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I N C R E A S E C H A I N L I F E . D E C R E A S E C H A I N C O S T S .

®

®

SPECIAL RISK FREE TRIAL

LongLifeLambda

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ContentsJANUARY/FEBRUARY 2013 • VOL 14, NO. 1 • www.LMTinfo.com

ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS

WHAT WORKS FOR OTHERS CAN WORK FOR YOUFEATURES

10 Building On Real-World Success � is year, we explore lubrication trends, techniques and bene� ts using the scale of proven success. Ray Thibault, Contributing Editor

15 ■ Big Money Talks William C. “Bill” Livoti

■ Effi ciency Showcase

ICML CERTIFICATION SERIES18 Industrial Lubrication Fundamentals: Friction Certi� cation matters. � e more certi� ed lube professionals there are, the stronger the “voice” of lubrication will be throughout industry. Ken Bannister, Contributing Editor

SUPPLY CHAIN LINKS22 Haas Automation: Turning Out 30 Years Of Innovation And Success A lot goes into being on the cutting edge of something. Here’s how a leading machine-tool manufacturer got there and stays there. Jane Alexander, Editor

UTILITIES MANAGER

DEPARTMENTS4 Publisher’s Notes

6 My Take

8 From Our Perspective

9 Motor Decisions Matter

26 Problem Solvers

30 Supplier Index

©Co

balt—

Foto

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om

JANUARY/FEBRUARY 2013 www.LMTinfo.com | 3www.LMTinfo.com | 3

www.LMTinfo.com

Apply for a free, one-year subscription at

Achieving Effi ciencies Through Practices & Products

The Maintenance & Reliability Technology Summit is:An annual, four-day educational experience and professional-development opportunity

Created for plant and facility managers, maintenance leaders and crew members, reliability engineers, industrial technicians and all other capacity-assurance professionals

Composed of two days of Conferences (60-minute sessions) and two days of Workshops (full-day sessions) presented by industry experts.

Scheduled for April 30-May 3, 2013 at the Hyatt Regency O’Hare, Rosemont, IL.

For more information, visit www.MARTSConference.com today!

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Page 4: LMT Jan/Feb 2013

January/February 2013 • Volume 14, No. 1

ARTHUR L. RICEPresident/CEO

[email protected]

BILL KIESELExecutive Vice President/Publisher

[email protected]

JANE ALEXANDEREditor-In-Chief

[email protected]

RICK CARTERExecutive Editor

[email protected]

KENNETH E. BANNISTERRAY THIBAULT, CLS, OMA I & II

Contributing Editors

RANDY BUTTSTADTDirector of Creative Services [email protected]

GREG PIETRASEditorial/Production Assistant

[email protected]

ELLEN SANDKAMDirect Mail

[email protected]

JILL KALETHAReprint Manager

866-879-9144, ext. [email protected]

Editorial Offi ce1300 South Grove Ave., Suite 105

Barrington, IL 60010847-382-8100 / FAX 847-304-8603 www.LMTinfo.com

Lubrication Management & Technology (ISSN 1941-4447) is published bi-monthly except Mar/Apr by Applied Technology Publications, Inc., 1300 S. Grove Avenue, Suite 105, Barrington, IL 60010. Periodical postage paid at Barrington, IL and additional o� ces. Arthur L. Rice, III, President/CEO. Circulation records are maintained at Lubrication Management & Technology, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Lubrication Management & Technology copyright 2013. No part of this publication may be reproduced or transmitted without written permission from the publisher. Annual subscription rates for nonquali� ed people: North America, $140; all others, $280 (air). No subscription agency is authorized by us to solicit or take orders for subscriptions. Postmaster: Please send address changes to Lubrication Management & Technology, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Please indicate position, title, company name, company address. For other circulation information call (630) 739-0900. Canadian Publications Agreement No. 40886011. Canada Post returns: IMEX, Station A, P.O. Box 54, Windsor, ON N9A 6J5, or email: [email protected]. Submissions Policy: Lubrication Management & Technology gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned.

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4 | LUBRICATION MANAGEMENT & TECHNOLOGY JANUARY/FEBRUARY 2013

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Bill Kiesel, Publisher

What We Need

PUBLISHER’S NOTES

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We begin 2013 with a number of challenges and opp-ortunities. On one hand, some of the strongest headwinds we face are associated with government

indecision (the debt ceiling, sequestration and wrangling over too many regulations vs. too few, for example). On the other hand, most of us are looking forward to what onshoring/reshoring trends and improving economic conditions could hold for our businesses and communities.

From my perspective, one of our biggest challenges (and something we’ve covered extensively) involves the changing workforce—and the thousands of industrial jobs going unfi lled across our underemployed nation. For whatever reason, the message that the manufacturing and process sectors offer great opportunities and career benefi ts seems to have been lost on much of our society. This sad fact was reinforced for me on Christmas Day, in a New York Times article by Jack Healy.

Entitled “Pay In Oil Fields Is Luring Youths In Montana,”* the article’s premise is that the state’s teenagers are selling themselves short by jumping off the college track to pursue good-paying trades and support-related jobs. It suggests that working “construction and repairing machinery,” or “fi rst [seeking] training as welders or mechanics” are not worthy goals. To sum it up, being an apprentice, as the author puts it, “alongside men old enough to be their fathers,” is a risky choice for young people hoping to ensure meaningful futures.

I agree that higher education is important. But then, all education is important, be it via universities, trade schools, apprenticeships or—if we’re really lucky—getting to work alongside our fathers, mothers and others of their generation.

Improving our industrial base is among the most noble of pursuits. If enough of our children heed that call, we all could be enjoying better lives (with fewer lawyers, fewer bankers, fewer indecisive politicians…). We need more proud, skilled men and women keeping our energy sources fl owing, our power grid working, our water-treatment facilities func-tioning, our transportation systems running and our plants humming safely, cleanly, effi ciently, reliably and profi tably. LMT

[email protected]

Best Wishes for a Happy & Prosperous 2013!

*http://www.nytimes.com/2012/12/26/us/26

montana.html?pagewanted=1&_r=0

ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS

Page 5: LMT Jan/Feb 2013

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MY TAKE

T he last Friday of 2012 found me listening to the Afternoon Shift, a program produced by Chicago’s WBEZ Public Radio station. In his wonderful voice, the host Rick Kogan was discussing New Year’s resolutions and how people tend to make them. Needing all the help I could get along those lines, I turned up the volume.

The truth is that I’m a horrible resolution maker. Most of mine don’t stick, including those perennial pledges to “Get Skinny” and “Get Rich.” (Alas, I like to eat and shop just a little too much, and most of my associates will tell you that I’ve never met a casino I don’t like.) But back to the Afternoon Shift…

Kogan detailed how he had gone about selecting his own 2013 resolutions and referenced several outside sources he used for inspiration. One of those ideas grabbed my attention: “Try,” as Otis Redding advised in the old Jimmy Campbell and Reg Connelly song, “a little tenderness.” Bingo! I had my resolution!

I may never achieve my desired weight or bank balance, but I’m confident I can be nice (or nicer) to everyone in my life—from a personal, as well as a professional standpoint. Interestingly, many people don’t realize how empowering the right kind of tenderness can be for those on the receiving end, even when it’s extended in the workplace. I do.

Several years ago, I sat in a room surrounded by a number of successful publishing executives who were vigorously interviewing me for a magazine job—a position for which I admittedly had neither training nor experience. In retrospect, I still don’t know how I got to that interview. Recently divorced after 25 years of marriage, my life was in shreds. I’d been floating from one dead-end job to another for the past two years, and my self-esteem (all of it) was long gone.

Having convinced myself that I didn’t have the slightest shot at being hired as an editor, I was eager to creep out of the building and start my long, dismal drive home. Just as the session appeared to be wrapping up, however, one of the men in the room stepped forward to say he had a final question for me (according to him, “the most important question of all”): “What’s your favorite Elvis song?”

All I could think of was “Love Me Tender.” It must have struck a chord with my interviewers. I later learned it was their policy to ask the same “most important” question of every applicant they grilled, but nobody had ever answered it the way I did. Long story short, I got the job. Furthermore, during the years I worked for the company, I was treated with a great deal of tenderness (i.e., nurtured, supported and respected). That, in turn, helped me grow professionally and eventually led me here.

