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AS I SEE ITDemand ‘Reliability Readiness’ from Equipment BuildersReliability should have shared responsibility. It must be fi xed in the DNA of the machine as well as in the minds of operators and maintainers.
FROM THE FIELDHow Lubricant Suppliers Impact Machine ReliabilityPlants often don’t take into account the effect that the lubricant supplier can have on machine reliability. If left unchecked, the results can be catastrophic.
LUBE-TIPSOur readers offer excellent advice on a host of lubrication-related issues, including safety tips for oil storage areas.
TURBINE LUBRICATIONHydrodynamic Cleaning and Flushing of Turbine Oil SystemsDiscover how the technology of hydrodynamic cleaning and fl ushing of oil systems can be an effective method of preparing new oil systems and restoring operated oil systems.
GREASESUsing a Grind Gage for In-Service Grease Analysis A quick and simple fi eld test utilizing a fi neness of grind gage can provide immediate results on the overall contamination of grease.
More 32 TEST YOUR KNOWLEDGE42 CROSSWORD PUZZLER54 BOOKSTORE
Editorial Features40 GET TO KNOW52 NOW ON MACHINERYLUBRICATION.COM
Departments 14 PRODUCT NEWS 26 PRODUCT SUPERMARKET
OIL ANALYSIS6 Ways to Maximize Your Oil Analysis Software ValueSelecting the proper oil analysis software and maximizing its features can provide a huge payback for the user through reduced machinery maintenance expenses.
LESSONS IN LUBRICATIONAnatomy of an Oil Analysis Report In order to properly interpret an oil analysis report and make sense of all the test data, you must understand a few important principles.
CERTIFICATION NEWSWorld-Class Reliability Starts with a Solid FoundationTechnicians are the human foundation of any reliability-improve-ment program and should be respected and supported in their professional development.
HYDRAULICSBecome an Expert through CertificationGetting certifi ed and holding multiple certifi cations demonstrates that you take your career seriously and can be the key component to increasing your worth to your employer.
BACK PAGE BASICSHow to Change Your Lubrication CultureChanging your facility’s lubrication culture may take time, patience and commitment, but the rewards will be well worth the effort.
November-December 2013
8COVER STORY Purchasing Lubricants Based on PerformanceLearn the pros and cons of using a specifi cation system to purchase lubricants, how to launch such a system and make it work, and how to handle exceptions.
Contents
AS I SEE IT
2 | November - December 2013 | www.machinerylubrication.com
When it comes to modern concepts in the fi eld of lubrication and
applied tribology, many users these days are far more sophisticated than those who are designing and building the machines they operate. This lack of sophistication by orig-inal equipment manufacturers (OEMs) is very evident when you see what’s not included with the sale of new machinery. One could assume that what’s missing from the machine and its documentation is func-tionally missing from the knowledge and awareness of the engineers and builders of this equipment. Ignorance is not bliss. The same is true for complacency.
Reliability needs to have shared responsi-bility. It must be fi xed in the DNA of the machine as well as in the minds of operators and maintainers. It’s like a reliability chain; every link in the chain must be equally strong in order for the chain’s full length to bear the load. Machinery Lubrication magazine is primarily devoted to advanced concepts in lubrication from a user’s perspective, more specifi cally lubrication-enabled reliability.
Users not only have a signifi cant infl uence on machine reliability during operation but also by what is being done (or not done) by equipment builders to “ready” machines for optimum reliability. They want the machine’s design to have an implanted genetic code that enables reliability.
Users defi ne what’s expected from OEMs and the machines they deliver. Of course, meeting the minimum required operating performance is a basic need of every machine, but prolonged sustainability of that performance is also important. This is not simply a matter of quality manufacturing to a design specifi cation in order to avoid defects. From the standpoint of reliability, it’s more about including design features that have little to do with the machine’s functional performance. At fi rst, this may seem unnecessary and wasteful, but when viewed over a timespan of several years, these “extra features” could translate to huge fi nancial benefi ts.
