastname@example.org
Isn’t it time you streamlined your fluid handling?
March - April 2011 23
GET TO KNOW…
Former Marine Spearheads ConAgra Lube Team J
ohn Adam, a mechanic at the ConAgra facility in Milton., Pa., is leading the lubrication team at his plant. He began his career in maintenance in the early 1980s after leaving the United States Marine Corps, where he served as a generator technician. He was hired at ConAgra in 1988, but volunteered his services to participate on his company’s lubrication team so he could learn more about machinery lubrication.
What made ConAgra Foods of Milton, Pa., redesign its program to be more effective with lubrication? We had corporate restructuring that put into effect our lubrication policy, for identification and consolidation of lubricants. It is to be incorporated with an AMD program for lessening downtime through operators as well as helping maintenance take ownership of their machines. How did you get your start in machinery lubrication and how did it happen? I have been in maintenance since 1980 when I entered the USMC as a generator tech. I entered the public life in 1988 and joined my current position, but I actually volunteered to participate in this lubrication team about one year ago, when we started out with baby steps to fulfill our corporate wishes. Since then, it has been an eye opening experience of what is out there. At first it was hard to change my thinking, that new oil could be dirty. What types of training have you taken? No formal training at all. We have had suppliers in for a few educational meetings. And as you know, Noria visited recently for a “best practices” meeting. What is the range of equipment that you service through lubrication tasks at your plant? Food processing equipment, can handling, cook pots, grinders, fillers, seamers, cookers, packaging, palletizers, etc. What’s a normal work day like for you? I work the first shift, from 6 a.m. to 2:30 p.m. I am primarily a mechanic/ coordinator with my spare time being taken up as lubrication team leader. What lubrication-related items are you currently working on? We currently are working on introducing new grease, new bearing types and sort of a culture change within our maintenance ranks. 24 March - April 2011
ConAgra mechanic John Adam serves as the leader on his lubrication team at his facility. He volunteered to participate on his company’s lubrication team.
How does your company view machinery lubrication in terms of importance, strategy, etc.? As in the last question, it is quite a culture change, but we have been more reactive in the past “firefighting,” to put it bluntly. But we are coming along; we have a good team to keep it running with what we are given. What have been some of the biggest lubrication project successes in which you have played a part? I can’t say I have been a big part of any as of yet, other than our identification project. We have had some supervisors involved in integrating the use of synthetic oils to some of our areas. This has made a big difference. What do you see as some of the more important trends taking place in the lubrication and oil analysis field? I see everything as important right now. It is all new to me. We have never analyzed oil, sampled oil, or even looked at what we were using. We used what we were given. An old friend of mine once was asked by a factory rep, “Is that the factory recommended oil for that equipment?” His answer was, “Yes, it is my factory’s recommended oil for use in this equipment.” We are in our infancy as far as lubrication goes. Most of our past information has come from oil suppliers that may have put their sales first and our equipment second. We have nowhere to go but up.
March - April 2011 25
GET TO KNOW…
ConAgra Tech Learns on the Front Lines J
odie Prieto-Salazar, a Quality Tech with ConAgra, has been with the company for almost four years and is currently working toward becoming a Quality Tech II. She, along with her other co-workers, perform testing on recycled water and cooker water for SPC. Prieto-Salazar also takes care of the dud detection reject spreadsheet for quality, and helps out in the quality control department when needed. What made the ConAgra plant at Milton, Pa., decide to redesign its program to be more effective with lubrication? Our plant decided to put more emphasis on lubrication because if we can get the machinery to run better, the better our performance will be. A Milliken group is coming in to our plant to help with the transition of making our machinery performance back to “like new.” There are different Pillar teams that are part of this task and one is the maintenance Pillar. Our group (the lubrication team) is a subgroup of the Maintenance Pillar. How did you get your start in machinery lubrication and how did it happen? One day, my boss, Eric Wolf, came up to me and asked if I would like to take his position on the lubrication sub group, and I said yes, that it would be a different experience for me since I have no idea or experience about machinery lubrication. Just so you know, I do not actually participate in lubricating the machinery, I just participate with the group to come up with how we can make our machinery run better and longer with the right types of oils and greases. And, maintaining/filtering the oil/grease in the machinery.
What types of training have you taken? The Noria training, when they came into the plant for the first time. What is the range of equipment that you service through lubrication tasks at your plant? I do not specifically lubricate the machinery; I just help in planning which type of lubrication is being put on the machinery and what type. The actual mechanics do the lubrication. What’s a normal work day like for you? Since I am just part of the subgroup and not actually doing the lubrication, I am part of the quality lab. We test the finished product with different tests. Every Wednesday I have a meeting with the lubrication subgroup to discuss what is going on and any new findings. What lubrication-related items are you currently working on? We just had Noria come in to give us a plan of what they can do to help. We are now in discussion as to what we should do with this plan. We are trying to get a filter room set up in the near future. We are focusing on pretty much every piece of machinery that needs lubricating with some type of oil or grease. How does your company view machinery lubrication in terms of importance, strategy, etc.? It has always been important but just within the last year or so since Milliken came in and we developed this lubrication subgroup that it has became a very important factor in keeping our machinery running smoothly. What have been some of the biggest lubrication project successes in which you have played a part? As a group we are trying to implement certain types of oil/grease on the machinery to see which type works the best. We have come up with many charts showing which type of oil/grease should be used and how much on every piece of equipment that needs lubricating. We are just a new group, but we are trying to come up with many more ideas to help with making our machines run longer and smoother.
Jodie Prieto-Salazar, a Quality Tech I at ConAgra, helps on her company’s lubrication team as well as the quality control department. 26 March - April 2011
What do you see as some of the more important trends taking place in the lubrication and oil analysis field? Going to synthetic lubricants - this keeps the water and particles out more easily. Also, filtered oil.
Welcome to Machinery Lubrication’s Bookstore, designed to spotlight lubrication-related books. For a complete listing of books of interest to lubrication professionals, check out the Bookstore at www.noria.com.
Oil Sampling Procedure Posters Publisher: Noria Corporation This set of 3 posters visually displays step-by-step oil sampling procedures for in-service lubricants and hydraulics. Posters include required sampling equipment lists and procedures for high-, lowand atmospheric-pressure systems.
Practical Lubrication for Industrial Facilities
How to Grease a Motor Bearing Training DVD Format: DVD Publisher: Noria Corporation How to Grease a Motor Bearing provides plant personnel an overview of the best practices for lubricating electric motor bearings. Anyone responsible for the maintenance, operation and reliability of electric motors will benefit. Use it to train operators, lubrication technicians, mechanics, electricians and maintenance personnel for years to come. The product has three main benefits: • Lubrication technicians will have a clear understanding of why proper motor bearing lubrication is critical. • You’ll reduce motor failures, downtime, rebuilds and replacement costs.
Author: Heinz Bloch Helps reliability professionals, mechanics, machinists or lubrication specialists understand what matters most in a lubricant, and to distinguish mere sales talk from relevant facts. It is intended to assist the professional in ensuring The Practical Handbook of that machinery operates at optimum performance Machinery Lubrication levels with a minimum of Author: L. Leugner costly downtime. If you want to establish yourself as the lubrication expert in your company, this book is a must-read. Once you pick it up, you won’t put it down until you’ve finished it. It’s that easy to read. Oil Analysis
• You’ll replace old-time lubrication procedures with vendor-neutral, bestpractice procedures that work.
Basics – Second Edition Publisher: Noria Corporation The new Second Edition includes more detailed information on oil sampling, filtration and contaminant removal, base oils and additives, water-in-oil contamination and removal, ASTM standards, glycol testing, flash point tests, plus 14 additional oil analysis tests.
Introduction to Lubrication Fundamentals Training DVD Format: DVD Publisher: Noria Corporation The Introduction to Lubrication Fundamentals training DVD teaches lubrication basics through highquality animation and video. DVD training makes learning fun and convenient while helping employers provide standardized training for every employee, every time.
For descriptions, complete table of contents and excerpts from these and other lubrication-related books, and to order online, visit:
www.store.noria.com or call 1-800-597-5460, ext. 104 Machinery Lubrication
March - April 2011 27
LUBE TIPS Send your tips to email@example.com
Readers Supply Super Solutions and Sound Suggestions Paper Thermometer Reveals Temperature Spikes
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, e-mail it to us at firstname.lastname@example.org. To sign up for the Lube-Tips newsletter, visit www.machinerylubrication.com and click on the “Newsletters” link at the top.
In time-critical situations where real-time infrared thermography is impractical and thermocouple/ recording equipment cannot be installed, consider temperaturesensitive tapes. These tapes are manufactured in a variety of sensing ranges and will clearly record the peak temperature that a machine area reached since the tape was first applied. A quick visual check is all it takes to read the “paper thermometer.”
Quit Replacing Those Seals If you are constantly changing gearbox oil seals, check the gearbox breather for plugging. When breathers become clogged, internal gearbox pressure can build and find its way out through oil seals creating a false impression that the seal has failed. This can become more problematic during summer months.
Dispersancy is Crucial for Engine Oils Coolant contamination, overextended oil drain, water contamination, high blowby, long idling, high elevation, and exhaust gas recirculation can all cause loss of dispersancy in motor oils. This loss can cause engine deposits, sludge, impaired lubrication and oil flow.
Is Your Oil a Breeding Ground for Microbial Growth?
Right-sizing Bearing Lube Lines When running lube lines to out-of-reach bearings, run your tubing out of 3/8-inch diameter tubing instead of 1/4-inch. It requires less pressure on your grease gun to push the grease through a larger opening than a smaller one. You are also less likely to overpressurize the tubing. Before making your final connection to the bearings, purge your line with the specified grease of lubricant beforehand. Then connect the fitting to your bearings.
Temperatures below 20°C (68°F) and above 40°C (104°F) will slow down microbial growth in lubricants. Rapid growth can occur between these temperatures when water is present.
Make Oil Sampling Easier When labeling oil sample bottles prior to taking samples, consider identifying the bottle caps as well as the labels. A felttip pen works well. This will save a lot of time as you will not have to pick up each bottle to tell which bottle you need next. 28 March - April 2011
Grease Gun Caps To keep the end of your grease gun clean and prevent contamination from entering a bearing when lubing the bearing, place a plastic cap over the end of the lube head. These come in all sizes and the 1/2-inch gives a tight seal to keep out everything from dirt to water. Machinery Lubrication
March - April 2011 29
PRACTICING OIL ANALYSIS
How to Select MachineSpecific Oil Analysis Tests BY ASHLEY MAYER
n important aspect of oil analysis is being able to produce machine-by-machine test slates which serve the performance requirements of the assets under the user’s control. There is no single oil analysis test slate which can serve all the needs of all the different types of oil-lubricated assets on a plant. A knowledge of what oil analysis can provide is invaluable in determining test slates for various different types of equipment. It is also essential to determine the type of maintenance profile suitable for the machine. Armed with this information, one is in a position to determine a test slate which is effective both in cost and performance. There are a few different perceptions of oil analysis. One view is that oil analysis is there to provide a warning of an imminent breakdown, or the predictive maintenance approach. Another view is that oil analysis is a metric of the overall health of a machine, or, the proactive approach. Oil analysis can fulfill both of these roles admirably, if used correctly. By ‘used correctly,’ means that the correct tests are chosen for the machine to serve its reliability profile. As an example: an iron mine, as much as they claimed differently, and as much as they wanted to believe differently, were practicing rudimentary preventive maintenance. This company was owned by a large international mining house which demanded their subsidiaries carry out particle counts on all their oil-lubricated assets. It was asserted, and rightly so, that particle counts are an Item 1 2 3 4 5 6 7 8 9 10 11
Test Particle Counting Water (crackle test) Water (Karl Fischer) Viscosity Ferrous Density Analytical Ferrography Filter Analysis Acid Number FTIR (oxidation) Patch Test Elemental Analysis
Onsite Laboratory ✔ ✔ ✔
✔ ✔ ✔
Commercial Laboratory ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔
Table 1. Common oil analysis tests. 30 March - April 2011
important part of any proactive maintenance program. Because workers at this mine weren’t practicing any type of contamination control, the laboratory they were using was seldom able to produce a meaningful particle count due to the severe dirt and wear metal contamination in the samples. The results: oil analysis data which was meaningless for the mine’s operation, loss of faith in the tool, undetected failures and an overall disdain of lubrication. Had this mine been able to acknowledge their maintenance abilities and been able to choose tests more suited to their existing maintenance procedures, they would have been able to detect more impending failures and act on them, rebuff the oil analysis skeptics, and use the proven savings to justify improvements to their lubrication program. Trying to determine the correct test slate for an oil-lubricated piece of machinery can be daunting. There are so many tests available, some appropriate for the application, others not. Having an idea about what the various tests are, what they can accomplish, and taking into account the maintenance philosophy being practiced, test slates can easily be drawn up to accomplish the desired results.
The Tests Eleven commonly performed tests are listed in Table 1. These tests are not all the tests that can be performed, but do include all the most common ones. The table also indicates whether the test can be reasonably done as at an onsite laboratory or whether they are more likely to be performed in a commercial oil analysis laboratory. Onsite laboratories range from very simple to very complex, and the third column in Table 1 represents an industry average of what might be found in an onsite laboratory. It is worth noting that test packages can be purchased from most laboratories at a price substantially cheaper than the sum of the individual tests purchased separately. Where possible these test packages should be used and complimented with extra tests if desired. Oil analysis can be broadly divided into three different categories: fluid condition, contamination and wear. Particle Counting The particle counter produces a count, in different size ranges, of particles per 1 mℓ of oil. It is concerned primarily with contamination,
but as some of this contamination may be internally generated, the wear aspect of oil analysis is also addressed. With most particle counters differentiating between internal and external wear is impossible, but there are new technologies available which are addressing this. A particle counter produces a number for each of the different size ranges, as shown in Table 2. Various different types of machines are used to generate these counts and different reporting structures are used, but Table 2 probably represents the most common one. Each column, except the last, reports the number of particles bigger than a certain size in microns per 1 mℓ of fluid. Trying to absorb all the information presented at once is not that easy, but a summary of the particle count is presented in the last column. The summary reports an index related to the number of particles in each of the following different size ranges: larger than 4 microns; larger than 6 microns, and larger than 14 microns. Increasing numbers as evaluated on a trend basis indicate the fluid is getting dirtier and decreasing numbers indicate the fluid is becoming cleaner. It is worth mentioning that there are interferences that can cause anomalies in the results. The interferences depend on the technology being used, but can include water droplets, air bubbles and heavily discolored oil. If significant differences in particle counts are noticed, the first course of action should be to ensure, as much as possible, that interferences have been dealt with in the testing process and that other significant test results have not changed, such as water contamination. Particle counters are not inexpensive, but the results they provide are generally seen as being important enough to warrant their inclusion in many onsite oil analysis laboratories. Water (crackle test) The crackle test is one of the simplest tests that can be performed on an oil sample and is an absolute must for any onsite laboratory. The test addresses the contamination aspect of oil analysis and involves heating the oil up to between the boiling point of oil and water. At this temperature, water in the oil will boil and produce noticeable bubbles. In practice, it involves putting a drop of oil onto a hotplate and watching for water bubbles in the drop. It is accurate to approximately 500 parts per million (ppm), or 0.05%, water content. Machinery Lubrication
Interferences are few, but probably the most significant is the presence of contaminants, such as refrigerant gas. The crackle test will suffice for most moisture content determination needs. If it passes the crackle test, moisture levels are acceptable. A failed crackle test should in most cases be followed up by a test to determine the exact water content. Various options are available, the most common being the Karl Fischer test. Water (Karl Fischer) The Karl Fischer method is used to determine the exact water content of an oil sample. It reports results as ppm water. It is most commonly used as an exception test generated by the crackle test, but should absolutely be run as a routine test in situations where water content below 1,000 ppm is important, such as electrical transformers. In most industrial applications Karl Fischer as an exception test from the crackle test should suffice. Viscosity Viscosity is a fluid’s resistance to flow. It is an important indicator of the condition of the oil and can also be negatively affected by contamination. There are various means of carrying out the viscosity test and it can be reported at temperatures of 40˚C or 100˚C. For most industrial applications a viscosity measurement at 40˚C is required. Many onsite laboratory instruments do not carry out the test at 40˚C, but rather perform the test at room temperature and then estimate a 40˚C measurement. The method used is of secondary importance to consistency in method in performing the test from sample to sample, and it is the trend that is ultimately the most important. Ferrous Density Ferrous density is a determination of the content of magnetic debris in the oil. As most wear metal is iron-based, this test is, in most cases, a good indicator of the amount of wear debris in the oil. It does not have a particle size bias, as does the elemental analysis test, but generally does not have good sensitivity at very low levels of wear metal contamination. As such, the nature of the test puts it squarely into the realm of predictive maintenance rather than being a proactive maintenance tool. There are several different instruments for performing the test, ranging from portable to www.machinerylubrication.com
March - April 2011 31
PRACTICING OIL ANALYSIS
4 / 6 / 14 18 / 16 / 13
Table 2. A typical particle count.