Perhaps it’s just my way of paying it forward: In 2013, I resolve to call on my better angels more regularly than last year, and to ensure that the “T-word” is a bigger influence in my life. I encourage you to give it a try as well. With all the bad, sad, mean-spirited things our country has seen of late, and all the ugly words we’ve been hearing, more than a little tenderness is certainly in order. LMT [email protected] Here’s Wishing Everyone An Awesome 2013!

Go Ahead And Try It: A Little More Tenderness

Jane Alexander, Editor-In-Chief

6 | lubrication management & technology JANUARY/FEBRUARY 2013

Page 7: LMT Jan/Feb 2013

Program Details & Registration Information Will Be Announced Soon

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8 | LUBRICATION MANAGEMENT & TECHNOLOGY JANUARY/FEBRUARY 2013

FROM OUR PERSPECTIVE

Ken Bannister, Contributing Editor

Over the holidays, I was one of the thousands upon thousands of passengers who boarded planes on the busiest air-travel day of the

year and flew across the country or globe to visit family and friends. It takes a hectic day like that to truly appreciate how much we (both as travelers and maintenance professionals), as well as other industries, owe the aviation industry—and how well the airlines’ systems and processes work when stressed to the max. Despite my personal lack of control over the situation, my plane departed on time, flew smoothly and arrived safely at the right destination. Moreover, even my luggage showed up exactly when and where it should have!

In life, there are often times when we must relinquish control. Such is the case when I must fly to a client’s site or event. Unlike Tom Cruise or John Travolta, who own personal jet aircraft and are licensed to pilot themselves around the world, I need to rely on commercial aircraft and pilots. To reduce my risk as much as possible, I put myself in the hands of reputable organiza-tions and people, and choose carriers based not on their ticket prices, but their safety records.

Thanks largely to the efforts of F. Stanley Nowlan and Howard H. Heap, travelling by air these days is much safer than in decades past. In the 1960s, Nowlan and Heap headed an industry group to develop a maintenance meth-odology that could reduce airline accident rates while increasing (and sustaining) the reliability of ever-more complex future-generation aircraft. The result, based on a simple seven-question process, was MSG-1—or what we now refer to as Reliability Centered Maintenance (RCM). This methodology has been responsible for greatly increasing equipment reliability across all indus-tries, while simultaneously simplifying levels of maintainability.

Going back even further in history, to those “magnificent flying machines” of World War I, we also can credit aviation with the advent of true

scheduled maintenance: That was introduction of 30-, 60-, 90- and 120-hour airframe checklists for combat aircraft along with staggered scheduling—providing planes lasted that long in combat!

In his recent book, The Checklist Manifesto: How to Get Things Right, Dr. Atul Gawande describes the first military test flight of the B17 bomber in the 1930s. Ending in a crash due to a simple pilot oversight, this flight led to the avia-tion industry pioneering operational and main-tenance checklists. As head of the World Health Organization’s Safe Surgery Saves Lives program, Dr. Gawande adapted the aircraft checklist and credits use of this simple, innovative tool for a dramatic reduction in hospital and surgical deaths, regardless of hospital conditions.

Designed correctly, a checklist can overcome both ignorance and ineptitude. Such a tool can be particularly effective in the field of lubrication where, so often, the wrong lubricant can be placed in the wrong place, in the wrong amount. . .

For more on the effective use of checklists, be sure to read the March 2013 installment of my Maintenance Technology magazine column “Don’t Procrastinate…Innnovate.”

In the meantime, I wish all readers a very happy and prosperous 2013! LMT

[email protected]

Making A List And Checking it Twice

Other industries, along with maintenance and reliability pros

everywhere, have plenty to thank the aviation industry for: Aviation helped birth RCM and pioneered the use of checklists.

Page 9: LMT Jan/Feb 2013

32 | MAINTENANCE TECHNOLOGY OCTOBER 2007

Tools To ‘Drive’ Your Motor Energy Savings

BOOSTING YOUR BOTTOM LINE

T

The Motor Decisions Matter (MDM) campaign is managed by the Consortium for Energy Effi ciency (CEE), a North American nonprofi t organiza-tion that promotes energy-saving products, equipment and technologies. For further information, contact MDM staff at [email protected] or (617) 589-3949.

oday’s marketplace is full of voices promoting adjustable speed drives (ASDs) with competing claims of savings and benefi ts. What’s all this

discussion about?An ASD controls the speed of an induction

motor by adjusting the voltage and frequency that supply the motor. Affi nity laws—which show that change in power consumption is proportional to the cube of the change in speed—illustrate energy-savings potential through the use of adjustable speed technology. What you may not have heard, however, is that in addition to saving energy, ASDs can improve operational processes and reduce motor maintenance costs.

Is ASD Technology Right for You?Adjustable speed drives can be very useful in applications with variable torque loads like centrifugal pumps, fans and blowers, as well as in HVAC and compressed air systems. However, ASDs are not a plug-in solution. In some cases, such as constant-power or constant-speed appli-cations and high-static-pressure pumps, ASDs will NOT save energy.

How can you fi nd out if ASDs will be a boon to your facility budget? Motor Decisions MatterSM (MDM) has you covered. On the MDM Website (www.motorsmatter.org), you’ll fi nd an entire section focused on this topic. Two resources, in particular, can help you assess whether ASDs are appropriate for your opera-tions and also help you develop a preliminary estimate of your energy savings and payback to identify and screen potential projects.

Get Answers to Your QuestionsThe National Electrical Manufacturers Associa-tion (NEMA) Application Guide for AC Adjust-able Speed Drive Systems is the fi rst resource you should review. Key selection and application factors include the motor, drive type, electrical supply, mechanical insulation and controls. The Guide also includes important safety and

operational considerations that help you make a smart decision.

Second, to help assess the economics of this investment, you’ll need to estimate how much energy can be saved—and what the payback period will be. The Bonneville Power Adminis-tration (BPA) developed an ASD Calculator to help you estimate the installed cost of an adjust-able speed drive, including materials and labor, energy savings and simple payback for installa-tions on fans and pumps. Users have the option of selecting from specifi c fan and pump types or providing measured power (kW) entries for application types not included in the calculator. Developed for the Department of Energy (DOE), the BPA ASD Calculator is an excellent tool.

With these resources, you’ll be in a better, more informed position to talk with an expert such as a utility account rep, motor distributor or your local service center about installing a drive. LMT

For more info, enter 04 at www.LMTfreeinfo.com

What you may not have heard is that ASDs can also improve operational processes and

reduce motor maintenance costs.

JANUARY/FEBRUARY 2013 www.LMTinfo.com | 9

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10 | LUBRICATION MANAGEMENT & TECHNOLOGY JANUARY/FEBRUARY 2013

WHAT WORKS FOR OTHERS...

10 | LUBRICATION MANAGEMENT & TECHNOLOGY JANUARY/FEBRUARY 2013

Ray ThibaultCLS, OMA I, OMA II, MLT, MLT II, MLA II, MLA III

Contributing Editor

Building on

This year, we explore

lubrication trends,

techniques and benefi ts

using the scale of

proven success.

Over the past eight years, I’ve written articles on lubrication principles, best lubrica-

tion practices, oil analysis, the importance of cleanliness to equipment reliability and

how to develop a world-class lubrication program. This year, I’ll cover many of these

topics, but from a real-world standpoint. Here’s a summary of what you’ll see:

Real-WorldSuccess

Page 11: LMT Jan/Feb 2013

JANUARY/FEBRUARY 2013 www.LMTinfo.com | 11

...CAN WORK FOR YOU

PART I: Developing a World-Class Lubrication ProgramA large chemical plant in the Southwest that lacked an organized lubrication program experienced many failures due to poor lubrication practices. A decision was made to hire an outside company to investigate the company’s prac-tices and implement a world-class lubrication program. A lubrication engineer with program experience at a major oil refi nery was placed in the plant full-time to evaluate and develop the new program. This was fi ve years ago. Since then, major reliability gains have resulted from dramatic improvements in the lubrication program.

In this and any world-class program, at least some of the following criteria must be met:

■ Right attitude

■ Lubricant champion

■ Updated lube survey

■ Proper scheduling & record keeping

■ Consolidation

■ Hiring of competent personnel

■ Training/certifi cation

■ Use of correct lubricants

■ Minimizing lubricant contamination

■ Utilizing an oil-analysis program for condition monitoring

■ Continuous updating and improvement of the lubricant program

Each of these criteria will be examined before and after the chemical company’s world-class program was imple-mented. Also covered will be the results achieved with the new program and future improvements to be implemented.