In sum, OEMs can achieve machine reli-ability in the following ways (used collectively):
• Design for functional robustness (functional design, material selection, lab and fi eld testing)
• Design for optimum maintainability by the user (ease and effectiveness)
• Quality manufacturing to reduce defects and other anomalies (e.g., Six Sigma)
• Provide a documented equipment maintenance plan (EMP) (see sidebar on page 3)
• Training and education of fi eld-service technicians, operators and main-tainers to execute the EMP
Developing Reliability Readiness Investments in machine reliability should
be purposeful. Certainly, there will be costs and even risks associated with reliability initiatives. You aren’t trying to maximize reliability but rather optimize it in the context of the user organization. OEMs must be keenly aware of how their machines will be deployed, the operating environ-ment and the minimum needs for reliability. Ideally, they should follow these steps:
Demand ‘RELIABILITY READINESS’ from Equipment BUILDERS
M a i n t e n a n c e a n d R e l i a b i l i t y
JIM FITCH NORIA CORPORATION
MAINTAINABILITY MACHINE DESIGN FEATURES
CORRECT LUBRICANT
STABILIZED LUBRICANT HEALTH
CONTAMINATION CONTROL
ADEQUATE AND SUSTAINED LUBRICANT SUPPLY
Seals and Leakage
Use of labyrinth and other premium seal technologies
N/A
Avoids lubricant distress from contamination and low lubricant levels
Reduces the severity of contaminant ingression (dirt, water, process chemicals, etc.)
Reduces leakage-induced starvation
Proper selection and installation of bearing seals and shields
N/A
Reduces excessive heat, churning and contaminant-induced grease degradation
Reduces the ingress of certain contaminants including heat, water and dirt
May reduce leakage, starvation and overlubrication issues
1. Determine the overall machine criticality. This process weighs both the probability of failure and the consequences of failure. For more information on quantifying machine criticality, see http://www.machinerylubrication.com/Read/29346/machinery-criticality-analysis.
2. Rank the most likely failure modes. This is often done using failure modes effects anal-ysis (FMEA). If you don’t know how the machine is likely to fail, you won’t know how to control it. Criticality defi nes the risk, while FMEA reveals the de-risking opportunities that bring focus and strategy to reliability.
3. Based on criticality and FMEA, develop the specifi c attributes of the optimum reference state (ORS). As described previously in Machinery Lubrication magazine, the ORS is defi ned as the prescribed state of machine confi guration, operating conditions and maintenance activities required to achieve and sustain specifi c reliability objectives. In the context of this article, the ORS defi nes the need for equipment modifi cations and acces-sories that optimize the state of lubrication.
While this is the critical beginning of the reli-ability life cycle, there are many stages that follow to the end of the machine’s life. These stages are described at http://www.machinerylubrication.com/Read/2471/reliability-engineers-holistic-phy-sicians-of-machine-care. Again, this article addresses only the fi rst design stage.