desktop units, and each instrument reports its results differently. Once again, the particular instrument used to perform the test is of secondary importance compared to consistency of method from sample to sample. Analytical Ferrography Analytical ferrography is the visual analysis of solid contaminants removed from the oil sample. As the name suggests, it is biased toward contaminants of a ferrous nature, i.e., wear metal, but some non-magnetic debris gets trapped as well. The test uses magnetic fields to separate the ferrous debris into different size ranges on a microscope slide, then examined under a compound microscope. It is an expensive test to perform and the results are subjective, so this test is usually only performed as an exception test. On filtered systems, the results of the test may be misleading due to the possibility of abnormal wear particles being filtered out. It can be used on filtered systems and on systems which are filtered by portable filtration units, but preferably a filter analysis should be carried out in such systems.
The high cost of equipment and the complexity of interpretation make it unlikely that analytical ferrography will be found in most onsite laboratories. Filter Analysis Filter analysis is a visual analysis of solid contaminants removed from the filter. It involves washing out a piece of the filter membrane and depositing the contents onto a filter patch for microscopic analysis. The debris can be separated into magnetic and non-magnetic components if desired, but unlike analytical ferrography, the particles are not separated according to size. Like ferrography, the test is time consuming, expensive and subjective. It provides better resolution of non-magnetic debris than analytical ferrography. This test should be carried out on filtered systems as an exception test, possibly generated by an out-of-specification elemental analysis, ferrous density or particle count. Filter analysis can be successfully performed in an onsite laboratory, however, more advanced diagnoses will probably be available from a commercial laboratory. Acid Number The acid number (AN) test measures the acid content of a sample. The AN is an indication of how much the fluid has oxidized or degraded. AN also is used to determine the rate of depletion of
the anti-oxidant additive. It is primarily focused on the condition of the oil, although some contaminants can also affect the AN. Units are mg KOH/gram oil. An increasing AN indicates increasing oxidation of the oil. Unlike some conditions, like contamination, which can be reversed, a high AN cannot be. Acid number can be easily and inexpensively carried out in an onsite laboratory.
The test involves filtering oil through a filter patch and then examining the filtergram through a microscope. This test focuses on the contamination and wear aspects of oil analysis. If desired, the contents of the oil sample can be separated into magnetic and nonmagnetic components and each part examined individually. It is worth attaching a camera to the microscope to record the resulting images on a computer for comparison purposes.
FTIR Fourier-Transform Infra-Red (FTIR) spectroscopy uses infra-red light of varying frequencies to search for the presence of absence of certain compounds in the oil. The scope of the test can range from very simple, or inexpensive, to very complex and expensive, depending on the desired results. FTIR examines both the condition and contamination of the sample. For most industrial applications the simple tests can give sufficient information. The primary property sought here is oxidation. FTIR is seldom found in onsite laboratories due to its high costs and moderate complexity of operation. It is worth noting that prices on the spectrometers are decreasing and the feasibility of including one of the devices in an onsite laboratory is increasing.
Elemental Analysis Arguably the most important test in the oil analysis arsenal is elemental analysis and it provides information on all three aspects of oil analysis: the condition of the fluid (levels of some additives), contamination and machine wear. The commonly used method is inductively-coupled plasma (ICP) spectroscopy, which utilizes light in the visible and ultra-violet ranges. It reports results in ppm of various elements. The major drawback of this test is the size of the particles it can detect. Particles larger than 5 to 8 microns in size are not detected by this test. However, in most wear situations, there will be an increase in wear particle sizes across the range, so elemental analysis can still provide excellent results. A knowledge of the metallurgy of the machine is vital in the interpretation of the results. It is also important to employ exception tests when anomalies in the elemental analysis are detected.
Patch Test Like the crackle test, the patch test is one of the easiest and most inexpensive tests to perform and is a must for an onsite laboratory.
PRACTICING OIL ANALYSIS
Item 1 2 3 4 5 6 7 8 9 10 11
Test Particle Counting Water (crackle test) Water (Karl Fischer) Viscosity Ferrous Density Analytical Ferrography Filter Analysis Acid Number FTIR (oxidation) Patch Test Elemental Analysis
✔ ✔ E(5)
Proactive ✔ ✔ E(2) ✔ E(1) E(5, 10)
✔ ✔ ✔
✔ ✔ E(1, 5, 11) ✔
Table 3. Gearbox test profiles. R = Routine. E = Exception (triggering tests in parentheses).
Item 1 2 3 4 5 6 7 8 9 10 11
Test Particle Counting Water (crackle test) Water (Karl Fischer) Viscosity Ferrous Density Analytical Ferrography Filter Analysis Acid Number FTIR (oxidation) Patch Test Elemental Analysis
Screening ✔ ✔ ✔
Predictive ✔ ✔ E(2) ✔
✔ ✔ E(1) ✔
Proactive ✔ ✔ ✔ E(1, 11) E(1, 10, 11) ✔ ✔ E(1, 11) ✔
when performing predictive maintenance is the correct course of action. Such occasions might include low replacement costs or low criticality of particular pieces of equipment, when more complex maintenance strategies are unwarranted. Proactive maintenance strategies would typically be performed on newer, more expensive equipment and where criticality of operation makes a high reliability desirable. In Table 3 and Table 4, the predictive and proactive test profiles have two types of tests indicated, routine and exception. Routine tests are performed each and every time the sample is tested. The screening profile has no exception tests indicated - the exception test for a failed screening test is a full routine analysis. The profiles presented are designed to serve as guidelines only to help with creating test slates for the most common industrial applications. There are instances when criticality of operation, cost, safety factors, environmental factors or fluid selection, make changes to the suggested test slates desirable. In all instances the previously mentioned factors need to be taken into account in deciding the final test slate. A knowledge of what oil analysis can provide in conjunction with the reliability goals are essential when making the final choice. Gearboxes Some suggested test profiles for gearboxes are presented in Table 3. There is more emphasis on abnormal wear in the predictive test slate, and more emphasis on contamination and oil condition in the proactive one. As an example, while ferrous density and patch tests are suggested as routine tests in the former, they are only exceptions in the latter. It can also be seen that AN is included in the proactive test slate more to monitor abnormal additive depletion rather than oxidation.
Table 4. Clean-oil systems.
Due to the high capital costs and complexity of operation, ICP spectrometers are found in only the most sophisticated of onsite laboratories.
The Profiles The most commonly encountered industrial test classes are going to be examined-gearboxes and clean-oil systems. The test profiles have been divided up into three categories: screening, predictive and proactive. A screening test can be run in a few different applications. It might be used on small, non-critical pieces of equipment where regular full-slate oil analyses aren’t cost-effective. Screening tests also can be run on any piece of equipment where a problem is suspected. The benefits of a screening test should be its low cost and high speed turnaround. Because of those reasons, a screening test would be performed at an onsite laboratory. A screening test should be seen as an enhancement to a routine oil analysis test slate rather than a replacement. The routine oil analyses have been divided into two categories: predictive and proactive. Ideally, one wants to be performing proactive maintenance as much as possible, but there are times 34 March - April 2011
Clean-oil Systems Clean-oil systems include machines such as compressors, hydraulics and circulating systems, such as turbines. As can be seen in Table 4, there is more emphasis placed on contamination in clean-oil systems than with gearboxes. Due to the nature of these machines they are generally less tolerant of contamination than gearboxes. Oil analysis can serve many goals, including failure prediction and overall health monitoring. But it is only able to do its job when the correct tests are chosen to serve the goals in mind. Before one can choose a test slate for a machine, one needs to take cognizance of both the reliability profile of the machine and have a thorough understanding of the basic tests. Once this has been done the user can confidently select an oil analysis test slate to accomplish the task at hand.
Hungry For More Information? The Machinery Lubrication Web site is the home for hundreds of technical articles, columns and reports related to lubrication research, solutions and best practices. Check out www.machinerylubrication.com and learn more. Machinery Lubrication
IN THE TRENCHES
Proper Lubrication Means Less Visits from Your Parts Vendor Clopay Techs Realize the Importance of Lubrication Training
or Scotty Lippert of Clopay Plastics in Augusta, Ky., a reliable and trustworthy vendor is a valuable asset for his company, just as it is to any other industry. But when a company puts in place reliability and lubrication maintenance programs designed to lengthen the life of a machine and its parts, it’s the vendor who notices the change when the call for replacement parts slows to a crawl. Several years ago, Lippert, a planned maintenance technician and lubrication leader for Clopay, a manufacturer of specialty films and plastics, received a brochure that invited him to attend a maintenance seminar on planning and scheduling. “I received that brochure about four years ago inviting me, and in that brochure something caught my eye,” Lippert said. The brochure stated what World Class Maintenance in lubrication means to the industry: 1. You are recognized as World Class by customers and competitors. 2. You are constantly being benchmarked by others who want to study what you are doing. 3. Your benchmark performance indicators are in the top 5 percent. 4. Few competitors are performing activities as well as you. 5. You are respected by customers and feared by competition. 7. Your performance numbers speak for themselves. 8. There is a strong sense of pride among employees.
36 March - April 2011
But Lippert, who has worked 24 years at Clopay, decided to add one more item to the list: When vendors call, concerned that the re-purchase of parts has drastically fallen. Lippert said he added the last item to the list because his company had a reliable vendor that they had used for many years that sent him a message asking why Clopay hadn’t purchased a particular part in more than two years. “It’s probably a very good assumption that this vendor is expecting my reply to be that I have found a better price with another vendor, but my reply was one he never expected,” he said. “I stated in my email to him that their prices always have and still are competitive compared to other vendors’ prices, but the reason we haven’t purchased anything from them in over two years is because we are now properly lubricating them, an answer he sure didn’t expect.” Lippert said when a reliability program is working correctly for a company, the first to recognize it within the organization will be the planner, maintenance buyer and maintenance staff. Outside of the organization, it’s the vendor who might believe something could be wrong when calls to the vendor slow down, and eventually stop for long periods of time, he said. “We weren’t purchasing parts near as much, and he thought we were buying the parts someplace else at a different price,” he said. “It’s because we were lubricating right. I thought that was a good sign.” This particular vendor is still considered an important asset, but now, Lippert doesn’t rely on his parts vendor as much because of the lubrication knowledge the maintenance staff at Clopay has received. In this case, the vendor’s loss is the company’s gain, he said. Lippert used as an example the rotary unions on Clopay’s extrusion lines, which, depending on the particular size, range in cost from $300 to more than $4,000. “It takes two or three hours for rotary unions on our extrusion lines to cool off. That’s because many of them rotate with hot water, cold water, lukewarm water or hot oil flowing through them, to make a quality product for our customers,” he said. “Needless to say, rotary unions are a critical part of Clopay’s operations”
“…the reason we haven’t purchased anything from them in over two years is because we are now properly lubricating them, an answer he sure didn’t expect.” - Scotty Lippert If a rotary union is not properly lubricated with the right product, the life of the part can be short. Lippert said the larger rotary unions, with hot oil flowing through them, can take up to eight hours to replace, leading to a loss of production and a toll on production costs. Before Lippert and members of his maintenance staff attended any type of lubrication training, he admits he and his fellow workers felt “grease was just a grease as long as you applied some type of grease to a bearing, and you felt good about it, even if it was the wrong type, wrong amount or wrong intervals. Applying it wasn’t appropriate because we didn’t know any better.” After Lippert and several of his co-workers on the maintenance staff attended training provided by Noria, they began reading lubrication instructions from the original equipment manufacturer that came attached to the equipment.
They discovered that workers were using a lithium complex grease to lubricate the rotary unions, but the parts came packed with a polyurea. The instructions noted that it should be continued to be lubricated with the same product, Lippert said. Using the right lubrication on the right equipment has been of particular importance, he said. “It’s caused us less work and for the company as a whole, a lot more uptime and a lot less expense for parts,” he said. “We used to have 3.9 percent unplanned downtime, which is a lot, but now we’re down under about 1.7 percent. World Class is considered 2 percent or under, so we’re doing something right.” Lippert said the bottom line is that the cost of lubrication training is pennies compared to the cost of downtime on a machine that hasn’t been properly lubricated.
March - April 2011 37
TEST YOUR KNOWLEDGE
his issue, Machinery Lubrication is beginning a new section called “Test Your Knowledge,” where we will focus on a group of questions from Noria’s Practice Exam for Level I Machine Lubrication Technician and Machine Lubrication Analyst. The answers are located at the bottom of the page.
1. Important factors when selecting a grease include: A. Thickener viscosity and base oil type B. Thickener type and color C. Thickener type, the base oil type and base oil viscosity D. Only the thickener type, the base oil type and base oil viscosity E. Base oil type and color
2. The Beta ratio of a filter: A. Is a measure of its dirt holding capacity B. Is a measure of its burst strength C. Is a measure of its particle removal efficiency D. Relates only to the price of the filter E. Is independent of the particle size
3. The proper time to drain the oil from a gearbox is: A. At the end of the shift B. At the end of the day C. At the beginning of the following shift D. While it is still hot from operation E. After it has cooled and the particles and water have settled near the bottom
4. Additive depletion can occur by which of the following mechanisms: A. Mass transfer, decomposition and adsorption B. Mass transfer (separation) C. Hydrotreating D. Hydrolysis and oxidation E. All of the above
5. The smell of a used oil sample can indicate: A. High temperature thermal failure B. Water contamination C. High wear debris D. A recent oil top-up E. Contamination from another oil
Answers: 1-C; 2-C; 3-D; 4-A; 5-A 38 March - April 2011
Get a Printable Version of This Puzzle Online at: MachineryLubrication.com/puzzle
ACROSS 3 Oils are often labeled â€œATFâ€?, what does this stand for? (3 words)
4 What is the element found in a common polymer used as a defoamant?
6 FTIR is a rapid means to monitor a number
DOWN 1 Typically, what is the main over-base additive in an engine oil?