PART II: Using Synthetics for Energy Savings and MoreProperly used, synthetic lubricants can result in signifi cant benefi ts that far outweigh their cost. Several case histories

involving various synthetic types will be investigated to demonstrate real-world cost benefi ts. Major benefi ts for synthetics are shown here in Fig. 1.

Fig. 1. The major benefi ts of synthetics

While the justifi cation for synthetics typically has been associated with energy savings, as the following points make clear, that’s just part of their appeal:

■ Temperature Extremes. . . Because synthetics contain no wax, many can be used in very low-temperature conditions. Because of their purity and molecular structure, many are also stable at very high temperatures, and will often greatly exceed the high-temperature stability of mineral oils.

■ Wear. . . Synthetics’ uniform molecular structures result in higher fi lm strengths and enhanced lubricity, causing less metal-to-metal contact between lubricated surfaces, which leads to less wear.

■ Energy Savings. . . Synthetics’ uniform molecular struc-tures also reduce internal fl uid friction between metal surfaces, lowering energy requirements. This is particu-larly evident with gears where a high level of sliding between the metal surfaces occurs.

The common synthetics we will investigate are detailed in Table I (page 12).

SuccessProblemSolvers

Temperature Energy Savings

Wear

Page 12: LMT Jan/Feb 2013

12 | LUBRICATION MANAGEMENT & TECHNOLOGY JANUARY/FEBRUARY 2013

WHAT WORKS FOR OTHERS...

PART III: Oil Analysis Improves Mine-Equipment ReliabilityOil analysis is one of the most power-ful tools you can use for achieving condition-monitoring objectives and enhancing equipment reliability. For example, a comprehensive oil-analysis program implemented at a major mine in the western U.S. generated substantial cost savings and reliability improvements. A case history on this mine will discuss the program from development through implementa-tion, and the benefi ts it produced, based on the careful documentation of its 40,000 annual samples.

The objectives of this program were to. . .

■ Improve asset reliability

■ Identify and eliminate repetitive problems

■ Reduce unscheduled maintenance

■ Maximize use of lubricants in service

■ Reduce maintenance and lubrication costs

■ Achieve fault-free component life extension

■ Utilize proactive maintenance, fl anked by predictive maintenance technology

■ Achieve condition-based maintenance

The following steps were identifi ed to properly implement the program. . .

■ Select an oil-analysis laboratory to help achieve objectives

■ Develop criteria for equipment to be sampled; prepare an equipment list

■ Develop a sampling strategy

■ Select the appropriate oil-analysis tests, based on equipment type

■ Select and allocate personnel for the program, along with a program coordinator

■ Work closely with the oil-analysis laboratory to improve program and meet objectives

■ Train personnel to use internal and external resources

■ Track and document cost benefi ts

■ Practice continuous improvement by adapting to changing conditions and requirements

PART IV: Improved Oil Cleanliness Boosts Pump ReliabilityA growing number of companies recognize the importance of oil cleanliness to equipment reliability. An estimated 70% of equipment failures in circulated fl uid systems are caused by particulate contamination. Abrasive wear, caused by clearance-size particles between metal surfaces, accounts for more than 66% of total wear. Therefore, controlling particulate contamination through exclusion and fi ltration will result in enhanced equipment reliability.

Table II illustrates the benefi ts of clean oil on the life of rolling element bearings.

Synthetic Type ApplicationsPolyalphaolefi ns Most versatile, with many applications

Low-temperature bearingsEnclosed gear boxes, non-fl ooded rotary screw compressors and high-temperature bearings in fans, blowers, pumps and motors.Oil mistAutomotive

Diesters Reciprocating compressors, high-temperature bearings and oil mist

Polyol Esters High-temperature aero-derivative gas turbinesRotary screw air compressorsFire-resistant and biodegradable hydraulic fl uids

Polyalkylene Glycols Hydrocarbon-fl ooded screw compressorsEnclosed gear boxesRotary screw air compressors

Table I. The Most Common Synthetics

Synthetic Type

Polyalphalefi ns

Diesters

Polyol Esters

Polyalkylene Glycols

Applications

Most versatile, with many applicationsLow-temperature bearingEnclosed gear boxes, non-fl ooded rotary screw compressors and high-temperature bearings in fans, blowers, pumps and motors.Oil mistAutomotive

Reciprocating compressors, high-temperature bearings and oil mist

High-temperature aero-derivative gas turbinesRotary screw air compressorsFire-resistant and bio-degradable hydraulic fl uids

Hydrocarbon-fl ooded screw compressorsEnclosed gear boxesRotary screw air compressors

Page 13: LMT Jan/Feb 2013

JANUARY/FEBRUARY 2013 www.LMTinfo.com | 13

...CAN WORK FOR YOU

Table II. The Benefi ts of Clean Oil on the Life of Rolling Element Bearings (Source: Eaton Corp.)

How to read Table II…Fluid cleanliness is designated by a three-number code per ISO 4406. This code is expressed as all particles ≥ 4µ[c], ≥ 6µ[c], and ≥ 14µ[c]. The numbers are obtained from the chart in Table III (page 14):

For example, consider a fl uid where the particles per milliliter of fl uid were measured as follows:

In the above example, fl uid cleanli-ness is expressed as 20/17/14, which comes by fi rst determining the range number that expresses the number of particles per milliliter. In this case, 7500 particles were found at the range number of 20 where the range is 5000 to 10,000 particles. Note that for every increase in range number, the number of particles can double. Thus, even a moderate increase in range number can result in a large introduction of particles.

≥ 4µ[c] 7500 particles

≥ 6µ[c] 850 particles

≥ 14µ[c] 95 particles

Current ISO Code

Target ISO Code2x Life

Target ISO Code3x Life

Target ISO Code4x Life

Target ISO Code5x Life

28/26/2327/25/2226/24/2125/23/2025/22/1923/21/1822/20/1721/19/1620/18/1519/17/1418/16/1317/15/1216/14/1115/13/10

25/22/1923/21/1822/20/1721/19/1620/18/1519/17/1418/16/1317/15/1216/14/1115/13/1014/12/913/11/813/11/813/11/8

22/20/1721/19/1620/18/1519/17/1418/16/1317/15/1216/14/1115/13/1014/12/913/11/8

----

20/18/1519/17/1419/17/1417/15/1216/14/1115/13/1015/13/1013/11/8

------

19/17/1418/16/1317/15/1216/14/1115/13/1014/12/913/11/8

-------

ms

ms

msm

s

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14 | LUBRICATION MANAGEMENT & TECHNOLOGY JANUARY/FEBRUARY 2013

WHAT WORKS FOR OTHERS...

Some of the best ways to make the case

for sound lubrication programs are success

stories about others. There are many of them.

For more info, enter 01 at www.LMTfreeinfo.com

Table III. ISO 4406 Chart

As can be seen by referring back to Table II, improving the cleanliness of lubricating rolling element bearings can result in a dramatic increase in rolling element life. For example, starting with a 22/20/17 fl uid and cleaning it to a 16/14/11 fl uid can result in a tripling of the rolling-element bearing life. These tables are available for many types of equipment components.

In Part IV, we’ll meet a specialty metals producer in the Northwest that was lubricating vacuum pumps with 23/20/14 oil and experiencing high failure rates. After real-izing that cleaning the oil could reduce failures, the producer enlisted the help of a fi lter manufacturer to create a fi ltra-tion program that improved oil cleanliness to 18/17/15. This resulted in a 70% reduction in pump failures and more than $350,000 per year in pump-rebuild savings. This case history will discuss the steps taken to improve fl uid cleanliness and the economic impact on the operation, as well as future steps that will further optimize pump reliability.

PART V: The Benefi ts of Training and Certifi cationLubricator training is not only a crucial element of any effort to improve job performance, it can—and should—lead to professional certifi cation for lubrication profi ciency. Two major organizations provide competency testing that

can lead to certifi cations: the International Council for Machinery Lubrication (ICML) and the Society of Tribolo-gists and Lubrication Engineers (STLE). Following are the certifi cations they offer:

■ ICML—Machinery Lubrication Technician Levels I and II; Machinery Lubrication Analyst Levels I, II, & III; and Laboratory Lubricant Analyst levels I and II

■ STLE—Certifi ed Lubrication Specialist; Oil-Monitoring Analyst Levels I and II; and Certifi ed Metalworking Specialist

Certifi cation is a hallmark of two major groups of users…The fi rst group includes the lubrication technicians and engineers in manufacturing plants. Certifi cations most popular with these professionals are Machinery Lubrication Technician Level I and Certifi ed Lubrication Specialist.