Designing for MaintainabilityMaintainability is typically defi ned as the
ease, economy, safety and accuracy with which the necessary maintenance of a machine can be effectively undertaken. When machines are designed and built for optimized maintainability, many benefi ts are realized including:
• Increased reliability
• Lower overall costs of enabling reliability
• Decreased time to complete maintenance tasks
• Fewer maintenance errors
• Reduced maintenance injuries
• Less training required to perform tasks
• Improved troubleshooting effectiveness
In seeking lubrication-enabled reliability (LER),
PUBLISHER Mike Ramsey - [email protected]
GROUP PUBLISHER Brett O’Kelley - [email protected]
EDITOR-IN-CHIEF Jason Sowards - [email protected]
SENIOR EDITOR Jim Fitch - jfi [email protected]
TECHNICAL WRITERS Jeremy Wright - [email protected] Cash - [email protected] Fitch - bfi [email protected] Green - [email protected]
CREATIVE DIRECTORRyan Kiker - [email protected]
GRAPHIC ARTISTS Julia Backus - [email protected] Kellam - [email protected] Couch - [email protected] Clark - [email protected]
ADVERTISING SALESTim Davidson - [email protected], ext. 224
MEDIA PRODUCTION MANAGERAlly Katz - [email protected]
CORRESPONDENCEYou may address articles, case studies, special requests and other correspondence to:Editor-in-chief MACHINERY LUBRICATIONNoria Corporation1328 E. 43rd Court • Tulsa, Oklahoma 74105Phone: 918-749-1400 Fax: 918-746-0925 Email address: [email protected]
MACHINERY LUBRICATION Volume 13 - Issue 6 November-December 2013 ( USPS 021-695) is published bimonthly by Noria Corporation, 1328 E. 43rd Court, Tulsa, OK 74105-4124. Periodicals postage paid at Tulsa, OK and additional mailing offi ces. POSTMASTER: Send address changes and form 3579 to MACHINERY LUBRICATION, P.O. BOX 47702, Plymouth, MN 55447-0401. Canada Post International Publications Mail Product (Canadian Distribution) Publications Mail Agreement #40612608. Send returns (Canada) to BleuChip Interna-tional, P.O. Box 25542, London, Ontario, N6C 6B2.
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.
Copyright © 2013 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 respon-sibility 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 inju-ries, loss of profi ts, business, goodwill, data, interruption of business, nor for incidental or consequential merchantability or fi tness of purpose, or damages related to the use of information or recommendations provided.
Machinery
Lubrication
3
Every link in the chain must be equally strong in order for the chain’s full length to bear the load.
• Detailed and illustrated lubrication procedures (oil change, grease change, grease addition, oil top-up, etc.)
• Detailed and illustrated fl ushing procedures and listing of suitable fl uids for fl ushing
• Oil change interval/regrease interval
• List of all lube points
• Recommended lubricants (performance specifi cation) for all lube points and operating conditions (speeds, loads, etc.)
• Brand/type cross-reference for all lubricants
• Equipment storage protection practices/products, including the use of fogging agents, shaft extension sprays, breathers and vapor-phase rust inhibitors
• Contamination control guidelines including target cleanliness/dryness needs
• Run-in procedures for gears and similar equipment
• Seal compatibility information for system lubricants and other fl uids
• Frequency and procedural information for all necessary PMs and inspections
• Comprehensive oil analysis and other condition-based maintenance guidelines
Topics for a Machine Lubrication Manual
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AS I SEE IT
MAINTAINABILITY MACHINE DESIGN FEATURES
CORRECT LUBRICANT
STABILIZED LUBRICANT HEALTH
CONTAMINATION CONTROL
ADEQUATE AND SUSTAINED LUBRICANT SUPPLY
General Lubrication System Maintainability
Optimum selection/use of a lubrication device (spray, mist, circulation, grease, bath, etc.)
N/AMay help stabilize lubricant health
May help reduce the ingress and removal of contaminants
Enables consistent and sufficient supply of healthy and clean lubricant
Lubricant type identification labels
Type on machine matches type on lubricant package
Lower risk of mixed, incompatible lubricants
N/A N/A
Fully swept (purged) drain sump bottoms N/A
Reduced residual, degraded oil (previous oil) from last oil change
Water, sediment and other low-lying contaminants are swept out during drains (minimal fishbowl effect)
N/A
Return-line diffusers and tank baffles
N/AReduced aeration prolongs oil life
Reduced oil aeration and foaming, enables more efficient and rapid contaminant settling
Fewer oil starvation issues related to aeration and foam
Heat exchangers/coolers
Ensures adequate viscosity to enable required film strength in frictional zones
Keeps oil at a stable tem-perature for optimum service life and reduces premature additive depletion (dropout, oxidation, etc.)