2 Related to oil analysis, what does BN stand for? (2 words)
5 Polyalphaolifin, dibasic acid ester, polyol
of oil parameters simultaneously. What does
ester, polyglycol, phosphate ester. What
FTIR stand for? (3 words)
class of lubricants are these?
9 What property of the oil has a major effect on the film-forming properties of the oil?
7 When an oil oxidizes, what kind of acids are normally formed: organic, hydrochloric, or hydrofloric?
10 Direct reading ferrography uses _________ to collect ferrous particles.
8 What is considered to be the most commonly used grease?
Get the solution on Page 42. Machinery Lubrication
March - April 2011 39
A New Era of Reliability for the Philippines BY SUZY JAMIESON
aintenance practitioners in the Philippines now have the opportunity to network, exchange ideas and learn best practices in their very place of belonging - catering specific for the practitioners in the Philippines and neighboring countries. Erwin Bernal, a training consultant with the Center for Reliability Excellence (CRE Philippines), is heading the effort in the creation of the Philippines’ own “Association of Maintenance and Reliability Practitioners of the Philippines.” AMRP is an independent, not-for-profit, professional association dedicated to instilling excellence in maintenance and reliability in all types of manufacturing and service organizations by promoting maintenance and reliability excellence in the Philippines and neighboring countries. ICML just had the pleasure of taking part in the first annual “Reliability Asia Conference and Manila, Philippines,” at their impressive exhibition center, SMX Convention Center. Erwin Bernal and his team offered preconference workshops taught by renowned educators from Asia and North America; keynote addresses from Felicitas R. Angocillo-Reyes of the Philippines Department of Trade and Industry, as well as Carlos Aguilar Jr. of Holcim Philippines. The event was a multi-stream conference, with technical presentations covering a range of topics of interest, from lubrication best practices, reliability excellence and lean/six sigma disciplines. The conference was complemented by an exhibition and counted on industry delegates and exhibitors from across Asia and beyond. ICML also presented at the conference, joined by speakers from CJC, NCH Philippines, ISOPur, CEMEX Philippines, Noria, FocusLab Thailand, Le Price, ZENPOWER, Synerflex Consulting, Gerlrad Asia Pacific, Eagles Wings, Hewlett Packard, Fastfill, PdMA, IDCON, John Sample Group, Indian Oil, Manila Water Company and Wyeth. Exhibitors, speakers and delegates came from as close as Manila and other areas in the Philippines; from Hong Kong, Singapore, Malaysia and Thailand; as far as Australia, United States, Denmark, India and Saudi Arabia. The Department of Trade & Industry of the Philippines, the Philippine Society of Mechanical Engineering, the American Chamber of Commerce of the Philippines and the European Chamber of Commerce of the Philippines were also present and endorsed this milestone event. During the conference, practitioners were given the opportunity to join AMRP and have a say in the future directions for the emerging association. If you have an interest in AMRP activities or next year’s Reliability Asia conference, email Erwin Bernal at email@example.com.
40 March - April 2011
The International Council for Machinery Lubrication (ICML) is a vendor-neutral, not-forprofit organization founded to facilitate growth and development of machine lubrication as a technical field of endeavor. Among its various activities, ICML offers skill certification testing for individuals in the fields of machine condition monitoring, lubrication and oil analysis. ICML is an independently chartered organization consisting of both paid professional staff members and volunteer advisors. It provides lubrication and oil analysis standard development support, scholarship, skill-based testing and certification, and recognition of excellence. For more information about ICML, visit www.lubecouncil.org.
ICML offers lubrication skills certification For ICML testing, candidates are tested through a written, closed-book, multiple choice format exam which consists of 100 different questions and covers the requirements for each certification offered. Those being tested have up to three hours to complete the exam and are required to attain a 70 percent passing grade in order to achieve certification. As an ICML Certified professional, you will receive industry recognition of your knowledge and proficiency in machinery lubrication and/or oil analysis techniques; logos and certificates to enable you to identity your ICML certified status to colleagues or clients. ICML certification brings much-needed credentials to an up and coming lubrication and oil analysis community, as well as a respect for oil analysis and lubrication professions, and it also increases professionalism within the oil analysis community. The certification is good for a period of three years, at which time candidates will need to recertify to maintain the MLA/MLT/LLA status.
Need to take an exam? ICML regularly holds exam sessions throughout the United States and the world. Upcoming dates and locations for ICML exams can be found at www.lubecouncil.org Machinery Lubrication
Recent Recipients of ICML Certifications MACHINE LUBRICANT ANALYST – LEVEL I Mark Clayton Adams Gateway Energy & Coke Co. Edward G. Blankenship Jr. DC Water & Sewer Authority Praxedes H. Carrillo Siancas Minera Yanacocha S.R.L. Clyde Ferguson AES Ltd William Spedden Friend AES Ltd Mark D. Jones Lubrication Engineers Inc. Bobby Ryan Kennedy Gateway Energy & Coke Co. David King Arizona Electric Power Co Aaron Kirby Mosaic Company Harold R. Lloyd Lubrication Systems Company Adam Mosher Michelin Tires Corporation Rocky Allen Nelson AES Ltd Steffen D. Nyman C.C. Jensen, Inc. Dennis R. Pedersen Wells Dairy Inc. Jerry Wayne Pinkard AES Ltd Jim Preston Gateway Energy & Coke Co. Richard Wayne Ringer AES Ltd Robert Tapia Luminant Power Todd D. Thrasher AES Ltd Denny R. Trimpey AES Ltd Adam Wilcox Orange County Container Group LLC (OCCG) Chad Williams Cargill Inc. Howard Lee Winters AES Ltd MACHINE LUBRICANT ANALYST – LEVEL II Pablo Antonio Delgado SQM Nitratos S.A. Pablo Guillermo Pluspetrol Energy S.A. Carl C. Jensen Industrial Oils Unlimited Elio Pomar Minera Barrick Misquichilca S.A. Rick Scruggs Clark Tesling Services, LLC Larry S. Smathers Industrial Oils Unlimited Melvin Streeter Industrial Oils Unlimited MACHINE LUBRICANT ANALYST – LEVEL III Eduardo Anibal Carpio S. Sociedad Minera Cerro Verde MACHINE LUBRICATION TECHNICIAN – LEVEL I Chris Apsey Holcim Inc. Saeed M. Asiri Noria/Saudi Aramco Douglas Berlin Lubrication Engineers Inc. Patrick J. Blewett Shaw Industries, Inc
42 March - April 2011
Steven Dewayne Boatwright Alabama River Cellulose Clint Bolyn Alcoa Ryan N. Brandon Freeport McMoran Zane Bryant Alcoa Roy Cabezas Jara SKF del Peru Luis Campuzano Freeport McMoran Mike Chesson General Mills Ashley Clark Norske Skog Tasman Ken Coombes Contact Energy Sylvester S. Copley Freeport McMoran James Cowles Lubrication Engineers Inc. James Cumbee Alcoa Charles Dangerfield Alcoa Brenda J. DuFresne DuPont Bert Duron Freeport McMoran Michael R. Earthman International Paper Calvin Edwards Cargill Inc. Kenneth Elee Alcoa Randy Ervin United States Gypsum Co. Jason R. Eskridge Orange County Container Group LLC (OCCG) Derek Gardner Contact Energy Johnny Gelzer Charleston Water Systems Eliseo Guevara Alcoa Richard Joseph Guy DuPont Mike Hamill Freeport McMoran Richard D. Hancock DuPont Kevin Hand DuPont Mark Winther Hansen DuPont Mike Orosco Hernandez Freeport McMoran Greg Edward Holtz Alcoa
Jesus Edgar Huamani Cruz Sociedad Minera Cerro Verde Ken Hughes Power Partners Inc. David L. Hull Holcim Inc. Manvil Johnson Power Partners Inc. Christopher Dale Jump Armstrong World Industries Robert R. Kessler Freeport McMoran Adam Christopher Kovach DuPont John N. Lott Alabama River Cellulose Ronald A. Marlow Fluor Industrial Services William Matthews DuPont Scott McCain Alcoa Marvin McCoy PSEG Nuclear Tony Moye Alabama River Cellulose Andrew James Muhic DuPont Jesus M. Murguia Freeport McMoran William Francis Naylor Jr. DuPont Herbert H. Nettles Alabama River Cellulose Damien Peter O'Brien Australian Paper Tim Osmer Nucor Steel Decatur LLC Francisco J. Paez Alfonzo Noria Latin America Donald Kyle Painter DuPont Claudio Alberto Palmas Invista Tracy Dean Phillips Invista Josh Pickle Noria Corporation Walter Raki Norske Skog Tasman John C. Rambo Fluor Industrial Services Andrew Reeve Contact Energy Edward Nicholas Reid Alabama River Cellulose Charles Russell Richman DuPont Robert C. Riley Jr. Alabama River Cellulose Jared Rusden Norske Skog Tasman
Chris Sackett Charleston Water Systems Alfredo Sallabedra Alcoa Gayron Scurlock DuPont Larry K. Seales Alabama River Cellulose Mark William Smith Australian Paper Keith Andrew Snyder DuPont Deepak Sodhi Freeport McMoran Marcus Ivan Stallworth Alabama River Cellulose Bobby Stephens Alabama River Cellulose Arthur Sumter Invista Jeremy Swanson Luminant Power Morgan A. Tunnicliffe AG Industrial Michael J. Tupa Alcoa David Edward Verner Freeport McMoran Timothy Alan Ward Fluor Industrial Services Scott Weatherford Alcoa Benjamin Weems Lubrication Engineers Inc. Thomas Cody West DuPont Kevin P. Wiley DuPont Dwight W. Willis General Mills Brian Wommack Power Partners Inc. Steve Zinn Freeport McMoran MACHINE LUBRICATION TECHNICIAN – LEVEL II Justin A. Burke Alcoa Patrick Eugene Garrett Alcoa Brenda K. Graham Alcoa Francisco J. Paez Alfonzo Noria Latin America Christopher Stuart Tindell Alcoa Gerardo Trujillo Corona Noria Latin America Roberto Trujillo Corona Noria Latin America
From Page 39
D E A U T O M A T I C T R A N E R S I L G F O U R I E R T R A N S R N G T A L N I V I S C O S I T Y M C H I U M
B A S M I S S I O N F L U I D E I C O N S U Y F O R M I N F R A R E D B T E H R E T A G N E T I S M C
Includes Level II MLA Certification Preparation
Learn how to unlock the full potential of an oil analysis program in this intensive three day course. Oil analysis offers far superior early warning signals than other maintenance tools - even vibration analysis. You Will Learn How To: • Easily interpret oil analysis reports • Squeeze maximum life from lubricants • Pull oil samples for optimum results • Reduce oil consumption for quick savings
COMING TO: • Seattle, WA July 26-28, 2011
• Las Vegas, NV • San Diego, CA September 20-22, 2011 December 6-8, 2011
Enroll today! For complete details visit Noria.com or call 800-597-5460
© Noria Corporation
BACK PAGE BASICS
The Real Story on Automotive Filters JEREMY WRIGHT NORIA CORPORATION
arly automotive engines didn’t use any kind of filtration for the oil. It wasn’t until a patent was granted to Ernest Sweetland and George Greenhalgh in 1923 for their product the “pure oil later” or “Purolator,” that you could buy an automobile with a full pressure lubrication system. It would be many years later before a full flow oil filter found on today’s automobiles was incorporated. The 1940s would bring about filtration systems on mass produced vehicles, and the 1960s made oil filter changes much more convenient with the advent of “spin on” disposable filters. Through the next few decades, advances were made in the internal construction and filter media, making the filters much more efficient. Today, all automotive engines, whether gasoline or diesel, come with filtration designed to improve oil cleanliness and thus extend the life of that engine. What makes today’s filters better than those of the past is the filter media itself. Early designs incorporated steel wool, wire meshes, metal screens and more to keep the particles from entering the system. The next iteration of the media was in the form of bulk cotton or various woven fabrics, like linen. When disposable filters became popular in the 1960s, cellulose and paper were used to minimize production costs. Although cellulose and paper filters still can be purchased today, a better technology exists: synthetic media. Today’s filters are made of cellulose or synthetic media encompassed in a steel can. The top of the filter has a threaded center hole with smaller holes surrounding it. Oil will enter through the surrounding holes, pass through the media and exit the threaded center. The can typically screws directly to the engine block and uses an O-ring gasket to prevent leakage. Some filters will also have a drain back valve at the smaller surrounding holes to prevent dirt and debris that is trapped on the face of the media from washing back into the system during depressurization. There is also a pressure relief or bypass valve that allows the oil to bypass the media in the event that it becomes plugged or the pressure differential becomes too high. A good filter has a strong steel can to withstand the high oil pressure (60-80psi when cold), an anti-drain back valve that works without creating too much back pressure, a pressure relief valve that doesn’t leak below its opening pressure, and a strong element and cap that can withstand the pressure and flow of oil without falling apart. 44 March - April 2011
The element media has to be able to trap small particles, but not restrict the flow too much. Cellulose is used on economy filters. The fibers in the paper act as a mesh to block particles while still allowing the oil to pass through. Some manufacturers add other media, such as cotton, to the cellulose to improve its performance. Also, there is synthetic fiber media for the high-end filters that has smaller passages to trap smaller particles, but can also pass more fluid through because it has more passages, thus increasing the inherent surface area. There is also media that is a blend of the two. Not only does the type of media play a role in the filters ability to remove debris, but also the construction. Depth filters are usually made of a synthetic material that has a passage size gradient to it. In other words, the deeper into the element the oil goes, the smaller the passages get. This way, large particles are trapped on the surface and small particles get trapped deeper within, allowing the filter to hold more particles before it becomes too restrictive. So how do you know which ones to buy? A large portion of all passenger car oil filters are sold to do-it-yourself oil changers. Last year, that accounted for 189 million oil filter changes. Cost plays a major role in deciding what oil filter to purchase. The cost of a synthetic depth filter is almost double of that of the cellulose filter. It may only cost a few extra dollars in the beginning, but there have been multiple case studies on the effect of the cleanliness of the oil affecting component life to the tune of three to four times the life extension of the engine. Ask yourself the next time you are standing in front of a store shelf full of engine oil filters … “Is it worth a few extra dollars to me now to save an expensive rebuild down the road?” About the Author Jeremy Wright is a senior technical consultant with Noria Corporation. He serves as a senior engineering consultant for Lubrication Process Design projects 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 firstname.lastname@example.org.
ONE BADGE. THREE CONFERENCES.
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BRING A TEAM FOR BIG DISCOUNTS! Bring your team to cover all of the sessions and save save big. Details inside.
• Find out what’s new for 2011 • Learn at 75+ best practice sessions • Lubrication Excellence Managers Summit • Compare solutions from 70+ exhibitors • Meet new contacts at free networking reception • Save with early registration • Win a new utility ATV!
Don’t Miss This Keynote VINCE LOMBARDI JR.
“OUTSTANDING! We’ve already seen a HUGE RETURN on our INVESTMENT in attending this conference – and we’ve only just begun to implement the STRATEGIES we learned.” - Glenn Moore, Alcoa Mill Products
Welcome to Reliable Plant 2011 Vince Lombardi Jr.
3 Co-Located Conferences The three co-located events at Reliable Plant 2011 supply the tactics and solutions for substantial advances in plant performance and profitability.
The leading conference devoted exclusively to using effective lubrication practices to get the most from a plant’s physical equipment assets. These unique presentations, delivered by subject matter experts and successful lubrication practitioners, demonstrate how to achieve the efficiencies and financial benefits of a proper, proactive lubrication program.