Certifi cation is also important to lubricant sales and marketing personnel. Becoming STLE-certifi ed gives this group an edge over the competition because lubricant purchasers want to deal with technically competent sales engi-neers. A recent industry salary survey, for example, revealed that salespeople who were Certifi ed Lubrication Specialists averaged $20,000 per year more than uncertifi ed salespeople. They also had greater management opportunities.

Part V of this series will focus on several lubrication professionals and the benefi ts they reaped after obtaining certifi cation.

Coming upLook for the fi rst installment of this series, “Building A World-Class Lubrication Program,” in the March/April issue. LMT

Ray Thibault is based in Cypress (Houston), TX. An STLE-Certifi ed Lubrication Specialist and Oil Monitoring Analyst, he conducts extensive training for operations around the world. Telephone: (281) 250-0279. Email: [email protected].

Range

Number2423222120191817161514131211109876

80000400002000010000500025001300640320160804020105

2.51.3

0.640.32

16000080000400002000010000500025001300640320160804020105

2.51.3

0.64

Number of particles per ml

More Than Up To and Including

Page 15: LMT Jan/Feb 2013

VOLUME 2 / NO. 2 UTILITIES MANAGER | 19

XX UMBIG MONEY TALKS UM

Power Generation 2013

William C. “Bill” Livoti

2012 was quite a year for change in the power industry. What can we expect in 2013? The keynote speakers at Power-Gen advised the attendees to expect changes, but what will they

look like? Here’s a brief run-down:

■ Industry executives (decision-makers) expect an increase in combined-cycle natural-gas power generation. Capacity factors for these plants will also increase.

■ Coal-fi red power generation is expected to decrease from a high of 52% to around 35% by the year 2030.

■ Nuclear power will retain 21% of the generating capacity in the US with a couple of new plants under construction after a 30-year hiatus. In spite of the negative press, nuclear power continues to develop new technology. There is quite a bit of interest in small modular reactor (SMR) technology, for which benefi ts include faster licensing and lower cost.

■ Renewable energy is expected to provide 24% of power generation worldwide by 2035. It appears wind-generation tax credits have been extended for another year. This extension will cover all wind projects that begin construction in 2013. Had the tax credits been extended earlier in 2012, wind generation could have seen 8 Gigawatts of new construction in 2013. Unfortunately, the delay in extending the credits means only 8000 to 8500 MW will reach the construction stage this year.

■ Solar photovoltaic is growing in leaps and bounds as the cost per KWH continues to drop. Photo-voltaic will also play a major role in distributed generation as increasing numbers of homeowners and businesses install the technology.

■ Geothermal, biomass and tidal and wave tech-nology will also play a role. How large that role may be remains to be seen, as a majority of funding is being focused on solar and wind development.

The long view of coalWhat’s to become of our coal-fi red power plants? The technology has an uphill battle to fi ght in dealing with special interest groups, EPA (Clean Air and Clean Water Act) and fl y ash issues. Few utili-ties are willing to take the risk of investing billions in new coal-fi red generation without clear, defi ned regulations from our government.

A number of large utilities have targeted older coal plants for decommissioning over the next few years, which will result in reduced capacity. However, due to the downturn in our economy and successful implementation of state, local and federal energy- effi ciency programs, power demand has decreased, minimizing the impact of reduced generation.

The changing landscapeIn a nutshell, we will see more combined-cycle natural-gas-fi red power plants with a mix of wind and solar. Coal will remain a staple for the foresee-able future, albeit with a smaller piece of the pie. Is this a good mix? I’m not so sure; remember the 1990s and the big push for natural gas? At least we have alternatives. UM

Bill Livoti is Power-Generation Business Develop-ment Manager for WEG Electric Corp. and Electric Machinery Co., Inc.

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VOLUME 8 / NO. 1 UTILITIES MANAGER | 15

While coal technology has an uphill battle

to fi ght with special interest groups, the

EPA and fl y ash issues, it should remain a

power-gen staple for the foreseeable

future, just with a smaller piece of the pie.

Page 16: LMT Jan/Feb 2013

UM EFFICIENCY SHOWCASE

16 | UTILITIES MANAGER VOLUME 8 / NO. 1

Packing Solution Reduces Flush Rates

Chesterton’s SuperSet has been specifi cally designed to increase packing and equipment service life while dramatically reducing fl ush rates. It combines the sealing capabilities of the company’s Mechanical Packing products (including enhanced performance,

sealibility, leak prevention, chemical compatibility, strength, toughness and thermal charac-teristics) with the patented design of the EnviroSeal SpiralTrac™ Version P Environmental Controller for Packed Stuffi ng Boxes. The SpiralTrac Version P enhances the utilization of the fl ow and centrifugal effects around the shaft by performing like a centrifugal separator. The built-in tangential lantern ring and helical grooving system impart motion to the fl ush, and the resulting centrifugal force throws the particulates in the fl uid to the outside of the bushing. The SpiralTrac grooving system then hydrodynamically pumps the solids to the bottom of the stuffi ng box and back into the pump casing.

A.W. Chesterton Co.Woburn, MA

Next-Generation, Eco-Friendly PAGs

Lubriplate®’s PGO & PGO-FGL Series products are 100% polyalkylene glycol (PAG) fl uids for gearboxes, bearings and chains operating in the most demanding conditions. They provide outstanding thermal stability, excellent extreme-pressure and anti-wear

performance, protection against micropitting and exceed 13 stages of the FZG test. With their extremely low coeffi cient of friction, fl uids in this series have been shown to reduce worm-gear energy use up to 7%. Free of zinc and other additives that could be undesirable in environmentally sensitive areas, they offer long service life and work well over extended fl uid-change intervals, which conserves resources and helps ease waste-oil disposal prob-lems. They’re available by the gallon, as well as in 5-gal. pails and 55-gal. drums.

Lubriplate® LubricantsNewark, NJ

and the resulting centrifugal force throws the particulates in the fl uid to the outside of the bushing. The SpiralTrac grooving system then hydrodynamically pumps the solids to the bottom of the stuffi ng box and back into the pump casing.

For more info, enter 264 at www.MT-freeinfo.com

AODD Accessories Boost Pump Effi ciency

Warren Rupp’s SANDPIPER brand has launched a new, improved line of Air Filter/Regulators and Lubricators for air-operated double-diaphragm (AODD) pumps. Features include a liquid-fi lled pressure gauge, as well as accessories such as lockout valves and mounting bracket kits.

These point-of-use Air Filter/Regulators have been specifi cally developed to reduce maintenance and lower operating costs. The addition of a Filter/Regulator will help prevent dirty, wet and contaminated compressed air from decreasing the performance of an AODD unit, and SANDPIPER recommends the use of these items with all of their pumps. Although the company’s AODD pumping equipment is designed to operate without lubrication, in applications with poor-quality air supplies or where nitrogen runs the pump, lubrication of the compressed air is required. For these situations, SANPIPER offers a full-line of Lubricators that easily connect to its Filter/Regulators.

Warren Rupp, Inc. A Unit of IDEX Corp.Mansfi eld, OH

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UM

VOLUME 8 / NO. 1 UTILITIES MANAGER | 17

For more info, enter 266 at www.MT-freeinfo.com

For more info, enter 265 at www.MT-freeinfo.com

Analyze Power And Quantify Energy Losses

According to Fluke, its 430 Series II Three-Phase Power Quality and Energy Analyzers not only offer exceptional power-quality analysis capabilities, they introduce, for the fi rst time, the ability

to monetarily quantify energy losses. The models in the Series II (the 434, 435 and 437) help locate, predict, prevent and troubleshoot power-quality problems in three-phase and single-phase power-distribution systems. Incorporating what the company calls revolutionary func-tions, they can help a facility reduce electrical-power consumption and improve the performance and lifespan of its electro-mechanical equipment. Capabilities include: ◆ Frontline troubleshooting: Quickly diagnose problems on-screen. ◆ Energy loss management: Measure and quantify causes of energy

losses to enable simple ROI, calculation of harmonics and unbalance mitigation.