Reduces the risks of heat contamination effects on additive depletion and base oil oxidation
Ensures proper fluid flow at cold ambient temperatures
Use of engine prelube systems N/A N/A N/A
Reduces engine dry-starts causing momentary starvation
Pressure, flow and temperature sensors N/A
May indicate lubricant-damaging conditions
May indicate heat contamination
May signal oil flow alarm causing starvation
Inspection Hardware Maintainability
Bottom sediment and water (BS&W) sight glass Oil color
Oil color, clarity, sediment, sludge
Sediment, water emulsions, free water, glycol (antifreeze), biomass, varnish
N/A
Bull’s-eye 3-D oil level gauges Oil color Oil color, clarity, varnish
Water emulsions, oil color, aeration, foam
Oil level, aeration, foam
Correct oil level markings N/A N/A N/AVisual confirmation of correct oil level
Easy-open inspection hatches/ports N/A
Visual inspection for bath-tub rings, floating debris, foam, aeration, emulsions, corrosion, varnish
Visual inspection for bathtub rings, floating debris, foam, aeration, emulsions, corrosion, varnish
Helps detect foam/aera-tion-induced oil starvation risks
Pressure differential gauges on filters (includ-ing engine oil filters)
N/A
Gauges help ensure filters are working properly, potentially prolonging lubricant service life
Gauges help ensure filters are working properly to control the concentration of contaminants
Well-filtered lubricants are less likely to cause excessive wear on seals, which can cause leakage and starvation issues
Expanded-metal guards and view windows for easy inspection
N/A N/AVisible inspection of potential contaminant ingression sites
Visible inspection of leakage areas and lubricant-delivery methods
the vast majority of the opportunity comes from paying close attention to the “Big Four.” These are vital attributes to the optimum reference state needed to achieve lubrication excellence. The “Big Four” individu-ally and collectively infl uence the state of lubrication and are largely controllable by machinery maintainers, especially if a machine is designed and built for optimum maintainability. The “Big Four” are:
1. Correct lubricant in use (meets reliability objectives)
2. Stabilized lubricant health (physical and chemical properties)
3. Contamination control
4. Adequate and sustained lubricant level/supply
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While it may seem to be an oversimplifi cation to reduce lubrica-tion excellence to just four basic objectives, as a practical matter, not much else is required. See the tables on pages 2, 4 and 5 to learn how machine maintainability can be applied in the context of the Big Four.
Role of Buyers/Purchasing Before buying new machinery, an engineering specifi cation
should be carefully and thoroughly developed. Engineers charged with writing these specifi cations should be educated on modern concepts in machinery lubrication. Simply working as an engi-neer or having an engineering degree alone does not qualify. Instead, training by leading consultants and instructors is strongly advised.
Training should be followed by certifi cation compliant to ISO 18436-4 and similar standards. Noria recommends that engineering specifi cations for new equipment only be written by professionals with Machine Lubricant Analyst (MLA) Level II and III certifi cation credentials. A specifi cation should address many, if not all, of the maintainability features shown in the preceding tables. It must also address hardware and design features that are not permitted. These might include ring oilers, drip oilers, screen fi lters, snorkel vents, high-watt-density tank heaters, long pump suction lines, etc.
Consider having the specifi cation carefully reviewed by an outside lubrication consultant, especially for the most reliability-critical machines. Remember that the cost of retrofi tting needed maintainability hardware will be many times the cost of the same hardware when installed at the factory (as part of the original bill-of-material).
Conversely, buying machines stripped to the bones in an attempt to reduce costs is almost always false economy. The astute reli-ability professional views new equipment in terms of the cost of ownership, not simply the cost of purchase. Most important is the overall machine reliability, which includes repair costs but also equipment utilization (uptime), maintainability (PMs, inspections, etc.), safety and other factors. All of these should drive the business decision to invest in reliability readiness.
About the AuthorJim 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 publica-tions. 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 jfi [email protected].