Coaching for Teamwork Vince Lombardi Jr. Tuesday, April 19, 8:00 am Following in his father’s footsteps, Vince Lombardi brought direction, enthusiasm, and the impetus to succeed to the Seattle Seahawks, the NFL Management Council and the US Football League as president and general manager. He has the remarkable ability to put people ahead of the organization, allowing each individual to do what he does best without losing sight of team goals. He gained a reputation for being tough, yet fair, uncompromising, and yet supportive. Vince Lombardi’s enthusiasm for growth, change, and improved performance, blended with his first-hand knowledge of his legendary father’s leadership techniques will guide you to building a cohesive, teamwork-oriented environment at your company. Don’t miss this opportunity to learn highly effective team-building techniques from Vince Lombardi.
Spotlights the winning strategies and best practices that drive reliability results to the bottom line. Industry experts deliver compelling, practical learning sessions, with particular focus on case studies where the use of effective reliability strategies has led to measurable economic and productivity benefits. Identifies and examines the specific tools needed to quickly improve a plant’s total productivity, profitability, and safety and environmental performance. Case studies reveal how best-in-class companies use lean tools to improve the reliability and performance of their mechanical assets and overall operations.
Table of Contents Lubrication Excellence Managers Summit ............................................3 Conference Schedule ..............................................................................3 Certification ............................................................................................4
Lean Manufacturing Sessions ..............................................................16
• Secure answers and ideas to address specific issues and needs at your plant • Acquire new skills you can immediately apply on the job • Go home with the best tools and processes to implement and sustain a successful plant reliability program
Utility ATV Giveaway ............................................................................18
• • • • •
Preconference Workshops ......................................................................5 Lubrication Excellence Sessions..............................................................6 Reliability World Sessions ....................................................................12
Hotel and Travel ....................................................................................19 Conference Fees....................................................................................19 Registration Form ..................................................................................20
How You’ll Benefit From Attending and Implementing What You Learn
More time operating – less downtime More output per hour – yield Higher first-pass quality – fewer rejects Help develop a new generation of leaders Teams leave with a common vision and understanding • Low maintenance costs – organizations with the highest reliability have the lowest maintenance costs
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Conference Schedule MONDAY, APRIL 18
Jim Fitch, Noria Corporation Monday, April 18, 1:00 pm - 4:30 pm There's a revolution occurring. Managers who once desired equipment maintenance reliability now demand it … it is a matter of corporate survival in the global economy, and effective machinery lubrication is an essential enabler to success. This movement has let companies in all industries to take control of reliability by reinventing their lubrication programs. Those who are responding to the challenge are seeing amazing results … on the bottom line, where it counts most. The change goes beyond simply using better lubricants. The leaders are employing technologies, empowering employees and building ultramodern new practices – creating a new and energized reliability culture. The workshop will address the following topics: • Performance metrics for PM compliance, contamination control and lubricant quality targets. • How to evaluate needed lubrication and oil analysis skills. • The top 10 things organizations do wrong when trying to attain lubrication excellence. • How to benchmark your program to world-class and construct a master plan for transformation. • The role of certification, education and continuous improvement. • How to convert 80% reactive maintenance to 80% plus proactive maintenance without diversions – and make it stick! • How to leverage the “behavior factor” in lubrication excellence. • How to build a first rate lubrication team with the specific collection of skills needed.
7:00 am – 6:00 pm Registration at the Greater Columbus Convention Center 8:00 am – 4:30 pm Pre-Conference Workshops 5:30 pm – 8:30 pm Certification Testing (ICML)
TUESDAY, APRIL 19 7:00 am – 6:00 pm Registration at the Greater Columbus Convention Center 7:30 am – 8:00 am Continental Breakfast 8:00 am – 9:20 am Opening Keynote Session 9:30 am – 10:50 am Exhibit Hall Grand Opening 11:00 am – 11:50 am Conference Sessions 12:00 pm – 1:20 pm Lunch in Exhibit Hall 1:30 pm – 5:20 pm Conference Sessions 5:30 pm – 6:30 pm Meet and Greet Reception in Exhibit Hall 9:30 am – 6:30 pm Exhibition Hours
WEDNESDAY, APRIL 20 7:00 am – 6:00 pm Registration at the Greater Columbus Convention Center 7:30 am – 8:00 am Continental Breakfast 8:00 am – 9:50 am Conference Sessions 10:00 am – 10:50 am Refreshments in Exhibit Hall 11:00 am – 11:50 am Conference Sessions 12:00 pm – 1:20 pm Lunch in Exhibit Hall 1:30 pm – 5:20 pm Conference Sessions 3:30 pm – 4:40 pm Refreshments in Exhibit Hall 5:30 pm – 6:30 pm Networking Reception in Exhibit Hall 6:00 pm – 9:00 pm Certification Testing (ICML) 9:30 am – 6:30 pm Exhibition Hours
• The critical role of well-aligned lubricant suppliers and machinery OEMs. • Why on-site oil analysis is a “secret sauce” for world-class lubrication. • What kind of return-on-investment you can expect from your program. • The importance of standardization and procedure-based lubrication. • The honest truth about synthetics and premium lubricants. • Lubrication low-hanging fruit and quick kills. • The power of the daily one-minute inspection when done correctly. • Three crucial requests to make of component rebuild shops. • How to select a lubricant supplier and what needs to be put in a supply agreement.
THURSDAY, APRIL 21 7:30 am – 11:00 am Registration at the Greater Columbus Convention Center 7:30 am – 8:00 am Continental Breakfast 8:00 am – 8:50 am Conference Sessions 8:50 am – 9:20 am Refreshments in Exhibit Hall 9:20 am – 11:10 am Conference Sessions 11:15 am Giveaways in Exhibit Hall 8:50 am – 12:00 pm Exhibition Hours 3
Need a Reason to Attend Reliable Plant 2011?
Bring yo ur te session am and cover a s at Re ll of th See pag liable Plant 201 e 1 e 18 for details. .
Here’s a preview of what you’ll be able to do after attending the educational sessions:
• Make lubrication PMs more effective
• Use two leading maintenance KPIs
• Employ precision greasing for rolling element bearings
• Design a kitting and staging process for daily maintenance work
• Plan and execute an effective contamination control program
• Provide efficient maintenance systems while satisfying customer demands
• Use best practices to consistently pull datarich, representative oil samples
• Systematically engineer costs out of your maintenance budget
• How to select an oil supplier and get corporate buy-in
• Use more effective problem-solving methods in maintenance
• Facilitate efficient and effective lubricant transfers
• Engage and invest in your people to improve your reliability program
• Interpret and understand an oil analysis report
• Build reliability and maintainability into new or modified assets
• Convert from a bath-type lube to a spray system without changing lubricant • Get lubrication personnel to own and actively improve lubrication tasks • Apply lean manufacturing concepts within a non-manufacturing environment
• Maximize the talent of a team so it works at the highest potential • Reduce your changeovers from hours to minutes with SMED • Accelerate operational improvement results by applying lean principles to maintenance and reliability
• Make effective use of kaizen teams and kaizen projects • Dramatically reduce your cycle times, as well as scrap and rework costs • Increase your inventory turns and on-time delivery • Attain the lean goals of “better, faster and cheaper”
Certification Set Yourself Apart as a Leader Among Peers The International Council for Machinery Lubrication (ICML) will offer certification exam opportunities during Reliable Plant 2011. Advance registration is required. All exams will be conducted at the Greater Columbus Convention Center on Monday, April 18, from 5:30 to 8:30 p.m. and on Wednesday, April 20, from 6:00 to 9:00 p.m. To learn more about the certification types, registration fees and exam preparation, visit the ICML Web site at www.LubeCouncil.org or call 918-259-2950
Who Should Attend Whether you’re entry-level or a seasoned member of your plant’s management team, you’ll benefit from the comprehensive schedule of sessions, case studies and peer interactions. Attendees include:
Asset Care Planners CBM Coordinators & Specialists Chief Engineers Design Engineers Engineering Managers Engineers Facility Managers General Managers Hydraulic Specialists Industrial Maintenance Supervisors Industrial Mechanics Infrared/Vibration Technicians Lab Managers Lean Leaders Lean Managers Lube Analysts Lubrication Specialists Lubrication Technologists & Technicians Machinery Engineers Maintenance Engineers Maintenance Managers Maintenance Planners Maintenance Supervisors & Foremen Managers of Maintenance & Reliability Mechanical Engineers Operations Managers PdM Analysts & Specialists Planners & Schedulers Plant Engineers Plant Managers Preventive Maintenance Coordinators Preventive Maintenance Specialists Production Managers Project Leaders Quality Managers Reliability Coordinators Reliability Engineers Reliability Team Leaders Reliability Technicians Safety Managers & Directors Senior Reliability Engineers TPM Coordinators & Facilitators … and more
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Case Studies at Reliable Plant 2011 Learn from These Practical, Real Life Examples G ALL ATIN STEEL
Pre-Conference Workshops Monday, April 18 Outage Work Planning: Coordinating Outage Tasks to Align with Outage Schedules Tim Kister, Life Cycle Engineering 8:00 am – 11:30 am, Monday, April 18 Scheduled outages are the most expensive of all maintenance projects not only because of the loss of production, but also due to the expense of the maintenance performed. In many cases, as much as one third to one half of maintenance budgets are consumed during this downtime. Effective task planning coupled with precision work execution has a direct correlation to extending the time between outages and maximizing the amount of work scheduled during an outage. Effective planning is necessary in order to accomplish the maintenance activity, successfully restart the process/equipment and attain the confidence that equipment will operate at the desired rate and quality. This workshop will engage participants in a focused evaluation of their outage task planning processes and the effect on scheduling in order to accommodate an outage window. The workshop will address the following topics: • Required criteria for a concise scope for outage work • Elements required for thoroughly planned work • Examples of hazards and obstacles typically overlooked • Processes to address scope creep and/or discovery work • Management of material, tool and equipment requirements
Effective Greasing Practices Rich Wurzbach, MRG Labs 1:00 pm – 4:30 pm, Monday, April 18 Several studies were recently conducted to evaluate new technologies for improving lubrication for greased components. Included in the findings are the results of experiments to evaluate the effectiveness of relubricating shielded bearings in several orientations, use of auto-greasers, determining relubrication frequencies and quantities, using sensors such as ultrasound during regreasing, and grease sampling and analysis methods. This workshop will provide an overview of the findings of these studies, along with the best practices outlined to establish an effective greasing program.
Lubrication Excellence Managers Summit Jim Fitch, Noria Corporation 1:00 pm – 4:30 pm, Monday, April 18 There's a revolution occurring. Managers who once desired equipment maintenance reliability now demand it - it is a matter of corporate survival in the global economy, and effective machinery lubrication is an essential enabler to success. The Managers Summit is for managers who don't require technical expertise in lubrication, but need enough information to plan, organize, staff and support a best practice lubrication and oil analysis program with guidance and resources.
Detecting and Controlling Sludge and Varnish
See page 3 for more details.
Greg Livingstone, Fluitec 8:00 am – 11:30 am, Monday, April 18 There's a revolution occurring. Managers who once desired equipment maintenance reliability now demand it it is a matter of corporate survival in the global economy, and effective machinery lubrication is an essential enabler to success. The Managers Summit is for managers who don't require technical expertise in lubrication, but need enough information to plan, organize, staff and support a best practice lubrication and oil analysis program with guidance and resources.
Pre-Conference Workshops Half-day with Full Conference Registration ............................................$225 Half-day without Full Conference Registration........................................$295
Lubrication Excellence Journey Begins with a Plan Brenda Graham, senior staff reliability engineer, Alcoa Reliability engineers recognize a sizable gap in lubricant maintenance and create a plan for a lubrication excellence program using succinct steps. These steps are integrated and implemented to focus first on oil processes as they enter the facility. Moving then to operating equipment (gearboxes, pumps, compressors and turbines), lubricant reservoirs are updated with contaminant isolation devices.
Installed visual systems encourage people to respond to poor oil conditions. Steps are measured for progress and results. For example, oil is sampled and tested for ISO contamination codes before and after filtering to confirm results. Locking in positive gains encourages further implementation and more steps in the journey to lubrication excellence. Strategies for success discussed in this session include: • How to gain support for program • Setting a conservative timeframe
Noria’s Lube Room Challenge. In this session, you will learn how Clopay turned its lubrication habits from traditionally lacking to world class. Today, job plans for machinery lubrication are laid out in the plant’s CMMS system; virtually any employee could lubricate the machinery by following the job plans. Every zerk and gearbox in the facility has been mapped and identified. Critical gearboxes that traditionally had oil changed twice a year are currently surpassing eight years as the result of oil analysis and filtration methods. Attend this session to also learn: • methods to lubricate critical bearings as required without using manual labor; • best practices for storage of spare gearboxes and electrical motors; • best practices to accessorize gearboxes; • how to construct and organize a storage facility to accommodate machinery; • how to handle new oil shipments and used oil; • how to select an oil supplier, get corporate buy-in and drive change plant-wide.
• Alternative measures to success
for failure, Tim will provide attendees with the knowledge they need to avoid them and, in turn, create a world-class analysis program.
Modifying Equipment for Precision Lubrication Jarrod Potteiger, product and educational services manager, Des-Case Corporation Equipment modifications are a key component of transforming a lubrication program from one that is average to one that is truly world class. Many of the best practice methods for lubricating, inspecting and collecting oil samples require minor modifications to machines. Normally, these modifications will not require much time or expense and many can actually be performed while the equipment is in operation. In the beginning, it is important to identify the appropriate modifications for different classes of equipment based on criticality and the potential value of deploying advanced lubrication techniques.
In this session, participants will learn: • The most efficient methods and configurations for modifying oil reservoirs
• Encompassing external resources
Grease – Base Oil Viscosity Selection for Rolling Bearings
• How to select the most appropriate sampling hardware and location
• How to facilitate efficient and effective lubricant transfers Robert Scott, president, LubeWorks Ltd. “Grease should contain the same type and viscosity of • How to prevent lubricant contamination with simple and inexpensive techniques oil that would normally be used by itself,” quote from Booser and Khonsari, January/February 2007, Machinery Jim Fitch and Josh Pickle, Noria Corporation The most important part of your oil analysis program is Lubrication magazine. obtaining a representative oil sample. Without precisionIf this is true, then why do most of the multi-purpose Strategic Greasing for Element Bearings collected, data-rich samples, your oil analysis results and greases that we use contain an ISO 150 or 220 centistoke program will suffer. In this session, you’ll learn how to use base oil; but if that same common bearing was lubricated Stephen Sumerlin, senior technical consultant, best practice oil sampling tools and techniques to improve with oil, we would use an ISO 68 (approximately) viscos- Noria Corporation oil analysis accuracy and effectiveness. Included in the ity oil. Are we using the wrong grease? This discussion will When it comes to greasing there are many ways to get session will be review of several recently introduced sam- center on the base oil viscosity used in greases and the se- it right and get it wrong. There are misperceptions that lection of the proper oil viscosity for rolling element greasing is a simple task and doesn’t require any skill or pling products and techniques. bearings. To do this, we will need to use and understand dedication. Greasing element bearings is more of an exact viscosity-temperature plots, kappa values, minimum (re- science than not, stemming from weighing a shot of quired) viscosity values for various machine elements and grease from “your” grease gun to calculating re-grease NDm speed factors for rolling element bearings. volumes and frequencies. When compared to other lubriBest Practices from the Only Two-Time cation tasks, greasing is one of the more simple tasks in ICML Award-winning Plant execution, but it can prove to be a difficult task to execute Scotty Lippert, planned maintenance specialist and lubrication without flaw. This session will explore the strategies for Six Reasons Why Oil Analysis systems leader, Clopay Plastic Products proper greasing techniques for element bearings, and Programs Fail Clopay Plastic Products Company in Augusta, Ky., is expand your perception of the dedication and precision the only recipient of both the John R. Battle Award and that is required to get the most from each stoke of the Augustus H. Gill Award. The site also is a past winner of Tim Nelson, technical services manager, Insight Services grease gun. The practice of oil analysis has been proved time and again to be an effective approach to reduce maintenance and downtime costs. However, many lube analysis programs do not deliver outstanding results. Join Tim Nelson How to Read an Oil Analysis Report as he explores some of the most common reasons why Full conference attendees receive an lube analysis programs fail and what you can do to help Jim Fitch, Noria Corporation $1,195 Noria training coupon. ensure yours will succeed. The goal of this session is to Interpreting an oil analysis report isn’t difficult once you See page 13 for details. provide valuable insight into the six most common reasons understand the different elements and how it is prewhy oil analysis programs fail. By focusing on the reasons sented. In this session, you’ll learn exactly what to look
Effective Oil Sampling Tools and Techniques
DID YOU KNOW?