◆ Power inverter effi ciency: Simultaneously measure AC input and DC out-put for power electronics systems.◆ Dynamic load testing: Capture instantaneous values to see the effect of load switch on generators and UPS systems.◆ Capture fast RMS data: Show halfcycle and waveforms to characterize electrical system dynamics.◆ Predictive maintenance: Detect and prevent power-quality issues before they cause downtime.◆ Quality of service compliance: Validate incoming power quality at the service entrance.◆ Long-term analysis: Uncover hard-to-fi nd or intermittent issues.◆ Load studies: Verify electrical system capacity before adding loads.

Fluke Corp.Everette, WA

Synthetic Improves Equipment Effi ciency

Royal Purple’s SYNFILM® GT is recommended for use in gas and steam turbines, blowers and vacuum pumps, bearings, gears, air tools, etc. It should be considered instead of SYNFILM® in applications where oil

reservoir temperatures exceed 200 F, improved low-temperature fl uidity is desired or when a viscosity grade is unavailable. Formulated with a superior blend of synthetic base oils plus Royal Purple’s proprietary SYNERLEC® additive technology that’s been proven to make equipment run smoother, cooler, quieter, longer and more effi ciently, Synfi lm GT rapidly and completely separates from water and has a very low-temperature fl uidity. According to the company, the product offers excellent protection against rust and corrosion and is extremely oxidation-stable, which leads to long oil life and extended oil-drain intervals. It typically replaces conventional, low-fi lm-strength R & O (rust and oxidation inhibited) oils that rely solely on their viscosity to protect equipment against wear.

Royal PurplePorter, TX

and DC out-put for power electronics systems.Capture instantaneous values to see the effect of load switch on generators and UPS systems.

Page 18: LMT Jan/Feb 2013

ICML CERTIFICATION SERIES

18 | LUBRICATION MANAGEMENT & TEChNOLOGy JANUARY/FEBRUARY 2013

The topic of lubrication can be easily divided into two

specifi c areas, 1) the science and chemistry of lubricating

materials, and 2) the practical application of lubrication

knowledge and materials to effectively reduce the fric-

tion, wear and energy loss of moving parts. LMT’s mandate is

to inform its readers, from those who are highly experienced

to those who are less so, not just about what’s new in the world

of lubrication, but about the basic concepts and principles

that guide GLP (Good Lubrication Practices). These funda-

mentals—or “Elements”—are what make up the International

Council of Machinery Lubrication (ICML) Domain of Knowl-

edge. They’re also the focus of a new 12-part series that kicks

off in this issue.

Industrial Lubrication Fundamentals: FRICTION

Certifi cation matters.

The more certifi ed lube

professionals there are,

the stronger the ‘voice’

of lubrication will be

throughout industry.

Domain of Knowledge Element #1

Ken BannisterContributing Editor

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ICML CERTIFICATION SERIES

JANUARY/FEBRUARY 2013 www.LMTinfo.com | 19

Keep in mind that the articles in this series aren’t meant to replace requisite formal preparatory training. The goal is to introduce (or refresh readers on) the fundamental knowl-edge requirements for working in a best-practice lubrication environment, spur them to pursue a certifi cation path (if they haven’t already) and give the lubrication community a stronger voice in the world of asset reliability.

Friction is why we lubricateThe word “tribology,” coined by Sir H. Peter Jost (see Sidebar below), comes from the Greek word tribos, meaning “to rub,” and is used to describe what happens when two hard surfaces move over one another. The resistive force causing this “rubbing” action is known as friction, and was fi rst recognized by Sir Isaac Newton in his laws of motion as an external force to motion.

Webster’s describes friction as “the force, which opposes the movement of one surface sliding or rolling over another with which it is in contact.” Simply put, friction is the resistive force that retards motion. And it’s not necessarily a bad force: We employ frictional forces when we want to intentionally

slow a body in motion (i.e., retarding the movement of a rotating machine or automobile by applying a rough and soft consumable braking material with a high coeffi cient of fric-tion against a smooth, hard [less-consumable] surface).

Friction becomes an undesirable force when it robs energy from an applied force used to intentionally move an object. Frictional forces have, in fact, been estimated to consume over one-third of the world’s energy. When ignored in such cases, friction causes heat, wear and, sometimes, catastrophic failure of the moving body. To understand friction we must recognize that there are two unchanging fundamental laws that govern it:

n Friction varies directly with load.

n Friction is independent of surface area.

Figure 1 depicts the forces at play on two bodies at rest. To begin to move Body “A” across Body “B,” we must fi rst overcome its resistive frictional force. This resistive force is a result of the load N representing the weight of the body

In the mid-1960s, a groundbreaking study by the British government (under the charge of Sir H. Peter Jost) quan-tifi ed the tangible effects of poor lubrication practices on the nation's gross national product. That study, now referred to as the Jost Report, introduced us to the word “tribology” (the science of lubrication, friction and wear). For the fi rst time, lubrication was recognized for its role as a bone fi de science in the area of asset reliability, and for its fi scal impact on industry when practiced poorly.

Once awakened, sleeping giants take time to stir and get moving. Unfortunately, it wasn’t until the turn of the new millennium that a heightened awareness surrounding the fi eld of lubrication began to emerge on a global scale. This has been emphasized through industry’s rapidly growing recognition of—and demand for—certifi ed lubrication specialists in the practical application and lubricant diagnostic/analysis fi elds.

Although there are no specifi c apprenticed trade designa-tions for lubrication specialists, over the past two decades many of the world’s leading lubrication experts and propo-nents (including scientists, engineers, consultants, suppliers and practitioners) have worked to develop certifi cation programs backed by a body and domain of knowledge.

Today, there are three lubrication certifying bodies: STLE (Society of Tribologists and Lubrication Engineers); ICML (International Council of Machinery Lubrication); and ISO (International Organization for Standardization).

Originally designed for engineers, the STLE Certifi ed Lubrication Specialist (CLS) program has been in place since 1993.

ICML has developed two certifi cations for “hands-on” lubrication practitioners: the MLT (Machine Lubrication Technician) and MLA (Machine Lubrication Analyst) designations.

A relative newcomer, ISO’s lubrication certifi cation program has chosen to adopt the ICML model and, in fact, has collaborated with the ICML to use its body of knowledge. Participants who attend the requisite prepa-ratory formal training associated with ICML certifi cation are also eligible to take corresponding ISO exams (upon payment of the appropriate examination fees).

Of these three programs, ICML’s (currently offered in nine languages) has issued the most certifi cations around the world. For information on the ICML program,please visit: www.lubecouncil.org.

In the mid-1960s, a groundbreaking study by the British government (under the charge of Sir H. Peter Jost) quan-

Today, there are three lubrication certifying bodies: STLE (Society of Tribologists and Lubrication Engineers); ICML

A Brief History of Lubrication Certifi cation

Continued on next page

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Page 20: LMT Jan/Feb 2013

ICML CERTIFICATION SERIES

20 | LUBRICATION MANAGEMENT & TEChNOLOGy JANUARY/FEBRUARY 2013

multiplied by the coefficient of friction. For example, if the upper body represented a full steamer trunk resting on a concrete floor, using the formula F = uN we can calculate the initial (static) resistive force we need to overcome to start the trunk moving across the floor. Thus, if we assume the loaded trunk weighs 100 lbs., and the coefficient of friction of wood on dry concrete is 0.65, the applied force required to start the trunk moving would be 0.65 x 100 = 65 lbs. Once the trunk has begun to move, the static friction barrier has been broken and the force required keeping the trunk moving reduces somewhat as long as the body remains moving. The frictional force has changed from a static frictional load to a kinetic frictional load

The Coefficient Of Friction (COF) (which is different for every material and fluid) is represented by the Greek letter mu (u). COF values range from almost 0 to well over 1, and the lower the value, the lower the resistance and retardation effect. Therefore whenever we want to produce work from moving parts, lower COF values are preferred because they require less energy expenditure to achieve movement—or work (i.e the motor requires less amperage draw, or the engine requires less fuel to achieve the desired work performance). Obviously, we would expend enormous amounts of energy to move things around if we were only to allow surface-to-surface contact on all moving parts. To reduce these forces and overcome the large static and kinetic forces we must introduce a fluid film to separate the two moving parts.