MAINTAINABILITY MACHINE DESIGN FEATURES
CORRECT LUBRICANT
STABILIZED LUBRICANT HEALTH
CONTAMINATION CONTROL
ADEQUATE AND SUSTAINED LUBRICANT SUPPLY
Oil Analysis
Properly selected and located primary and secondary live-zone oil sampling valves
More accurate oil analysis confirms the right lubricant is in use
More accurate oil analy-sis confirms the health of the lubricant
More accurate oil analysis detects and quantifies the presence of a range of contaminants
More accurate oil analysis can detect air entrainment issues and thermal degrada-tion/wear conditions
Proper installation of magnetic wear debris inspection plugs
May reveal inade-quate film strength from wrong oil in machine frictional zones
May reveal inadequate film strength in machine frictional zones from degraded lubricant (additives, viscosity, etc.)
May reveal inadequate film strength in machine frictional zones from contaminated lubricant
May reveal inadequate film strength in machine fric-tional zones from lubricant starvation
Online oil analysis sensors
Sensors can confirm the use of the right lubricant
Sensors can detect degrading lubricant properties
Sensors can report the concentration
N/A
Contamination Control Maintainability
Quick-connects for adding or draining oil, periodic portable filtration and flushing requirements
N/AContamination control prolongs lubricant life
Minimal use of funnels, contaminated fill ports, etc.; contamination control from flushing and filtration
Simplified oil change and control of oil level
Quality headspace management (breathers, headspace purge, dehydration, etc.)
N/AReduced contaminant ingression extends oil service life
Reduced water, dirt and process contaminants
N/A
Suitable performance, quality and location of filters
N/AContamination control prolongs lubricant life
Faster and more effective removal of damaging contaminants
Reduced risk of contami-nant-induced internal and external lubricant leakage causing starvation issues
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JEREMY WRIGHT | NORIA CORPORATION
L u b r i c a t i o n P r o g r a m s
FROM THE FIELD How LUBRICANT
SUPPLIERS Impact Machine RELIABILITY
Plants often do not take into account the effect that the lubricant supplier can have on machine reliability. If left
unchecked, the results can be catastrophic.You might be surprised what you can learn from a quick visit to
your lubricant supplier. Does your supplier know your reliability and lubrication goals? How can suppliers help you succeed if they have no idea that you are playing for the same team?
Supplier audits are a small part of Noria’s service offerings. In this article, I will share a few key tips that have been learned over the years so you can be better informed when visiting your supplier.
I like to use a simple checklist when conducting a supplier audit. It helps remind me to be vigilant on key practices and physical attri-butes that are associated with the optimum reference state of handling lubricants. I usually start with an overview of the storage facility and how lubricants are handled. The fi rst observation should be related to the identifi cation of lubricant-handling equipment. Are all lines and tanks clearly marked for a specifi c lubricant? If not, the likelihood of cross-contamination becomes signifi cantly higher.
The warehouse should also be in good condition. It must be free of spilled oil, settled water and dust. The building should be enclosed and, if possible, climate-controlled. All products should be in sealed containers, stored indoors away from direct sunlight and not allowed to collect rain water on the top edge.
The inventory in the warehouse should be rotated so that the oldest containers are being used fi rst, while the newest containers are sent to the back. Remember that the cleaner, cooler and drier the lubricant is
kept (even when in the sealed drum), the longer it will last.
If you can witness the handling and transferring of lubricants during your supplier visit, watch for instances of cross-contamina-tion. Make sure that all transport lines are product-dedicated or at least fl ushed well between uses. For bulk incoming transfers, check if samples are taken to verify compliance for both properties and performance. These samples should be kept on record for at least six months. Also, see if you can fi nd current seals on all meters showing calibrations within the last year.