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for on a report, how to get the most out of the data reported, and when to suspect a poor sample or bad test result. Included in the session will be the importance of new oil baselines, proactive limits, predictive alarms, and exception testing.
Lubrication Journey – Setting the Cornerstone for Improved Plant Reliability Paul Bonorden, mechanical reliability engineer, INVISTA This case study session provides one plant’s story of how they built a lubrication program to increase their overall plant reliability. INVISTA in Victoria, Texas, will describe how its plant was transformed both physically and culturally. Building a world-class lubrication program is not simply a matter of building a lube room and filling it with clean oil. This presentation will give an overview of the concerns that were identified along with the thought processes behind the choices. Key take-aways will include:
• Who needs to be involved in setting up a lubrication program • What do you keep and what do you throw away • Evaluating vendors • What needs to be included in the scope • How lubrication storage and distribution integrates with daily and outage needs • Sometimes more is not better • What metrics can do for your program
Effective Lubrication Storage Eliminates Failure Modes
Successful Lubrication in an OperatorDriven World-Class Manufacturing Initiative Al Wills, senior Asset CARE engineer, and John Rowell, condition-based maintenance technician, MillerCoors MillerCoors’ lubrication systems ensure that the operating teams avoid premature equipment failures due to inadequate lubrication in a high-speed production environment. To be successful, the team must use the correct lubricants. The lubricants must be clean. The correct amount must be consumed. The team must know and react when rotating components are outside normal operating temperatures. Since the operating team has a limited understanding of lubrication principles, the systems must be designed so that it’s difficult to make a mistake. In this case study session, you’ll get an in-depth look at the innovative ways this is accomplished at this MillerCoors facility.
Implementing Lubrication Excellence at Goodyear – A Case Study James (Jim) Brown, Maintenance Manager Tire Assembly Division, Goodyear The Tire Assembly Business Center of the Goodyear Tire & Rubber Company plant in Fayetteville, NC was selected to pilot a Lubrication Excellence program. The advantages of a relatively clean environment, newer machines and seemingly easy accessibility of lubrication points were quickly overshadowed by multiple difficulties. There was very little lubrication related technical information available. The training of the associates was not at the desired level. There was not a well-defined way to store and handle lubricants. While the organizational culture was favorable to a Lubrication Excellence Program, they were unknowledgeable on the essential requirements. In this case study you’ll learn what this program has achieved, what it took to get there and its plans for the future.
Terry Harris, president, Reliable Process Solutions Developing effective lubrication excellence programs is a giant step toward becoming more reliable and extending equipment life. Efforts to decrease particles in lubricating oils are very effective at reducing component failures in bearings and gears. We do this by establishing a cleanliness level for our lubricants and then filtering our lubricants to that level. A real effort needs to be made up How to Construct a Lube Supply front by designing and installing proper lubrication receivAgreement ing and storage areas that filter all lubes and keep the stored lubes away from any contaminants and in a con- Mike Johnson, principal consultant, AMRRI trolled environment. Portable lube storage may be an Establishing corporate contracts to purchase materials, economic option. particularly lubricants, holds a bittersweet appeal to many. Mill personnel work closely with their vendors, in some cases for a prolonged period, to establish business relationships deliver results when the chips are down. While it makes good sense to bundle purchases together in order to leverage increased volume into improved pricing, improved Bring your team and cover all of the delivery and the hope of improved service, the reality for sessions at Reliable Plant 2011 and save many is that corporate purchase agreements do not deup to $645 per person liver. However, sometimes they do deliver. Come take a look at one approach that has worked well.
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Practical Field Results of a New Reservoir Design Used in Circulating Oil Lube Systems Matti Lopponen, business development director, SKF USA Inc. Although overall technology and new material development has accelerated since World War II, very little has happened in the traditional design of a circulating lube oil system. Recently an efficient oil circulating lubrication system and reservoir design has been developed. Now after several field installations, there is clear evidence that this solution is far better than the traditional designs. Air and moisture/water content can be greatly reduced and total oil volume in a system can be reduced. The solution improves the reliability of the machinery to be lubricated and has a positive environmental impact.
Converting from a Bath-type Lube to a Spray System Without Changing Lubricant Juan Bautista Lee, preventive maintenance consultant, Center for Reliability Excellence Branded as the sunset industry in the Philippines, one sugar cane mill decided to challenge traditional practices and saved big. Find out how the plant managed to shift from bath-type lubrication to their modern, fully automated spray system without the need to change their economical lubricant. This generated tremendous savings in environmental cleanup costs without the need for a premium in
REAL RESULTS REAL HEROES Frito-Lay Fayetteville, TN Since concentrating their efforts on improving their reliability and lubrication programs Frito-Lay has achieved a 58 percent decline in equipment downtime and a 44 percent drop in overall downtime company-wide. Equipment-related downtime at the Fayetteville plant is only 0.7 percent.
the recurring lubricant purchase cost. You will also learn • How the reliability of equipment is directly affected by Online Particle Counters = Predictive lubrication personnel how they managed to spray 12 spray panels with just one Maintenance = Cost Savings centralized system, and it is operational for seven years • How to elevate the critical nature of the lubrication tasks and counting in the eyes of management Phil Keep, managing director, MP Filtri UK Ltd. The approach presented in this session revolves around Online particle monitors can analyze your systems 24/7, the fact that by elevating the status of lubrication person- initiating internal and external alarms should any levels of Putting the Simple Back into Viscosity nel through increased responsibility, ownership and contaminate or (in some cases) moisture levels change. recognition of their contributions, lubrication personnel will These alarms can initiate external functions from simply John Sander, vice president of technology, add more value to the reliability of equipment. putting a warning light on, controlling a traffic light seLubrication Engineers quence (red, amber and green), turning an offline filtration Simply stated, viscosity is defined as the resistance of a Kidney loop system on or even shutting down the system. fluid to flow. That doesn’t sound too difficult, does it? Protection is provided for your components and applicaUnfortunately, new temperature, speed and pressure New Standard Guide for Microscopic tions, thus eliminating and reducing high-cost breakdowns demands on lubricating fluids have changed over the years, Characterization of Particles from Inand unscheduled downtimes. resulting in more and more classifications being created to Service Lubricants (ASTM D7684-2011) describe lubricant viscosity. Some examples are SUS, cSt, If you are inquiring, “Can I afford contamination monicP, ISO 46, SAE 5W30, AGMA 5EP and 80W90. It’s enough Ray Garvey, engineer, Emerson Process Management toring products?”, the answer is, “Can you afford not to?” to make a person’s head start to spin. This presentation This session introduces a new ASTM Standard, D7684- The benefits of online particle counting include: will summarize some of the more commonly used viscosity standards, describe briefly the basics of the tests used 11, “Standard Guide for Microscopic Characterization of • Saving money on total cost of filtration, eliminating unscheduled filter changes to verify the fluid against the specification and eliminate Particles from In-Service Lubricants”, which suggests stansome of the confusion all of these standards may create dardized terminology to promote consistent reporting, • Constant system monitoring = predictive maintenance provides logical framework to document likely or possible for the end-user. = cost savings root causes, and supports inference associated machinery • Constant system monitoring = tracking system cleanhealth condition or severity based on available debris liness = cost savings analysis information. Microscopic characterization of parElevating the Status of Lubrication • Prolonging major component life due to predictive mainticles extracted from in-service lubricants is extensively Personnel and its Effect on Reliability tenance used today. Tom Hiatt, reliability engineer, Covance Inc., and Wayne Ferguson, former consulting engineer (recently retired), Eli Lilly This session will provide real-world examples of how elevating the status of lubrication personnel can improve the reliability of equipment and, as a result, can increase the bottom line and give a company an advantage over its competition. By giving individuals tasked with lubrication responsibilities, the proper tools, education and respect, they will seek out new and innovative ideas to assist in the journey toward reliability excellence.
Technicians extract particulate debris from an oil sample, display it on a flat surface, and inspect it using a microscope, looking for shapes, textures, colors and other characteristics associated with particular contaminant particles or wear particles typically found lubrication systems. These techniques may be used for extracting and displaying the debris: ferrography, membrane filter patch analysis, filter debris analysis, magnetic plug inspection. During this presentation, participants will learn how to apply this new ASTM Standard for achieving common The audience will learn examples of: form and terminology to facilitate broader use with better • How to get lubrication personnel involved in the main- understanding of microscopic wear particle analysis findtenance decision-making process ings. Participants will also understand how ASTM • How to get lubrication personnel to own and actively D7416-2010, ASTM D7670-2010 and ASTM D7690-2011 improve lubrication tasks recommend best practices for minilab patch analysis, • How to recognize the accomplishments of lubrication more-generic membrane patch analysis and analytical ferrography, respectively. personnel
• Save time: high-cost processes effectively monitored • Predictive control: low-cost, efficient method of system monitoring when system cleanliness levels are exceeded
The Pros and Cons of the Various Wear Analysis Methods Patrick Kilbane, North American sales manager, ALS Group – Tribology Division This session will cover the most basic particle analysis methods from spectrochemical analysis and particle counts to ferrous concentration instrumentation to analytical ferrography and other advanced testing. We will explore these methods and instrumentation to assess what they are measuring, any interferences, target applications for these methods, and how to use them effectively.
“Excellent conference! We’ll
“This is a CAN’T-MISS EVENT for me.
“I got a WEALTH OF INFORMATION
REDUCE OPERATING EXPENSES
I took what I learned back to the plant
from sessions and workshops, and the
by at least $35,000 annually. The
and PUT IT TO USE IMMEDIATELY. ” - Hack Hensley, Mitsubishi Polyester Film
INTERACTION with PROFESSIONALS helped me SOLVE SOME ISSUES
BENEFITS DEFINITELY OUTWEIGH THE COST of attending.” - Jim Schneider, East Texas Salt Water Disposal Co. 8
at my facility.” - Kenny Myers, ISP Chemicals
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Analyze This: Why You Need to be Analyzing Your Oil David Haught, president, Esco Products Robert De Niro and Billy Crystal understood the risks associated with allowing things to take their own course in their 1999 hit movie “Analyze This”. And although the consequences of not doing any analysis may not be as dire as theirs, the rewards of doing something can produce results that will surely meet your ROI objectives and make you look like a hero in avoiding unnecessary downtime repairs through an oil analysis program.
Optimum Filtration Strategies for Industrial Fluid Systems (Lube, Hydraulic, Fuel) Christian Bauer, staff scientist, Pall Corporation Fuel, lubricants and hydraulic fluids are the lifeblood of many modern industrial processes, from mining, the fuels and chemical industry, to power generation and manufacturing. In order to maximize productivity and reliability, it is critical to maintain a specified level of fluid cleanliness, which can be achieved through a comprehensive approach to cleanliness control, integrating filtration and separation technologies with complementary, process-related solutions. The selection of the right filtration and separation technology for any specific process can be a daunting task, because different fluid applications require different filtration solutions.
Do you wonder about the condition of your oil and not know how to assess it? As with training for a marathon or preparing for any other long-term objective, the hardest step is the first one. Don’t be overwhelmed by oil analysis; don’t think it has to be complicated, sophisticated or expensive. In this work, the author introduces typical filtration and Come join others at “Analyze This” and learn how easy it is separation solutions for a wide range of industrial fluid apto start and maintain a complete visual oil analysis program plications, from on-board hydraulic systems to lubrication with just a series of steps to get a lot out of a little. systems and large bulk fuel delivery and distribution systems. Some of the topics include: stress-resistant, high-efficiency filter elements for hydraulic applications; A New Look at In-Service Fluid Analysis low-differential pressure, optimized service life filter elements for lubrication systems; and specialized kidney-loop Dave Wooton, founder and principal, Wooton-Consulting, and solutions like varnish removal filtration, purifiers to deal Dave Hilligoss, lubricants segment leader, PerkinElmer with non-particulate contamination. For each of the fluid The process of understanding a lubricant’s degradation applications, guidelines for selecting, placing and sizing an is the key to any maintenance program. With proper infor- appropriate filtration system are also discussed. mation, one has the ability to design maintenance programs that fits properly with what is happening to the lubricant. Today, there are many methods of testing the Gill Award: A Case Study of fluid that allow great opportunity to understand the Recipients and their World-class process. However, this objective cannot be obtained by Oil Analysis Programs simply measuring one chemical or physical property, but the measurement of many such properties. To draw a full Suzy Jamieson, executive director, International Council for understanding the analyst must obtain the array of test re- Machinery Lubrication sults, then observe the relationship between these results. Oil Analysis is an important function of maintenance and This session is designed to show the advantages of a total reliability. Although many companies have now identified holistic approach to the analyses. It will show that the cor- the need to develop or improve oil analysis programs, just relation between multiple test types for a lubricant is a where and how to start is still a mystery to many. A road preferred approach. It is also designed to show what can map is needed for world-class lubrication, and with this in be seen when one looks into having complementary data mind, the International Council for Machinery Lubrication (ICML) created its Augustus H. Gill Award for Excellence in on the sample. Oil Analysis. This session will explore the criteria of the Gill Now that the lubricant analyses programs have matured Award as exemplified in the oil analysis best practices imthe concept of using multiple test protocol to properly unplemented by some of its recipients. These oil analysis derstand the fluid and equipment condition is important. program have earned international recognition as benchThe interpretation of the data then becomes the most immark programs for the oil analysis industry. This session portant aspect of the testing. By cross-correlation these also addresses the impact of world-class oil analysis prodifferent results in an expanded interpretation one yields a grams on the reliability of lubricants and machinery. It will much bigger picture of the fluid’s condition. The better we describe the proper steps taken in the design and implecan develop a clear understanding of the fluid’s condition mentation of oil analysis programs at two recipient the better we can predict its life and build our maintenance companies and the impact of such programs in their maprograms. This presentation is designed to discuss how chine reliability and corporate support of overall this holistic approach can be implemented. There will be maintenance activities. It describes how their oil analysis several examples that will demonstrate how it is success- programs were established, how they obtained buy-in of ful in improving the understanding of the fluid’s condition – stakeholders and the actual steps for implementation of and thus the equipment’s status. their programs.
Real Results. Real Heroes.