The fluid film is referred to as the lubricant. The principle of reducing friction while supporting a moving sliding load is

referred to as lubrication. Lubricants or fluid films are not themselves “frictionless,” as they rely on an action known as “shearing,” depicted in Fig. 2, whereby fluid friction occurs between the molecular shear planes of the lubricant as they move across one another when the load moves. The following exercise demonstrates this point: First sweep your hand back and forth quickly on the surface of a table. Then place your hand atop a deck of cards on the table and move it back and forth. Compared to your hand's movement on the table, sweeping it back and forth over the deck of cards will be relatively effort-less. That’s because the movement generates little or no heat as the cards “shear under the load” (slip over one another). Fluid friction is a similar phenomenon, in that it increases as viscosity becomes thicker or as a lubricant becomes dirty. Although a small amount of energy is required to overcome fluid friction, it’s negligible compared with having no fluid film present.

When mechanical moving parts are present, the amount of lubrication required depends on the state of friction that manifests itself in three specific ways:

n Sliding frictionn Rolling frictionn Combination friction (sliding and rolling)

Sliding friction is common where any plain surfaces move over one another (like in plain bearings where a journal moves within a sleeve). Sliding friction arrangements require the most lubricant, as the friction is evident over a larger surface contact area.

Fig. 1 Forces on bodies at rest (Source: Engtech Industries, Inc.)

Frictional Force

Normal Force (Weight)

Applied

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JANUARY/FEBRUARY 2013 www.LMTinfo.com | 21

Rolling friction is found in all rolling element bearings that at one time were described as “friction-less” bearings. The contact surface is considerably smaller than in sliding friction bearings, and thereby requires much smaller amounts of lubrication to achieve a protective full-fl uid fi lm.

Combination friction, on the other hand, is unique to meshing gears. This is due to the changing gear-tooth profile that requires the teeth to slide on one another until the opposing pitch surfaces meet and rolling friction takes over as they disengage. Certain types of gears, such as hypoid gears and worm gears, are capable of producing much higher degrees of sliding friction.

Whenever moving parts are present, friction will be present—ever present, that is. Understanding friction helps us develop effective lubrication practices that, in turn, help us tame the harmful effects of friction and increase the life cycles of our equipment components. For more info, enter 71 at www.LMTfreeinfo.com

Fig. 2. Magnifi ed cross-section of two bodies in motion separated by a fl uid fi lm (Source: Lubrication for Industry, by Ken Bannister, Industrial Press)

For more info, enter 31 at www.LMTfreeinfo.com

Because viscositymeasurement should

be simple

2139 High Tech Road • State College • PA • 16803814-353-8000 • 800-676-6232Fax 814-353-8007

[email protected] • www.cannoninstrument.com

Watch a video of the new SimpleVIS

at www.cannoninstrument.com

Simple to Use: Graphical Touch Screen

Rapid Automated Analysis: ~3 min.

Reliable: Only 2 Moving Parts

Small Sample Volume <1 mL

Range: 10 to 700 mm2/s at 40 or 100°C

Coming upThe next issue will cover ICML's Body (Domain) of Knowledge Element #2: “The Functions of a Lubricant.” LMT

Ken Bannister holds certifi cations as both a maintenance professional and a lubri-cation management professional. A Prin-cipal with ENGTECH Industries, Inc., he’s the author of the Machinery’s Hand-book “Lubrication” chapters, as well as the best-selling Lubrication for Industry textbook recognized as part of the ICML and ISO Domain of Knowledge. Bannister also teaches numerous formal prepara-tion courses for the ICML MLT/MLA program and ISO LCAT certifi cations. For information, including details on his ICML Pro Course at MARTS 2013 and the opportunity to take the ICML exam, telephone: (519) 469-9173; or email: [email protected].

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MOVEMENT OF FORCE

SHEAR PLANES LUBRICANT

ICML CERTIFICATION SERIES

Page 22: LMT Jan/Feb 2013

SUPPLY CHAIN LINKS

22 | LUBRICATION MANAGEMENT & TECHNOLOGY JANUARY/FEBRUARY 2013

A lot goes into being on the cutting edge of something. Here’s how a leading machine-tool manufacturer got there and stays there.

Jane AlexanderEditor

Technology Q&A…

Haas Automation:Turning Out 30 Years

Of Innovation And Success

Since its founding in 1983, Haas Automation, Inc., has grown into one of the largest

machine-tool builders in the world, producing industry-leading products at consis-

tently affordable prices. As it celebrates its 30th anniversary, this Oxnard, CA-based

corporation's commitment to innovation and proactive equipment maintenance

remain essential core values. To learn more about the company's recent accomplishments

and the keys to its ongoing success, we caught up with Haas veteran, Thomas Velasquez,

Manager, Rotary Products Engineering.

Editor's note: This story originally appeared in the Sept. 2012 issue of Maintenance Technology.

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SUPPLY CHAIN LINKS

JANUARY/FEBRUARY 2013 www.LMTinfo.com | 23

QUESTION:Haas Automation recently celebrated a major milestone with production of the 125,000th Haas CNC machine tool. Can you tell us more about that?

Velasquez:It certainly was a big milestone. Since 1988, when we intro-duced the industry’s fi rst American-built vertical machining center (VMC) priced less than $50,000, our Haas VF-1 (like the unit shown in Fig. 1) has been the industry stan-dard for affordable CNC technology.

The 125,000th Haas CNC machine tool was a 2012 VF-1 vertical machining center (like the one shown in Fig. 2). This product is a perfect representation for how we have continued to enhance the performance of our machines over the years. Its many advanced features include the ability to operate at speeds as high as 8100 rpm stan-dard, brushless servos on all axes, 1000-ipm rapids and a 20-tool ATC.

So, that milestone was a great way for us to refl ect on our history, legacy of innovation and commitment to delivering the best machines to our customers.

Fig. 1. The fi rst Haas VF-1, still considered an industry standard for affordable CNC technology

Fig. 2. A Haas 2012 VF-1 vertical machining center

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SUPPLY CHAIN LINKS

24 | LUBRICATION MANAGEMENT & TECHNOLOGY JANUARY/FEBRUARY 2013

QUESTION:Why do you think Haas Automation products remain so popular with customers?

Velasquez:We cater to many industries, like aerospace, automotive, mining, appliances, electronics and, especially, the “Mom & Pop” shop. In the process, we’ve always focused on deliv-ering innovative products that help our customers address the challenges they face on a daily basis.

We never lose sight of the fact that, at the end of the day, our success stems from the performance of our machines. Frankly, our customers don’t have time to deal with mainte-nance issues and have their equipment be down, so we develop our products to be as durable and reliable as possible.

We focus on manufacturing four major product lines: vertical machining centers (VMCs), horizontal machining centers (HMCs), CNC lathes and rotary tables, as well as a number of large fi ve-axis and specialty machines. We make them easy to operate and maintain. We also ensure that our equipment has more standard features, high-tech innova-tions and rock-solid engineering than the many other CNC machines in the world.

Moreover, the support we provide customers through our network of Haas Factory Outlets (HFOs) is another major advantage. Today we have more than 170 HFOs across more than 50 countries. Each one combines the convenience and security of a local dealer with the strengths of an interna-tional organization.

Every HFO has complete showroom facilities, factory-trained service personnel, extensive spare-parts inventories and fully stocked service vehicles to provide the industry’s best service and support. Each HFO employee is dedicated to helping our customers succeed. This local approach is the best way to provide our customers with superior sales, service and applications assistance.

QUESTION:How is the company the same since its founding three decades ago?

Velasquez:The company’s approach to developing products and serving customers has remained exactly the same. Haas machine tools and rotary products are built to the speci-fi cations that (company founder) Gene Haas has set forth to ensure exceptional accuracy and durability. We produce all critical components for our machinery in-house, using dedicated state-of-the-art CNC machine tools—of which more than 70% are Haas machines. And, before leaving the plant, the typical Haas CNC machine is subjected to more than 300 quality-control tests.

We always try to find new ways to do things better. To that end, we never overlook anything or dismiss some-thing as “too minor.” We constantly challenge ourselves to keep improving—and we're constantly asking questions of ourselves. For example, can we find a new part to make our machines go faster and be more efficient? What kind of lubricants do we need to make our equipment as durable as possible? How can we make the operation of our machines even easier for our customers?

We never stop asking questions and never stop looking for new and potentially better solutions.

QUESTION: You mentioned lubricant selection. You have played a key role in the decision to factory-fi ll equipment with synthetic lubricants and to put them in the equipment used at the company’s production facilities. Can you tell us why?

Velasquez:In the age-old equipment maintenance debate over conventional oils vs. synthetic oils, we are big proponents of synthetics.