In the packaging area of the plant, you will want to make certain that at a minimum the supplier is fi ltering the incoming oil through a 60-mesh screen. Again, confi rm that meters and scales are up to date on their calibration. Inspect the condition of the drums prior to being fi lled. Are they reconditioned? If so, what processes do they have in place to prevent clean oil from being put into a dirty drum?
Ensure that the empty drum inventory is stored appropriately as well. Every particle that contaminates the drum from this point will have an effect on your program. You will either have to remove it through fi ltration or suffer the consequences of particle contamina-tion in your machine. Keep in mind that the cleaner the supplier can keep the oil, the less time, energy and money you will have to spend later in its life cycle to get it to an acceptable level for your machines.
Your lubrication knowledge will be a tremendous asset when visiting your supplier. If you are not confi dent in your knowledge, just remember “clean, cool and dry.” Look at everything with this in mind and ask yourself if the lubricant is being kept as clean, cool and dry as possible. You then will have your answer as to how well your supplier is helping you achieve your reliability initiatives.
About the AuthorJeremy Wright is vice president of technical services for Noria
Corporation. He serves as a senior technical consultant for Lubrication Program Development projects and as a senior instructor for Noria’s Fundamentals of Machinery Lubrication and Advanced Machinery Lubrication training. He is a certifi ed maintenance reliability profes-sional through the Society for Maintenance and Reliability Professionals, and holds Machine Lubricant Analyst Level III and Machine Lubrication Technician Level II certifi cations through the International Council for Machinery Lubrication. Contact Jeremy at [email protected].
b b || hi l b i i
1. Audit your oil supplier routinely. 2. Establish clear parameters and work with suppliers to help
them achieve the improvements that are necessary. 3. Expect the lubricant supplier to conform to new, higher-
quality expectations. 4. Include mill mechanics and lube technicians in the process.5. Provide training to reinforce the necessity and benefi t of
the new measures.
5 Tips for Dealing with Your Lubricant Supplier
of lubrication professionals never visit their lubricant supplier, according to a
recent survey at Machinery-Lubrication.com
62%
8 | November - December 2013 | www.machinerylubrication.com
ML COVER STORY
www.machinerylubrication.com | November - December 2013 | 9
Lubricants initially arrive in industrial plants usually via one of two methods:
1. New equipment generally comes with a “lubricant list” from the equipment supplier with a few recommendations for each application. Brand names are typically listed, a selection is made and, if it works satisfactorily, it is chosen.
2. Maintenance personnel express concern to a supplier or a competitor about a lubricant’s performance, and a change is made.
There are other ways lubricants are acquired, but in each case, maintenance personnel don’t know why a product does or does not work; they simply accept the outside expert’s opinion. In these situ-ations, maintenance workers may not realize there are several products in the plant with different brand names but similar char-acteristics. They may be unknowingly contributing to the proliferation of products in the plant. Without understanding what makes the products work, the maintenance person may be reluc-tant to consolidate. In this case, there is little encouragement for competition and no reason for any oil company to lower its prices. Naturally, maintenance personnel want their equipment to have the highest quality lubricants but at a reasonable price. How can this be accomplished?
Jim Fitch’s “Hazards of Changing Lubricant Brands” article in the November-December 2013 issue of Machinery Lubrication put the maintenance person’s concerns in perspective. The article brought to mind a system that was developed and used for many years at a U.S. steel company. In order to address the concerns discussed in Fitch’s article, the company established a system whereby lubricants and hydraulic fl uids were purchased by perfor-mance specifi cations. If a product worked in an application satisfactorily, it was tested to determine which ASTM tests (or others) it would pass that were relevant to the application. A spec-
ifi cation was then written around those test results that could be placed out for bid by the purchasing department. If a lower bid was received, the competitor was asked to submit a sample to an inde-pendent lab to verify a few very important requirements. If successful, the lowest bidder was awarded the business for a specifi c period.
Lubricants are unique in that objective lab tests are available to the user that will predict fi eld performance. Very few maintenance products have this advantage.