Bulk Oil and Fuel Filtration System Designs and Recommendations Philip Johnson, director for new business development – Liquid Filtration, Donaldson Company This session will cover filtration system design concepts to reduce the cost of filtration and to correctly size systems for high-viscosity, medium-viscosity and lowviscosity fluids, and how to minimize maintenance and downtime associated with contaminated fuels and oils. It will give guidance to setting effective cleanliness levels for both oils and fuels to meet modern OEM specifications. It will cover aspects of the new Tier 4 diesel engine cleanliness requirements and touch on some unusual but increasing contamination issues associated with biofuels, ultra-low sulfur diesel and electrostatic damage to bulk filters.
The system design aspect of the session will explain the changing philosophy on where the best place is to position filters in order to minimize filtration costs and improve performance, and how filter design has changed to be able to achieve this. The session will also cover new approaches to removing water contamination from oils and fuels, in particular diesel fuels, where traditional coalescer water separators are no longer affective due to new fuel additives.
Navigating the Options for Worm Gear Lubricant Selection Greg Kayes, Klüber Lubrication North America L.P. Can the type of gear oil really improve the efficiency of my worm drive gearbox? What allows certain gear oil chemistries to have significantly longer drain intervals for
REAL RESULTS REAL HEROES MillerCoors Within 5 years of beginning a lubrication improvement program MillerCoors realized approximately 25 percent improvement in machine efficiency, translating into millions of dollars in savings.
worm drive gearboxes? How can I reduce the sump temperature in my worm drive gearbox without installing an oil cooler? Answers to these questions will be discussed during this presentation as well as why synthetics in general are better lubricants for worm drives. There will be a comparison of gear oil chemistries on a worm gear test rig that will show how each base oil chemistry (mineral, PAO, PAG and ester oil) affects sump temperature, friction and wear. This information will benefit lubricant specifiers for gearbox manufacturers and OEMs as well as lubricant purchasers for end-users. Learning points will include: • Key characteristics of various base oil chemistries.
detect contamination or lubricant breakdown in condition monitoring applications. This session presents the concept of measuring viscosity of in-service lubricating fluids using Poiseuille’s Law, which equates the pressure drop of a fluid flowing across a pipe to its viscosity. The session will show how this method is quite suitable for condition monitoring applications and how this technique compares to traditional laboratory-based kinematic viscometers.
The Basics of Designing an Effective Electric Motor Re-greasing Program
• The application benefits of polyglycol gear oils over Jeremy Wright, senior technical consultant, Noria Corporation Most electric motors are designed with grease lubriother synthetic and mineral oils in worm gear drives. cated, anti-friction, rolling element bearings. Grease is the • Test data/results used to compare the various oil lifeblood of these bearings, providing an oil film that prechemistries in worm gear drives vents the harsh metal-to-metal contact between the • Considerations for the changeover from one oil chem- rotating element and races. Bearing troubles account for istry to another 50-65% of all electric motor failures, and poor lubrication practices account for most of them. Good maintenance • Seal and material compatibility considerations procedures, planning, and the use of the correct lubricant can significantly increase productivity. The rolling element bearings used in electric motors potentially have many A New Way to Measure modes of failure if an incorrect strategy is implemented. Dynamic Viscosity for Condition These modes include incorrect lubricant selection, contamination, loss of lubricant, and over-greasing. In this Monitoring Applications presentation you will learn several effective strategies to Thomas Barraclough, and Daniel P. Walsh, Spectro Inc. minimize the likelihood that one of these failure modes Viscosity remains the most important physical property will happen. of a lubricant and is still an essential measurement to
Planning and Executing a Lubricant Contamination Control Program
REAL RESULTS REAL HEROES Valero Energy Valero Energy has had dramatic results since improving their lubrication beginning in 2007:
Stephen Sumerlin, senior technical consultant, Noria Corporation While contamination control sounds simple in theory, hitting your target lubricant cleanliness levels is often difficult. Knowledge and time are two of the biggest obstacles. To outfit equipment with proper contamination control devices, you must understand the lubrication program goals, what contamination control devices are needed for each application, and how to use and maintain them to maximize their ROI. In this session, you’ll learn how to plan and execute a contamination control program that meets your needs. You’ll learn the contamination control devices, modifications and time management techniques necessary to ensure a successful program.
compressors. One of the failure modes of the lubricant is the development of deposits, which will increase the temperature of the fluid risking further degradation and system reliability. This session summarizes the common lubricant failure mechanisms in compressors and the impact that this has on plant reliability. In addition, key condition monitoring tests are detailed to predict the failure point of compressor oils in order to determine the optimum oil change interval. Finally, the presenters outline contamination control strategies that have been useful in extending the life and performance of these fluids.
Effective Lubrication for Mining Equipment – A Case Study Alejandro Meza, Confialub Consultoria em Lubrificação, and Daniel Sarges, Engineering Manager, Mineração Rio do Norte In this case study session learn how best practice lubrication, contamination control and oil analysis were reengineered for equipment in a bauxite mine in Brazil. As a result lubricant purchases and machine breakdowns were greatly reduced and bearing life improved substantially. Get the details in this informative case study.
Cost Benefits of Routine Grease Sampling and Analysis for Mission Critical Equipment Rich Wurzbach, MRG Power Labs As part of a comprehensive predictive or condition-based maintenance program, oil analysis is an effective complement to other diagnostic technologies, and cost-benefits have been well documented. However, when the equipment is grease lubricated rather than oil lubricated, the important lubricant analysis piece is usually left out of the mix. New tools have been developed for improved sampling techniques and grease analysis tests to include lubricant analysis for grease lubricated equipment. In this session you'll learn how these new technologies can produce improvements in reliability and reductions in lubrication costs through condition-based greasing and trending of wear levels.
Motor, wind turbine, motor-operated valve, and robotic assembly examples will be given for these cost-benefits, and case studies will be shared that demonstrate the return on investment in routine grease sampling and analysis technology.
• $140,000/year savings on lubricants • Plant availability approaching 98 percent - impressive for a refining plant • Reduced slip/fall and environmental hazards, plus fewer injuries
Improving the Performance of Industrial Compressor Lubricants Greg Livingstone and Jo Ameye, Fluitec International The high thermal stress and possible ingression of reactive gases accelerates lubricant degradation in industrial
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Overcoming Extreme Online Condition Monitoring Challenges Rick Brooks, Project Manager, Timken Services Group A “Catch-22” situation exists in applying online condition monitoring systems. The applications where condition monitoring is most needed and would provide the greatest return on investment are also the applications that are the most technically challenging. Very low speeds and short machine duty cycles present great difficulty in obtaining accurate PdM results. Dangerous environments and mobile or difficult to reach locations present challenges to gathering the data. In this session you’ll learn about a convergence of new technologies that can now be applied to achieve extraordinary ROI results in variety of industries.
Real Results. Real Heroes.
bricants tailored to the unique needs of the food industry Adding an Online Filter has been achieved by the lubricant industry. This session – Practical Examples and Frequently will explore the advances in food-grade lubricants with a Asked Questions discussion of the different chemistries involved, synthetic vs. non-synthetic, and the performance characteristics of Steffen Nyman, C.C. Jensen each. In addition, it will discuss where the industry is Offline filters are one of the most cost effective ways to headed with regard to new product certification. Key learnachieve and maintain oil target cleanliness levels. In this ing points are as follows: session you'll learn how offline filters are typically dimen• How and why an optimized lubrication program can pos- sioned and installed, how you can design an offline filter itively impact the bottom line yourself, which oil cleanliness level you should aim for • Technology trends (synthetics vs. minerals, perform- based on the oil system components, how much water ance of food-grade vs. non-food-grade lubricants) contamination is recommended in different oil applica• Understanding the registration and certification pro- tions, and which systems could benefit from an offline grams related to lubrication (ISO 21469, NSF H1/ H2) filter capable of removing varnish. The speaker will also address several other frequently asked questions about offline filtration.
Bearing Repair Provides Valuable Alternative to Bearing Replacement
Special Lubricants for the Food Processing and Pharmaceutical Industries Kimberly Eldridge, North American market manager – Food, Beverage, Pharmaceutical, Klüber Lubrication North America L.P. Choosing the right lubricant for any application is critical to its success, but it is especially so in the food industry, where specific criteria that must be met. While food-grade lubricants must meet the general technical requirements of reducing friction and wear, protecting against corrosion and dissipating heat, they must also go one step further. The challenge of developing specialty lu-
Dan Szoch, The Timken Company When a bearing is damaged, it is often removed from service and replaced before it reaches its full, useful and economical life. Advancements in bearing design, materials, bearing maintenance and repair methods have greatly improved the potential for and popularity of bearing repair as an effective way to extend the life of the bearing. In this session you’ll learn how a repaired bearing can often be returned to like-new specifications in about 1/3 of the time and at a savings of up to 60 percent of the cost of a new bearing.
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Hydraulic Power Unit Contamination Mitigation Case Study Brian Womack, Reliability Engineer, Power Partners, Inc.
This well-documented case study describes how Power Partners transformed their fluid storage and handling and contamination control procedures to drastically reduce oil consumption plant-wide and save more than $46,000 annually. You’ll see how 94 hydraulic power units were cleaned-out and modified to keep contamination out, resulting in major improvements in fluid cleanliness.
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Leading Key Performance Indicators for Maintenance Organizations
resulting in lost revenue. These outages can damage the reputation of power providers, whose primary objective is to deliver high-quality, reliable and uninterrupted power at the lowest cost to consumers. This session will explain how Westar Energy implemented a condition-based monitoring (CBM) program across its fleet of energy centers. The advantages and benefits of each technology will be discussed along with considerations you might contemplate if deploying a program at your site. Additionally, case histories from actual finds will be covered in detail.
Mike Shekhtman, North American manager of maintenance and reliability, Goodyear Tire & Rubber Company Key performance indicators (KPIs) are used by business leadership to set objectives, measure performance, identify if the team is ahead or behind, and then make strategic and tactical adjustments. Quite often, especially in industrial maintenance organizations, KPIs are of the lagging kind. Those are reactive indicators when a certain business measurable is already achieved. Common equipment downtime metrics are of that type. Decisions based on downtime numHow to Sell Maintenance to Upper bers can only affect outcome of the future business time Management intervals. This session will demonstrate two unconventional indicators that fall into the category of leading KPIs, the met- Christer Idhammar, IDCON rics that help drive current business cycle objectives. These Selling maintenance to upper management can be a are “Percent Planned Maintenance Man-hours” and “Six- challenge. In some cases, it depends on current manageMonth Trend of Percent Maintenance Downtime”. ment’s attitude toward improved maintenance; but often, it depends on the ability to sell the concept of improved maintenance. The starting point is to avoid selling maintenance services. Maintenance departments should NOT Reliability Optimization through Kitting provide maintenance service; they should provide equipand Staging ment reliability in a partnership with operations. This session will discuss practical and simple tools in how to Robert Crotty, senior manager for materials and approach management from financial, practical and praginventory, Luminant Luminant began applying lean manufacturing principles matic angles. Come listen to this session speaker, who in 2004 and started a reliability optimization initiative in presents the benefits of improved reliability for managers 2005. One of the key areas where the maintenance work- in different industries all over the world.
flow and the materials workflow converge is providing the right parts at the right time in an efficient method to maintenance crews. This led to the challenge of delivering parts ACH Foods Shifts from Run-to-Fail to for a work order to the point of use for a maintenance crew. True Equipment Reliability Luminant’s Martin Lake Steam Electric Station was the pilot site to design, test and prove out the concept. The Michael Pratt, maintenance supervisor, ACH Food Companies process began implementation in 2008 and is now a stanIn February 2008, ACH Foods’ Argo plant had very poor dard being implemented across the Luminant Fleet due to efficiency numbers and increasing production costs. They the success of the application. hired a reliability specialist to bring equipment reliability Attendees of this session will learn how to design a kit- (ER) and effective/quality maintenance (EQM) to a 100ting and staging process for daily maintenance work. This year-old plant and an aging workforce that ran the will include what are the main activities to complete with equipment to failure with little or no preventive maintethe planning and scheduling components along with the nance. The broke-fix and run-to-failure operations were warehouse workflows. Interactions with EAM, CMMS and impacting efficiencies, cost and production capacities. This inventory control systems and the necessary audit re- case study will highlight the successful implementation of quirements will be addressed. They will also understand ER fundamentals that have seen downtime decrease by 75 some of the key challenges, lessons learned and cultural percent, lubrication failures lower to near zero in 2010, changes needed to be successful. Attendees will get an MRO spend savings of 20 percent, and implementation of understanding of the basic lean, reliability and IT methods a method to collect, store and report data for established key performance indicators. used to deliver a successful outcome. Equipment and plant reliability does not have to be reserved for the large corporations with millions to spend and billions at stake. Small companies that are struggling to run The Use of Multiple Predictive their production processes reliably can benefit from ER iniTechnologies in Electric Power tiatives like lubrication management, MRO control, Generation thermography, ultrasound and CMMS management by folBy Mike Paulsen, maintenance technician, Westar Energy lowing a pay-as-you-go and a methodic step-by-step Catastrophic equipment failures at power generation fa- process. ACH Food Companies has seen steady and concilities can result in costly repairs and forced outages tinuous improvement since 2008.
Sifting Through the Facts and Myths to Increase CMMS/EAM Functionality Terry Harris, president, Reliable Process Solutions CMMS and EAM systems have many facts and a few myths attached with the sales programs and actual operational capabilities in the plant. Looking at the CMMS through the eyes of the plant accountant can be much different than through the eyes of the plant maintenance hourly worker. How can we make it more effective for both groups and improve functionality? This session will show you how!
How Lubrication Practices Can Contribute to an Overall Reliability Program Chad Chichester,Dow Corning Proper lubrication can contribute significantly to reliable, long-lasting, quality performance of equipment. This discussion will highlight practical application of lubrication knowledge to improve asset reliability and maintainability at Dow Corning’s Midland, MI Manufacturing Plant. Discussion points include a brief overview of lubricant fundamentals and lubricant selection, an overview of lubricant best practices and management in reality, and lubricant condition monitoring techniques, along with case histories where lubrication understanding led to improved asset reliability. Interested in learning how your lubrication practices can help optimize preventative maintenance operations and help reduce non-scheduled maintenance? If so, this session is for you.
REAL RESULTS REAL HEROES Packaging Corporation of America, Tomahawk, WI Packaging Corporation of America focused intensely on their lubrication processes, training and lubricant contamination control. As a result oil usage dropped 28% and unscheduled downtime dropped 62% on one paper machine and 37% on another.
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pairs. Implementing and sustaining a kitting program to support planned maintenance can be a challenge in any manufacturing environment; however, when multiple business units are involved, the magnitude of the challenge Stephen Hilscher, rotating equipment inspection leader, INVISTA increases exponentially. This presentation will discuss the various items that a During this session, participants will learn how U.S. company needs to consider before implementing a new reliability program. There are many different justification and Sugar Corporation applied materials management best benefits that you can use to sell a program other than the practices to combine several existing storerooms into a data that you get from your CMMS. The benefits of a pro- single, central storeroom. A planned work kitting program gram can come from non-traditional sources. This session was implemented to support equipment reliability in two will discuss many different topics that INVISTA addressed separate business units.