Today, we fi ll synthetic lubricants in much of the equipment that we sell and the equipment we use in our facilities. The move toward synthetics started nearly 18 years ago when, working with Gene Haas and other members of the engineering team, we sought to enhance the performance of our rotaries.

We now factory-fi ll our rotaries, gearboxes and spin-dles, as well as some of our tool-changer gearboxes, with Mobil SHC™ 600 oils. Since we made the switch, we’ve seen gearbox life increase two-to-three times based on backlash measurements.

We also use Mobil SHC synthetic greases (Mobilith SHC™ 007) in our linear guides and ball-screw grease systems, and we’ve recently switched to Mobil SHC 500 synthetic hydraulic oils for our hydraulic power units and rotary hydraulic brakes.

For our customers, the performance that synthetics offer, as compared to conventional oils, can help deliver fi nancial and operational benefi ts, like improved equip-ment performance and durability and longer oil drain intervals.

The longer oil drain intervals you can obtain through the use of synthetics translates into less time that personnel need to spend on oil change-outs and less exposure to equipment, both of which are defi nite safety benefi ts.

In addition, from an environmental-care perspec-tive, using certain synthetics, like Mobil SHC 600, can help reduce oil consumption and minimize oil dispo-sal costs.

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JANUARY/FEBRUARY 2013 www.LMTinfo.com | 25

QUESTION: As the company approaches its 30th anniversary, what do you think the future holds for Haas Automation?

Velasquez:From a manufacturing standpoint, the trend toward faster, leaner and more effi cient equipment will increase.

I can also see that more equipment in the future will incorporate advanced diagnostic electronics like on-board maintenance alerts.

That said, we think the competition will evolve and become even more global than it is today. In addition, our customers will be challenged to fi nd new ways to improve productivity and minimize their environmental impact.

But as we have over the past 30 years, we remain very confi dent that Haas Automation will continue to thrive and be seen as an industry leader for high-quality machine tools at affordable prices. LMT

For more info, enter 03 at www.LMTfreeinfo.com

Haas Automation builds roughly 60 CNC machines per day.

All of its machines are manufactured in the company's

1-million-square-foot facility in Oxnard, California.

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26 | LUBRICATION MANAGEMENT & TECHNOLOGY JANUARY/FEBRUARY 2013

PROBLEM SOLVERS

For more info, enter 32 at www.LMTfreeinfo.com

For more info, enter 31 at www.LMTfreeinfo.com

NSF H1-Registered Spray Lubricant

Klüberpaste UH1 96-402 from Klüber Lubrication is a light-colored, high-temperature paste available as a spray. Designed for assembly purposes and the

lubrication of screws at temperatures between 392 and 2192 F, it’s registered as NSF H1, making it suitable for food-processing and pharmaceutical use. The product adheres to metals and is water-resistant.

Klüber Lubrication North America L.P.Londonderry, NH

Lube System Overcomes A Variety Of Challenges

Techno-Sommer’s Sharpshooter system addresses a number of lube challenges, including, among others, hard-to-reach lubrication points and the unaccept-

ability of mist lubrication. Working off standard shop air at up to 90 psi, it can place a drop of lubricant at up to 1m away with pinpoint accuracy. A pressurized tank generates internal pressures up to 750 psi. When a pulse is generated, a fi xed drop size is dispensed. Up to eight dispensing nozzles ranging in size from 5mm3 to 100mm3 can be attached to one tank.

Techno-SommerNew Hyde Park, NY

26 | LUBRICATION MANAGEMENT & TECHNOLOGY JANUARY/FEBRUARY 2013

ReliableGadgets

Air Sentry® is a leading developer of contamination control products that keep particulate matter and excess moisture from the headspace inside vessels like

gearboxes that hold lubricants, greases, hydraulic fl uids and fuels. This extends the life of critical machinery and equipment, and signifi cantly reduces lifecycle costs. The company’s innovative products have been the gold standard in contamination control since 1997. Its line includes nine series of desiccant breathers, anodized color-coded closed system adapter kits that prevent cross-contamination, mani-fold adapters and pressure-vacuum-indicating gauges.

Air Sentry has recently introduced a revolutionary new line of desiccant breathers called Guardian™. These “next-generation” contamination control products are the fi rst breathers constructed of Tritan™. This patented material provides the most chemical-, temperature- and impact-resistant casing on the market. Guardian also is the fi rst desiccant breather to incorporate an isolation check valve that protects the adsorbent from exhaust air and volatile splashing fl uids. This lengthens the desiccant’s service life and reduces replacement frequency. Learn more about how Guardian increases fl uid life, improves lubrication and lowers maintenance costs by visiting www.airsentry.com/air-sentry-breathers/guardian.htm.

Air Sentry®A Division of WhitmoreRockwall, TX

Next-Generation, Extended-Life Contamination Control Products

SPON

SORE

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FORM

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JANUARY/FEBRUARY 2013 www.LMTinfo.com | 27

PROBLEM SOLVERS

To view and order from our complete line of

Visual Systems Products, go to...

www.swspitcrew.com

“Visual systems, when applied to equipment, can reduce training time by 60 to 70% and eliminate errors.”

—Robert Williamson, lean equipment specialist

Our Visual Supplies Can Improve Your Equipment’s Performance!

To order by phone or fax, call (864)862-0446

Strategic Work Systems, Inc.PO Box 70

Columbus, NC 28722

Colored gauge marking labelsProblem and Opportunity Tags in English or SpanishRed Move TagsColored paint pensColored grease fi tting caps and lube point labelsVibration analysis pickup discs and labelsProven Tips for Equipment Troubleshooting handbookLean Machines instructional book for applying visualsTemperature indicating strips and more

Visual systems supplies that deliver results...fast!

For more info, enter 69 at www.LMTfreeinfo.com

Compact AndEasy-To-CleanCNC Oil Skimmer

Abanaki’s Mighty Mini® SST is intended for the removal of unwanted oil in coolants

and parts washers. Capabilities include removal rates of up to two gallons of medium-weight oil per hour, depending on belt selection. An improved wiper blade system fi ts securely in the trough and allows for cleaning on both sides of the belt. Its light-weight and small footprint allow it to fi t underneath most CNC machines.

Abanaki Corp.Cleveland, OH

For more info, enter 33 at www.LMTfreeinfo.com

Multi-Point Lubrication Delivery System

Oil-Rite’s Hydraci-sion multi-point lubrication system

can distribute to as few as 12 or up to hundreds of separate points. It combines effi cient hydraulic movement of fl uid with the precision of positive displacement injection. The reservoir housing contains a gear pump motor which pressurizes the outlet for uniform fl uid distribution. A PLC with programmable display allows selection of lube cycles, while a low-level switch prevents operation when oil supply is depleted.

Oil-Rite Corp.Manitowoc, WI

pump motor which pressurizes the outlet for uniform fl uid distribution. A PLC with programmable display allows selection of lube cycles, while a low-

For more info, enter 34 at www.LMTfreeinfo.com

Page 28: LMT Jan/Feb 2013

28 | LUBRICATION MANAGEMENT & TECHNOLOGY JANUARY/FEBRUARY 2013

PROBLEM SOLVERS

For more info, enter 31 at www.LMTfreeinfo.com

For rate information on advertising in the Information Highway Section Contact your Sales Rep or JERRY PRESTON at:

Phone: (480) 396-9585 / E-mail: [email protected]

INFORMATION HIGHWAY

For more info, enter 36 at www.LMTfreeinfo.comFor more info, enter 35 at www.LMTfreeinfo.com

Air Sentry® is a leading developer of contamination control products that keep particulate matter and excess moisture from the headspace inside gearboxes, drums, reservoirs, oil tanks, etc. that hold oils, greases, hydraulic fl uids, and fuels. Air Sentry breathers and adapters ensure longer fl uid life, better lubrication and lower maintenance costs.

For more info, enter 71 at www.LMTfreeinfo.comwww.airsentry.com

Bio-Based Oil With No VOCs

Master Chemical’s TRIM® OV 2200 is a bio-based straight oil free of volatile organic compounds. Developed to machine diffi -

cult alloys and stainless steel, the chlorine-free oil contains no sulfurized EP additives and protects aluminum and copper alloys. It also has improved oxida-tion inhibition compared with other vegetable oils, according to the company.

Master Chemical Corp.Perrysburg, OH

oils, according to the company.