This article will outline the pros and cons of using a specifi cation system, how to launch such a system and make it work, and how to handle exceptions. If a company’s lubricant purchases are substan-tial and could benefi t from a 10- to 15-percent reduction in costs, this system may offer an advantage while assuring only the highest quality lubricants are used in the equipment.
What is a Performance Specification?Every lubricant and hydraulic fl uid has a detailed list of tests that
must be passed at the oil company before it is released for shipment. The experts at the oil company know how the fl uid must perform in your equipment. Several organizations (ASTM, SAE, etc.) have devised lab tests that will measure various aspects of this performance.
For instance, because viscosity and viscosity index are very important in most lubricants, numerous tests have been devised and agreed upon by industry experts to measure these parameters. Figure 1 provides a list of some of the more common tests for oil and grease.
Once a list of important performance specifi cations is compiled for a given product such as a gear oil, any successful product must be tested to determine the numbers or evaluation for each test. Compatibility is always a concern when switching products. The steel company’s solution was to give the competing supplier the
BY THOMAS L. LANTZ, LANTZ CONSULTING SERVICES
Purchasing Lubricants Based on Performance
10 | November - December 2013 | www.machinerylubrication.com
responsibility of assuring that its product would mix properly with the incumbent product. Any problems in this area were the respon-sibility of the new supplier. Removal and disposal of the contaminated tank contents were also part of their job. Of course, this rarely needed to be done.
Figure 2 is a typical performance specifi cation for a gear oil. A complete written specifi cation from which the summary sheet is derived is too extensive to be reproduced here. A comprehensive set of summary sheets for several types of oil and grease may be obtained by contacting the author at [email protected].
How a Performance Specification is WrittenWhile the above information offers details on how to assemble
the essential data, writing the specifi cation is more involved. Plant personnel often see lubricants as their domain. They issue requisitions to the purchasing department and expect all the details to be taken care of, including the issuing of a purchase order to the supplier of the plant’s choice. The purchasing depart-ment often will talk to competitors about supplying a comparable product. This is a common source of confl ict between the plant and the purchasing department. Both groups should have input into these decisions.
The steel company’s solution to this problem was to form a committee composed of both plant and purchasing personnel who worked on the specifi cation together. The procedures for qualifying new suppliers and the bidding process were agreed on by both parties and strictly followed. Each plant in the corporation was represented on the committee, and all parties kept a three-ring binder of all the specifi cations.
Even after the specifi cations were written, meetings were held periodically to consider any new information acquired, problems encountered that might be due to a product or changes that a supplier thought was necessary.
The science of lubricant testing is constantly evolving, and staying up to date is imperative. The steel company also learned that most oil suppliers take great pride in their quality control, and problems that initially were attributed to the oil company often were the result of something the plant had done or an equipment malfunction.
Importance of Code NumbersIn order to wean everyone in the maintenance department away
from brand names, it is imperative to establish a coding system. Every performance specifi cation written may have a name, but it also needs a number.
The steel company’s system involved all maintenance products (gears, bearings, couplings, lubricants, etc.) and thus required long numbers, but the last three digits were unique to a specifi c product. For lubricants and hydraulic fl uids, those three digits acquired the title “maintenance code” or MC number. All drums, in-plant tanks, supplier paperwork and written specifi cations had to have these code numbers. Although the drums and paperwork from a supplier might have brand names on them, the MC number had to appear as well.
There are four basic reasons for this strict adherence to code numbers:
1. To prevent maintenance personnel from thinking in terms of brand names.
2. To simplify computer systems that record the lubricants to be used in a given piece of equipment. If a change must be made, a new brand name is brought in under the existing code and no change in the computer is required.
3. Survey sheets and routing lists used by the lubrication techni-cian would require constant updating if brand names were used. MC numbers eliminate this problem.