How to Introduce a New Reliability Program
not only to start a reliability program but to instill a reliability culture. This is a reflective view of a lubrication program that was successfully instituted by INVISTA in Victoria, Texas, but is applicable to any new initiative. Key learnings will include:
What’s Next for Infrared Thermography? An Examination of Next-Gen Technologies
• What needs to be considered prior to announcing a new Ray Garvey, engineer, Emerson Process Management program Today, an excellent thermography system will fit in the • Who needs to be involved in the program palm of your hand and cost as little as $2,000. The trend to less expensive and smaller, more ergonomic and versatile • How the critical is the timing of a program rollout computerized thermography systems continues. Prices are • How to influence a culture change still dropping while camera system performance and relia• How complex does the program need to be bility are maintained. For the first time ever, you can now choose from more than a dozen different makes and many • Tips to stay on track to avoid scope growth more different models to get an infrared camera system suited to your particular needs. During this session, you will learn, “What’s next?” The speaker will provide his Planned Job Kitting Drives Equipment views and insights on next-generation technologies and Reliability at U.S. Sugar applications and explain the potential benefits to plant professionals. He will detail how next-gen cameras will be Randy Hall, warehouse manager, United States Sugar more application specific, ready to use and simpler, parCorporation, and Wally Wilson, senior subject matter expert, ticularly for new users. Life Cycle Engineering A planned job kitting program is an effective materials management practice that can support and drive equipGo Green or Go Home: How to Raise ment reliability. Planned job kitting means that the right Reliability and Efficiency and Survive parts are in the right place at the right time and at the right the Corporate Ax price in order to increase maintenance craft utilization. Job kitting ensures that the correct parts are available for equip- Harold Joyce, PdMA Corporation ment maintenance before production is interrupted and In the wake of sweeping energy regulations and inmaintenance crews are lined up to perform the needed recreased competitive strategies, aging facilities are no
Real Results. Real Heroes.
longer being allowed to perform at sub-energy efficient levels. As corporations choose which facilities are too costly to maintain, ultimatums have been handed down to facilities to either increase their energy efficiency levels or face the inevitable plant closure possibility. For those working at these aging facilities, asset reliability and energy efficiency have never been more important. This session will follow the efforts of multiple facilities within a corporation to increase their productivity through reliability and efficiency in an effort to survive the corporate ax.
The Basics for a Sound Asset Reliability Maintenance Management Program Jim H. Davis, vice president of business development, Performance Consulting Associates Inc. Over the last few years, the expectations for the maintenance function have changed more than in any other industrial discipline. Equipment has become more complex and sophisticated. There are much higher business expectations related to the results and performance of the maintenance function and, to complement it all, there are many more methodologies, tools and equipment for predicting and preventing maintenance related failures than ever before. Today, managers are feeling the pressure to respond to these changes and a continuously increasing pressure to achieve higher plant availability and lower costs; as a result, there is a growing awareness of the effect of maintenance in safety and the environment, accompanied by a growing awareness of the connection between maintenance and product quality and a continuously increasing pressure to achieve higher plant availability and lower costs.
However, everything said above in association with reliability, typically refers to the maintenance function, not just the maintenance department. The maintenance function is a responsibility shared with every department in the plant. The production department is responsible for oper-
Get a $1,195 Noria Training Coupon FREE Full conference registration includes an $1,195 training coupon you can use toward Noria’s training courses for up to one year. Use it yourself or give it to a co-worker to use for training. It’s like attending the conference and getting Noria training for free! Terms and conditions below.
Imagine the possibilities … • Attend Reliable Plant 2011 in Columbus. Then redeem your coupon for three days of Noria classroom or online lubrication best practices training. • Bring a group of 10 to Reliable Plant 2011 in Columbus for only $350 each. Get 10 coupons for Noria training worth $1,195 each. • Attend Reliable Plant 2011 in Columbus. Give your coupon to a co-worker for three days of Noria lubrication or oil analysis training. • Bring a group of 3 to Reliable Plant 2011 in Columbus for only $550 each. Get 3 coupons for Noria training worth $1,195 each.
Terms and Conditions. Only one coupon will be issued per person. The coupon is transferrable within your organization and must be presented when registering for the training. The coupon is valid for Noria public training courses in the United States taking place between April 22, 2011, and April 21, 2012, or online training courses purchased prior to April 22, 2011. Coupons are given to full conference (Tuesday – Thursday) attendees who pay their conference registration fee and attend the conference. Speakers and exhibitors are not eligible unless paying full conference registration fees. Coupons may not be used for onsite training.
ating the equipment within its established parameters, to perform certain tasks to maintain the equipment within those parameters and to report operating anomalies to maintenance so corrective action can be planned and scheduled. In this day and age, production/operations must be more involved in the whole asset care (maintenance) function. They must work with the reliability/maintenance department as “partners”, forgoing the old “customer/supplier” relationship. Before any effort to improve asset reliability has any chance of success, all departments and all personnel, managers and workers alike, must have a complete understanding of the process and a firm commitment to support organization asset care.
departments (steelmaking, rolling mill, caster, cranes and material handling) that were using 10 different vendors. It wanted to consolidate down to the best three. The facility did an audit of each vendor, and recorded each company’s procedures, processes and capabilities. It settled on three vendors, but one was subsequently removed due to issues and another dropped out. That left the site with one qualified vendor. In 2009, the site started to have issues with its current vendor and started looking for a backup. After visiting five more repair shops, it selected the backup. Within six months, the current vendor quality claims had reached the limit, so the site switched repairs to the backup vendor and elevated that firm to primary In this session, we will explore three main ways to ac- status. In this presentation, Gallatin Steel will review complish this objective: the lessons learned over the last five years as it strives • The principle of the production/operations maintenance for reliability. coordinator You will leave this session with information on: • The basics of operator basic care (OBC) • Creating your own repair specification guidelines • Production/operations use of EAM • Pit falls of changing seal material
Repairing Hydraulic Cylinders and the Vendor Base Jeff Stegemiller, process manager of maintenance systems, Gallatin Steel Over the past several years, Gallatin Steel has been on a mission to increase the reliability of its hydraulic cylinders. The company’s facility in Ghent, Ky., has addressed vendor selection, repair specifications and shop audits. It has had some setbacks, but the speaker believes it is on the right track now.
In 2005, the site was unhappy with the reliability of its hydraulic cylinder repairs across the site. It was getting inconsistent results from its vendors. Ghent has five main
and extra skill-building when training budgets are being reduced? High-quality e-learning that is executed with skill and care can be an effective solution. In this session, learn about Holcim’s experiences with elearning as part of a global training rollout of root cause analysis. Benefits of the e-learning rollout include just-intime deployment, cost effectiveness and time savings for trainees (same deliverables in half the time). Case studies and specific examples will be woven throughout.
Field Flatness Measurements for Baseplates and Machinery. Daus Studenberg, applications engineer, Ludeca Inc. This session will present an overview on techniques used in flatness measurements for field conditions. In addition, techniques in assessing the measurement profile as well as corrective actions also will be discussed. An overview of topics is as follows:
• Flatness and levelness • The effects of heat, contamination, chrome thickness, • Measurements objectives fluids, workmanship, blue prints, design issues and • Typical accuracy requirements for flatness and levelness (most important) communication measurement • Most popular measurements methods used in field environments How Holcim Utilized E-learning to Boost • Best measurement practices in flatness measurement Skills and Save Money • Interpreting results Bill Lyons, maintenance optimization manager, Holcim (US), ● Optimized methods for displaying elevation change and Chris Eckert, president, Apollo Associated Services ● Assessing pass/fail conditions In today’s business climate, as employees increasingly ● Determining corrective action wear multiple hats, and administrative costs not directly • Case studies on actual field measurements related to the bottom line are being cut, employees require ● Compressor casing more cross-training and knowledge in order to maintain ● Diesel engine safety, maintenance and reliability standards, and avoid costly problems. But how do you provide the necessary ● Turbine casing
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- Doug McBride, Temple-Inland 14
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Let Operators Lead the Way to Improved Reliability Bruce Wesner, managing principal, Life Cycle Engineering
Today’s Reliable Plant: Where Am I? Brian Gleason, Des-Case Corporation Have you wondered how your plant is doing in implementing best practices? Are you ahead, behind, or on pace with others in moving your plant toward your goals? This session will help you measure your program against others in the industry with a 2011 survey of 10 key lubrication best practices. Additionally, you’ll learn how optimizing one area may not be as beneficial as a holistic approach to some or all of the areas. In the end, you’ll walk away with key questions to ask your team, data to help identify where to improve, and tools to help you get there.
Operations-led reliability can maximize an organization’s investment in a continuous improvement initiative. Operator care is a commitment by plant management, operations and maintenance to ensure that assets maintain their expected level of quality and volume for output, while reaching their expected lifespan within the plant. This approach to reliability often requires a new mind-set for operators and their supervisors. Operations-owned reliability can greatly reduce reactive maintenance practices but improvements must be reinforced through a rigorous change management process. When implemented sucMechanical Seal Reliability cessfully, improvements in production, safety and quality can be attained without major staffing or capital invest- Buddy Lee, AESSEAL, Inc. ments. This presentation will detail key steps and benefits In this session you’ll learn how pump reliability is imof an operations-led approach to reliability. pacted by increasing mechanical seal reliability and explore the basic operation of a mechanical seal along with some of the best practices of elastomer and face combination selection to maximize mechanical seal reliaFundamentals First! Mastering bility. Specifically, the application of seal support systems Maintenance Basics and Reaping has dramatically improved the MTBF of pumps through the Rewards the improved fluid film stability between the faces of the Wayne Vaughn, Vesta Partners seal, despite pump operational challenges. Documented When efforts are focused on doing the fundamentals cor- improvements in MTBF and the generic commercial imrectly, and in an organized way, success will follow. In this pact for a couple of key industries will be presented, along session you’ll learn about the ABC’s of maintenance, how with a sample construction of a business case for a meto engage operations and others in teamwork, and how to chanical seal and support system application. measure success. You’ll learn how applying a little TLC (tightening, lubrication and cleaning) will make a huge difference in unplanned downtime and receive some practice Building a Corporate Reliability Strategy tips on how to move from a reactive firefighting environJoe Park, North American Manager for Reliability, Novelis ment to one that is more predictable and sustainable. In this case study session learn how Novelis, a leading recycler and producer of aluminum rolled products, developed a reliability roadmap and began their “ReliabilLaunching Maintenance Communities of ity Journey” towards establishing reliability excellence as Best Practice to Achieve Reliability a business strategy through sustainable systems, organiExcellence zations, processes, procedures, and knowledgeable resources. You’ll learn about pitfalls to avoid, things that Greg Walker, director of maintenance excellence, Pfizer, and worked and what Novelis is still trying to accomplish Thomas Povanda, Genesis Solutions Many industry sectors are currently looking at “create in reliability. the future” scenarios in an effort to transform yesterday’s work flow processes into leaner, more cost-effective, cusWorld Class Equipment Reliability: tomer-focused processes. The common problem is Establishment and Standardization of positioning maintenance organizations to be viewed as a Best Practices at ArcelorMittal competitive advantage rather than a cost center. This session describes how establishing a Community of Practice Darrin Clark, reliability specialist, ArcelorMittal USA (CoP) within the engineering network can dramatically imArcelorMittal is the largest steel producer in the world, prove the process of defining and implementing the master operating in 60 countries, with more than 300,000 emplan. The end result, shown in this Pfizer case study, is ployees and $100 billion in annual sales. ArcelorMittal USA transforming the maintenance organization into a proactive is the largest steel producer in North America, with probusiness unit and a source of competitive advantage. duction capacity of 23 million tons.
Real Results. Real Heroes.
In early 2008, ArcelorMittal USA launched World Class Equipment Reliability (WCER), an initiative to ensure the highest possible working ratio, yield, quality and safety performance at 14 plants across the country. WCER uses the fundamental philosophies of Reliability-Centered Maintenance to develop technically sound maintenance programs for each asset. The programs are then implemented using enabling technology to allow execution of planning and scheduling best practices. This session will outline the WCER strategy, citing examples of success and difficulty to demonstrate what has worked and what hasn’t. Those in attendance will leave with an understanding of what it takes to implement and manage a large-scale reliability improvement initiative from conception to plant floor execution.
Central Plant Cooling Systems: Transitioning PWR Rocketdyne to an RCM Based Maintenance Strategy John L’Engle, Reliability Centered Team Lead, Pratt & Whitney Rocketdyne and Jason Price, Management Resources Group, Inc.
Last year, Pratt & Whitney Rocketdyne began a focused and targeted reliability centered maintenance program on its central plant chilled water systems. The old reactive, undocumented methods of maintenance had resulted in increased central plant repair costs of 30% in 2008 and 2009 – it was time for a change. In this case study session you’ll learn how reactive maintenance was causing loss of efficiency, diminished cooling capacity and higher energy consumption, plus the costs and impact of the new RCM focused approach.
REAL RESULTS REAL HEROES INVISTA In 2007 INVISTA made improvements to its lubrication excellence program and have been reaping the benefits ever since. Pump mean time between failure has increased 50 percent and seal life has gone up 25 percent.
Quick and Simple Lean Simulations that Your Employees will Understand! Mike Thelen, continuous improvement leader, Wells Dairy
Have you ever wondered how you can get your employees to gain a basic understanding of lean philosophy and why they should be excited to jump on board? Handson participation and classroom presenting are great learning aides, but they don’t seem to be driving home the message? Feel bogged down with tools and techniques that still aren’t helping with culture and concepts? How about a few quick and simple simulations to help speed the learning?
Sustain the Progress with Kamishibai Cards: Tips from a Former Toyota Group Leader Scott E. Cornell, project manager, Argo Inc.
Using OEE to Drive TPM Adrian Pask, management analyst, Vorne Industries
Are you interested in reducing breakdowns, minor stops, and slow running by up to 80%? The concepts of OEE and TPM have been around for over 50 years, and while many sites have implemented these tools, few see long term sustainable improvement. In this session you'll learn how to identify and explore the fundamental foundations that enable long term results with the tools of OEE and TPM. We will provide real, practical steps that you can take straight from this session and put into place in your factory the very next day.
As businesses begin their lean transformation, they often struggle with how to sustain the improvements that they have begun to see. Usually, setting up frequent audit systems can help some, but how do you manage that audit system? Usually, it is set up with a system of “supervisors or managers” auditing the work of “operators or workers”. In the short term, this can work. However, who audits the auditors? Do we have a system set up to verify that the Participants in this session will actively participate in auditors are doing what they are supposed to do, and are You will learn: simple, easy-to-use and easy-to-understand simulations they doing it correctly? This is where a “management •How to increase OEE by 6-11% with virtually no that will help them educate their workforce in either the kamishibai card” can be extremely beneficial. investment shop or the office. Get exposed to: the “5-S numbers” •5 Top Tips for successfully implementing a TPM program Management kamishibai cards are a way for managers’ game (and see how standardized work can even be in- work to begin to be standardized, as well as injecting much •How to practically use OEE to get results in the real world cluded), a fast and simple “gemba kaizen” ball-pass needed accountability into the existing system. It is a top•What TPM is, and how it can help your machines run technique, and the ergonomic “OK” in this interactive, full- down managed approach, so it is important that every more efficiently participation seminar. Other simulations that support a member of management is involved (director, plant man•A simplified 5 Step TPM roadmap that you can take variety of lean tools also may be discussed. All partici- ager, area manager, supervisor, team leader – as well as away and apply to your factory pants will receive supporting documentation and contact the continuous improvement manager). Management Get to this session for practical, interesting, and you will information to assist with running the simulations at their kamishibai cards eventually become part of a manager’s get some real actions that you can take away. place of business. daily standard work, just as much as checking their em-
Lean in the Utilities Sector: Luminant’s Operational Excellence Model Steve Wells, Operational Excellence strategist and Lean Six Sigma consultant, Luminant Luminant Power was one of the first utilities in the electricity producing industry to start down the path of continuous improvement. In 2004, the company implemented a model of CI using a program titled “The Operating System”, which used the combined elements of Lean, Six Sigma and Plant Reliability to cut costs, increase revenue and provide savings. These improvements were realized through eliminating waste by revamping processes, increasing generation through standard work and best practices, and evaluating project costs utilizing the principles of changeover and SMED. As The Operating System matured, it was retitled Operational Excellence to indicate the depth and breadth of principles, systems and tool usage across the enterprise.