Air-Operated Piston Pumps

ARO Fluid Prod-ucts’ AFX™ line of air-operated

piston pumps and systems features air motors in fi ve sizes from 4.25” to 12”. Each includes ARO’s Progressive Exhaust™, True Link Valve™ and integrated regulator technology used on 2-ball, 4-ball and chop-check pumps. The pumps are well suited for transfer of shear-sensitive, viscous, corrosive and abrasive fl uids in a range of applications.

ARO Fluid ProductsAn Ingersoll Rand Co. BrandDavidson, NC

www.atplists.com

Contact: Ellen Sandkam847-382-8100 x110 800-223-3423 x110

[email protected] [email protected]

1300 S. Grove Ave., Suite 105, Barrington, IL 60010

Customized, Customized, Customized, Targeted Lists Targeted Lists Targeted Lists Targeted Lists Targeted Lists Targeted Lists Targeted Lists Targeted Lists Targeted Lists Targeted Lists Targeted Lists Targeted Lists

For Your For Your For Your For Your For Your For Your For Your For Your For Your For Your For Your For Your Marketing NeedsMarketing NeedsMarketing NeedsMarketing NeedsMarketing NeedsMarketing NeedsMarketing NeedsMarketing NeedsMarketing NeedsMarketing NeedsMarketing NeedsMarketing Needs

Customized, Customized, Customized,

ATP List Services

For more info, enter 70 at www.LMTfreeinfo.com

The Maintenance & Reliability Technology Summit is the #1 learning venue and source of practical solutions for anyone concerned with the reliability, maintenance and the overall capacity assurance of critical equip-ment systems in a plant or facility. Mark your calendars! MARTS 2013 is taking place April 30-May 3, 2013 at the Hyatt Regency O’Hare in Rosemont, IL.

For more info, enter 72 at www.LMTfreeinfo.comwww.MARTSConference.com

Page 29: LMT Jan/Feb 2013

JANUARY/FEBRUARY 2013 www.LMTinfo.com | 29

PROBLEM SOLVERS

For more info, enter 37 at www.LMTfreeinfo.com

Unlock the Secrets that let you Tap your True Maintenance Potential

and Maximize Asset Reliability!

Unlock the Secrets that let you Unlock the Secrets that let you Unlock the Secrets that let you Tap your True Maintenance Potential Tap your True Maintenance Potential Tap your True Maintenance Potential Tap your True Maintenance Potential Tap your True Maintenance Potential

and Maximize Asset Reliability!and Maximize Asset Reliability!and Maximize Asset Reliability!and Maximize Asset Reliability!World Class organizations know that increased asset reliability, utilization and maintainability, reduced operating costs, downtime, contamination, energy consumption and carbon footprintall commence with a best practice lubrication program!

“Industrial Lubrication Fundamentals”3-Day, On Site, Certifi cation Preparation Training Program

Course design is based on ISO 18436-4 and the ICML body of knowledge and exceeds minimum training requirements to write the ICML, MLT1, MLA1 and ISO LCAT1 International lubrication certifi cation exams. Exams can be arranged to take place at your site immediately following the training.

For more information on this unique training program developed and delivered by internationally accredited lubrication and maintenance expert Ken Bannister, author of the best selling book Lubrication for Industry endorsed by ISO and the ICML as part of their certifi cation Domain of Knowledge Content.Contact ENGTECH Industries Inc at 519.469.9173 or email [email protected]

With over 70% of all mechanical failures attributed to ineffective lubrication practices, you will want to have professionally trained and certifi ed lubrication personnel working on your reliability efforts!

For more info, enter 73 at www.LMTfreeinfo.com

Cost-Effective ‘Check-Engine-Light’ Technology For Monitoring Semi-Critical Equipment

SKF’s new CMSS 200 Machine Condition Indicator is a low-cost, battery-powered, stand-alone monitoring solution for semi-critical machines with constant operating conditions that usually aren’t evaluated on a regular basis. Independent and self-suffi cient, it periodi-

cally measures vibration and velocity, and monitors for problems relating to misalignment, imbalance, etc. It also measures enveloped accelera-tion to detect bearing degradation and keeps a running check on operating temperatures. Built-in intelligence evaluates data and helps avoid false alarms. Performing like a car’s check-engine light, the device indicates alarm status on three LEDs. Individual units can be stud-mounted or epoxied to the monitored equipment.

SKFLansdale, PA

Page 30: LMT Jan/Feb 2013

IndexADVERTISER WEBSITE CIRCLE # PAGE #

JANUARY/FEBRUARY 2013 • Volume 14, No. 1

1300 South Grove Avenue, Suite 105Barrington, IL 60010

PH 847-382-8100 FX 847-304-8603

www.LMTinfo.com

SALES STAFF

AR, KS, LA, MO, NM, OK, TX5930 Royal Lane, Suite E #201

Dallas, TX 75230972-816-3534; Fax 972-767-4442

GERRY [email protected]

CLASSIFIED ADVERTISING3605 N. TuscanyMesa, AZ 85207

480-396-9585 JERRY PRESTON

[email protected]

AZ, CA, CO, ID, MT, NV, OR, UT, WA, WY, AB, BC, MB, SK

3605 N. TuscanyMesa, AZ 85207

480-396-9585 JERRY PRESTON

[email protected]

IL, IN, MI, WI1173 S. Summit StreetBarrington, IL 60010

847-382-8100 x108; Fax 847-304-8603TOM MADDING

[email protected]

CT, ME, MA, NH, NY, RI, VT, ON, QC P.O. Box 1059

Osterville, MA 02655508-428-3331; Fax 508-428-2545

VINCENT [email protected]

AL, DC, DE, FL, GA, MD, MS, NC, NJ, PA, SC, VA, WV 1750 Holmes Drive

West Chester, PA 19382610-793-3093; Fax 610-793-3094

JIM [email protected]

IA, MN, NE, ND, SD1300 South Grove Avenue, Suite 105

Barrington, IL 60010847-382-8100 x116; Fax 847-304-8603

BILL [email protected]

OH, KY, TN135 N. Rocky River Road

Berea, OH 44017440-463-0907; Fax 440-891-1254

JOHN [email protected]

30 | LUBRICATION MANAGEMENT AND TECHNOLOGY JANUARY/FEBRUARY 2013

©

Air Sentry .......................................................www.airsentry.com .....................................30,71 ..26,28

ATP Lists .........................................................www.atplists.com .......................................70 ............ 28

Cannon Instrument Co. ................................www.cannoninstrument.com ...................67 ............ 21

Engtech Industries Inc...................................www.engtechindustries.com .....................73 ............ 29

MARTS ...........................................................www.martsconference.com .......................65,72 .... 7,28

Miller-Stephenson Chemical Co. .................www.miller-stephenson.com .....................66 ............ 13

NSK Corporation ..........................................www.nskamericas.com ..............................64 .............. 5

Royal Purple ...................................................www.royalpurpleindustrial.com ...............75 ............ 32

Strategic Work Systems, Inc. .........................www.swspitcrew.com .................................69 ............ 27

U.S. Tsubaki Power Transmission, LLC .......longlifelambda.com ...................................61 .............. 2

UVLM, Inc. ....................................................www.uvlm.com ...........................................68 ............ 25

Access LMTfreeinfo.com and enter the circle number

of the product in which you are interested, or you can search

even deeper and link directly to the advertiser’s Website.

Submissions Policy: Lubrication Management &Technology gladly welcomes submissions. By sending us your submission, unless otherwise negoti-ated in writing with our editor(s), you grant Applied Technology Publications, Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish, and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned.

CLASSIFIED

For rate information on advertising in the Classifi ed Section contact your Sales Rep or JERRY PRESTON at: Phone: (480) 396-9585 / E-mail: [email protected]

REPRINTS ARE IDEAL FOR:

New Product Announcements

Sales Aid For Your Field Force

PR Materials & Media Kits

Direct Mail Enclosures

Customer & Prospect Presentations

Trade Shows/Promotional Events

For additional information, please contact Foster

Printing Service, the official reprint provider for

Lubrication Management.

PMS 370 C

C: 60M: 0Y: 100K: 28

Use reprints to maximize your marketing

initiatives and strengthen your

brand’s value.

CUSTOM REPRINTS

Call 866.879.9144

or [email protected]

ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS

Page 31: LMT Jan/Feb 2013

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LUBRICATION MANAGEMENTAND TECHNOLOGY

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