Attendees will take away insight into the critical foundations of an Operational Excellence program, which will enable them to review their own continuous improvement efforts for missing elements, or to lay a foundation in the preparation of a program. Examples will be presented of how Luminant utilized this model to instill a high-performing culture in a mature workforce in existing plants and mines, while ramping up employees into newly constructed facilities.
ployee’s time cards or performing root cause analysis on specific downtime events.
Lean at Federal Heath: The Results Speak for Themselves Rick Foreman, director of manufacturing and lean development, Federal Heath
Manufacturing Intelligence: The Art of Making Factory Data Talk Michel Baudin, owner, Takt Times Group Recommending a road map to lean for a plant requires understanding its business and its technology. Much – but not all of this understanding – can be gained by observing the shop floor and listening to the concerns of managers, engineers and operators. Direct observation and human perceptions, however, must be supplemented by data analysis. Manufacturing operations always need and generate data: production is driven by orders converted to schedules, it is performed according to specifications, its status is monitored, and results are recorded both in terms of quantities and quality. The analysis of this data often reveals internal inconsistencies, discrepancies and unsuspected patterns that are key to identifying and quantifying improvement opportunities. It is done with tools that are either already present on engineers’ laptops or can be downloaded at little or no cost. Focused data cleaning is the most challenging first step. Once you have good, clean data, making it talk requires tools that are much simpler and easier to use than those described in the data mining literature.
Federal Heath’s culture change comes from being a learning organization, maintaining a consistent sense of urgency, and through engaging, connecting and influencing lean thinking behavior. Its culture of striving to standardize and make some small improvement on a daily basis has developed more of a point-kaizen focus that contributes to the pursuit of excellence and an improved bottom line. The results speak for themselves. In a tough economic environment, which greatly impacted its industry, Federal Heath has seen significant improvements with customer satisfaction, improved inventory turns, strong cash flow, improved setup efficiencies and savings throughout every area of the organization. Recognition was given by TMAC for the company’s Euless facility in 2010, and the Jacksonville, Texas, facility will receive the same recognition Attendees of this session will learn how to: for operational excellence from TMAC in the first quarter of 2011. Lean thinking is in the company’s DNA, and it sim- • Work with the information systems staff to retrieve factory data from the multiple and often incompatible ply asks daily, “Did we have a good day?” and “How can I legacy systems in which they typically reside. improve on it tomorrow?”
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Your full-conference badge gets you into sessions from all three co-located conferences.
• Decrypt arcane and inconsistent naming conventions to should be used to accomplish the aforementioned objecreverse-engineer a clear, easily understandable infor- tives. Specific points are itemized to address the mation model. successful implementation and sustainment of the programs in the organization’s culture. The required concepts • Clean the data and structure it for analysis. may seem almost heretical by today’s thinking and, • Apply a variety of tools to uncover and quantify relevant perhaps, this is one reason they have lost favor over the characteristics years. For example, training is not complete unless 100% • Map these results to decisions on actual processes. of the prescribed material has been transferred to and absorbed by the learner. The author explains why concepts such as this are still valid over time.
Real Results. Real Heroes.
face these same type of problems. This session will address these issues and your specific challenges to implementing and sustaining lean in your organization. The speaker has twenty two years of lean consulting experience, covering dozens of industries in over one-hundred plant sites, combined with a solid manufacturing management background, including CEO and owner of a manufacturing plant. Bring your top issues and questions to this problem-solving session designed to get you on the right track with your lean transition.
Training Within Industry – Fundamental Skills in Today’s Workplace Donald A. Dinero, principal, TWI Learning Partnership
The Training Within Industry (TWI) Programs have been called “the most underrated achievement of 20th-century industry.” They are “underrated” because most Americans do not know about them. They are an “achievement” because they helped America and its allies win World War II. In addition, however, they involve fundamental skills that every person should master and use on a daily basis. As such, they are necessary for all members of any organization to use in order to be as successful as they can be. These programs were developed in the USA in the 1940s and have since proven themselves around the world in that they provide a simple yet powerful methodology of providing fundamental skills. They fell from favor in the U.S. and have been used continuously by others, mainly the Japanese. Their resurgence in America has been due to the discovery that they are a foundational element of Toyota’s Production System (TPS), which Americans and others around the world are attempting to emulate as Lean Production or Lean Thinking. The developers of these programs recognized the dichotomy between knowledge and skill and created programs to address each separately. Program development was created to address knowledge-based issues and three other programs (Job Instruction, Methods and Relations) were developed to deal with skills.
Using the 3P Approach in Process and Workplace Design Mike Wroblewski, Senior Operations Consultant, Gemba Consulting North America
In this session, the 3P (Production Preparation Process) in both manufacturing and healthcare will be presented showing the overall Lean design approach that includes the rapid testing of ideas and the embedding of Lean principles into process and workspace design. The Production Preparation Process is an approach used to design production process and equipment to conform to lean principles such as one-piece flow, building quality into the process, quick changeover, and flexibility. Production Preparation Process involves consideration and testing of various process alternatives using a cross-functional team approach and providing feedback to product design in order to improve the production process.
Lean Maintenance Transformation: Transform Ineffective Maintenance Practices to World Class Ken Hughes, Maintenance and Facilities Manager, Power Partners, Inc
In this case study presentation you’ll learn how Power Partners, a transformer manufacturer, effectively implemented a plan to go from reactive to proactive by changing culture and removing waste from the maintenance department. Discover just how easy it is to transform your maintenance department from being a burden to an asset and partner with operations in this insightful presentation.
Maintenance Black Belt Certification at Sonoco Jeff Slater, Operating Excellence Leader, Sonoco
While on their journey to develop their Continuous Improvement Culture, Sonoco realized that the statistical aspect to Lean Six Sigma tended to deter maintenance personnel from participating. This realization led to the birth of a Maintenance Black Belt Certification program. There are some statistical tools that are related to MTBF (Mean Time Between Failure) and MTTR (Mean Time to Repair), but the certification I focused on a hands on approach with daily team maintenance, 5S, and predictive maintenance. Learn more about Sonoco’s Maintenance Black Belt Certification in this intriguing case study presentation.
This session discusses why these programs, developed almost 70 years ago, are still not only relevant but also necessary in today’s workplace. Not only have organizations’ cultures changed over time, but management’s focus on culture has changed. Yet today, these programs produce the classically required results of increasing quality, safety records and productivity as they did when they were developed. In addition, however, they Senior Management Guide to the substantially improve morale, teamwork and communiLean Transition cation, which are also of great concern in today’s workplace. Moreover, they do this without coercion, but Jack Harrison, The Hands-On-Group Running into lean implementation problems? Having rather by building an intrinsic motivation in employees. This is done by getting employees more engaged in their trouble sustaining the gains? Difficulty getting some of your work. The session also discusses how the programs peers or subordinates on-board? You aren’t alone – many
REAL RESULTS REAL HEROES Alcoa Point Comfort Operations Five Alcoa Point Comfort reliability and engineering leaders attended this conference in April 2005. After beginning a lubrication excellence program they achieved an annual savings of $800,000 in lubricants, bearings and rotating equipment alone. “Listening to the technical papers and the case studies was a real culture shock. We started to see what was truly possible.”
(as of March 21, 2011)
Interested in exhibiting at Reliable Plant 2011?
The exhibits at Reliable Plant 2011 work in tandem with sessions and workshops to enhance your experience. Youâ€™ll have the opportunity to compare products, solutions and services from leading vendors. Take what you learn in the classroom to find and evaluate solutions you need on the exhibit floor.
Contact Brett Oâ€™Kelley at 800-597-5460 extension 112 or e-mail email@example.com. Sponsorship opportunities also available.
CITGO Petroleum Corporation
ICML Indiana Bottle Company Inpro/Seal Company Insight Services International Council for Machinery Lubrication JAX INC. Jet-Lube, Inc. Kaman Industrial Technologies Kluber Lubrication North America L.P. Koehler Instrument Company Life Cycle Engineering Liquidynamics
CMMS Data Group
Lubrication Technology, Inc. LubriSource, Inc. Ludeca Master of Business Operational Excellence
A.T.S. Electro-Lube AESSEAL, Inc.
Air Sentry Alemite ALS Tribology Analysts, Inc. Argo-Hytos, Inc. Brady Corporation Cannon Instrument Company CheckFluid, Inc. Chevron Lubricants
Dexsil Corporation Donaldson
Emerson Process Management Esco Products Fluidall Fluitec International Genesis Solutions Hach Compan Harvard Corporation Herguth Laboratories HYDAC Technology Corporation Hy-Pro Filtration IFH Group
MP Filtri USA
Rock Valley Oil & Chemical Company Royal Purple Schroeder Industries SDT North America SenGenuity
Shell Lubricants SKF USA, Inc. Solution Recovery Services Specialty Manufacturing, Inc.
Spectro, Inc. Stop-Painting.com Tannas Company The Timken Company UE Systems Utilx Corporation Whitmore Manufacturing Company Y2K Fluid Power *Sponsors shown in orange
Noria Corporation Oil Filtration Systems, Inc. Pamas USA PdMA Corporation PerkinElmer Petrolink USA, LLC POLARIS Laboratories R&G Laboratories Reliable Process Solutions
Utility ATV Giveaway How to Win: Check out the latest products and services from the sponsoring exhibiting companies, get your entry form stamped and then register to win. Visit our Web site at conference.reliableplant.com for complete contest rules. Come learn how to drive your plant to better reliability and you might find yourself driving a new Massimo Motor Utility ATV. Giveaways sponsored by: ALS Tribology, Argo-Hytos, CITGO Petroleum, Des-Case, Donaldson, Emerson Process Management, Esco Products, Fluidall LLC, Harvard Corporation, Herguth Laboratories, Indiana Bottle Company, Inpro/Seal, JAX Inc., Life Cycle Engineering, Liquidynamics, Lubrication Engineers, Ludeca, Inc., MP Filtri USA, POLARIS Laboratories, Shell Lubricants, SKF USA, Inc., Spectro, Inc., Utilx Corporation, Whitmore Manufacturing (Air Sentry), Y2K Fluid Power
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Hotel and Travel Hotel and Venue Reliable Plant 2011 is held at the Greater Columbus Convention Center in Columbus, Ohio. Reliable Plant 2011 attendees receive discounted room rates at the Hyatt Regency Columbus Hotel, which is connected via skywalk with the Convention Center. You can take advantage of these rates by booking your room(s) directly with the Hyatt using the group name “Reliable Plant Conference” at the time of reservation. Availability is limited and you are encouraged to make reservations early. Hyatt Regency Columbus Hotel 350 North High Street Columbus, OH 43215 Telephone: 614-463-1234 Room Rates – Book by April 1 and Save Single or Double Occupancy: $141.00 * All room rates exclusive of state and local taxes or applicable service, or hotel specific fees in effect at the time of the meeting. Hotel tax rates are subject to change without notice.
Reserve Your Room Today! • Call the hotel at 614-463-1234 or Hyatt Central Reservations at 800-233-1234 • Be sure to provide the group code: RP2011. • Make all hotel reservation changes or cancellations directly with Hyatt.
Airlines and Car Rental Air Travel American Airlines is offering discounted fares for attendees of Reliable Plant 2011. Some restrictions may apply for airline tickets and discounts may not be available on all fares. For reservations and ticketing information, call American’s Meeting Services Desk at 1.800.433.1790 from anywhere in the US or Canada and reference Authorization number: 2441DA Discount fares are valid for round-trip travel on American Airlines and American Eagle and can be booked online at www.aa.com/group without a ticketing charge. Valid group travel dates are April 15 - April 24, 2011.
Real Results. Real Heroes.
Conference Fees (USD) Full Conference Registration ..........................................$995 Full Conference Registration Includes: • All sessions in the 3 co-located conferences • Conference Proceedings in CD-ROM format • Opening General Session • Exhibition Hall Access (Tuesday-Thursday) • Lunches in the Exhibit Hall (Tuesday-Wednesday) • Daily Refreshment Breaks (Tuesday-Thursday) • Daily Continental Breakfasts (Tuesday-Thursday) • Networking Receptions (Tuesday-Wednesday) • Plus, a FREE $1,195 Noria training coupon. See page 13 for details.
Group Discounts 3 to 9 Attendees: Send three or more full conference registrations for only $550 each, plus a 20% discount on all pre-conference workshop fees. 10 or More Attendees: Send 10 or more full conference registrations for only $350 each, plus a 20% discount on all pre-conference workshop fees. Multiple registrations must be purchased at the same time. Call 800-597-5460 to take advantage of this offer.
1-Day Conference Registration ....................................$395 1-Day Registration Includes: • Day’s sessions in the 3 co-located conferences • Opening General Session (Tuesday Only) • Exhibition Hall Access for One Day • Lunch in Exhibit Hall for One Day (Tuesday-Wednesday) • Day’s Refreshment Breaks • Day’s Continental Breakfast • Day’s Reception (Tuesday and Wednesday Only)
Exhibition Only Registration With Exhibitor Guest Pass......................................................................FREE Without Guest Pass..................................................................................$50
Continental Airlines is offering discounted fares for attendees of Reliable Plant 2011. Some restrictions may apply for airline tickets and discounts may not be available on all fares. For reservations and ticketing information, call Continental's MeetingWorks at 1.800.468.7022 and refer to Group Code 313982 and Z Code ZJZF.
Pre-Conference Workshops Half-Day (with Full Conference Registration) ............................................................$225 Half-Day (Workshop Only) ..............................................................................$295 Workshop Registration Includes: • Course Materials • Opening General Session (Tuesday Only) • Refreshment Break(s) • Exhibit Hall Access (Tuesday Only)
Spouse/Family Registration..............................................$135 Discounted group car rental rates are available from April 11 - April 28, 2011. Reservations can be made by calling 1-800-331-1600 or online at www.avis.com and reference Discount Code: J907635.
Discounted group car rental rates are available from April 11 - April 28, 2011. Reservations can be made by calling 1-800-654-2240 or online at www.hertz.com and reference Discount Code: 04NZ0001.
Spouse/Family Includes: • Opening General Session (Tuesday Only) • Exhibition Hall Access • Daily Lunches in the Exhibit Hall (Tuesday-Wednesday) • Daily Continental Breakfasts (Tuesday-Thursday) • Receptions in the Exhibit Hall (Tuesday-Wednesday)
Registration Columbus, OH - April 19 – 21
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Monday, April 18 Lubrication Excellence Managers Summit . . . . . . . . . . . .$295 Detecting and Controlling Sludge and Varnish . . . . . . . . . .$295 Outage Work Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . .$295 Effective Greasing Practices . . . . . . . . . . . . . . . . . . . . . .$295
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Cancellations/Substitutions You may cancel a registration before March 19, 2011. Cancellations must be in writing. A $75 cancellation fee will be applied to all cancellations received after March 19, 2011, but you will also receive a $75 coupon good for use against the cost of a Noria training course or conference. This coupon is fully transferable. If you don’t cancel and you don’t attend, you will be charged the full registration fee. Substitute attendees are welcome at no extra charge with written notice prior to the event.
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