COVER STORY
TEST NO. NAME APPLICATION
GREASE TESTS
D-2596 4-Ball EP Measures film strength of base oil
D-2266 4-Ball Wear Measures wear resistance of greases
D-1742 Oil SeparationMeasures tendency of grease base oil to separate from soap
D-4048 Copper CorrosionMeasures grease tendency to corrode copper, bronze and brass
D-942 Oxidation StabilityMeasures grease tendency to combine with oxygen
D-217 Penetration Measures the stiffness of grease
D-1831 Roll StabilityMeasures resistance of grease to change stiffness after working
D-4049 Water SprayoffMeasures resistance of grease to resist heavy water spray
D-2509 Timken TestMeasures film strength of base oil in grease
OIL TESTS
D-445 ViscosityMeasures an oil’s resistance to flow (indicator of film strength)
D-2270 Viscosity IndexMeasures change of viscosity with temperature
D-92Flash and Fire Points
Indicates dilution by volatile fluids
D-97 Pour PointLowest usable temperature without heating
D-130 Copper CorrosionIndicates corrosive action of an oil on copper, bronze or brass
D-2711 DemulsibilityMeasures the ability of an oil to separate from water
D-4172 4-Ball WearMeasures wear prevention ability of a lubricant
D-3604Elastomer Compatibility
Measures effect of a lubricant on elastomers at static conditions
D-892 Foam ResistanceMeasures the tendency of a lubricant to foam in systems
Figure 1. Common tests for oil and grease
4. Tanks permanently installed in the plant may have the MC number stenciled on them if there is little chance a change will be required.
Vendor RelationshipsOne of the main reasons for the specifi cation system is to
prevent “cozy” relationships between vendors and plant personnel. When this situation occurs, prices tend to rise whether quality rises or not. Confl icts then occur between plant personnel and the purchasing department, as the latter attempts to stabilize prices. Using the specifi cation system allows an “arm’s length” relation-ship. Looking primarily at the test results promotes objectivity. Of course, quality consistency, dependable deliveries and knowledge-able service are considered as well. No one likes vendors who provide inconsistent quality, unreliable deliveries or spotty service.
Adjusting SpecificationsThe performance specifi cation should be considered a “living”
document. It must be periodically adjusted to refl ect new knowl-edge. Once written, the specifi cation may become outdated by new
developments in the fi eld. New tests may be devised that assess a parameter better than previous versions. The consensus of opinion among industry experts might also change regarding which param-eters are important or which test provides the best measurement. Therefore, vendors are encouraged to offer suggestions on ways to improve the specifi cations. Their input can be valuable.
ExceptionsIt does not pay to employ performance specifi cations on low
volume items. Below a certain dollar amount, the use of specifi ca-tions is a waste of time. Simply fi nd something that works and use it if the cost is not excessive. However, in a multi-plant organization, small quantities in several plants can add up to enough money to make using a specifi cation worthwhile. Every situation is different, and good judgment must be used.
One of the questions that might be asked when considering the use of specifi cations is: “Do we need to consolidate our products?” According to the Pareto principle (80/20 rule), 80 percent of the lubricant volume in a plant should be concentrated in 20 percent of the individual products. Take a survey of the products and the
www.machinerylubrication.com | November - December 2013 | 11
LUBRICANT SPECIFICATION
PRODUCT: EXTREME PRESSURE LUBE OIL MAINTENANCE CODE NUMBER: MC - 43, 51, 87, 21, 93, 71 & 31
Test No. Description Test Limits Comments
D-2270 Viscosity Index Minimum=85
D-445 Viscosity See Figure 3
D-92 Flash and Fire Points
D-97 Pour Point See Figure 3
D-189 Conradson Carbon Should contain no more than 2.5% residue
D-130 Copper Corrosion No worse than Class1-b 3 hours at 212°F
D-874 Sulphated Ash Matter of record
D-892 Foam Characteristics Less than a trace after 10 minutes
D-665 Rust Prevention No rust after 24 hours Procedure A
D-2711 Demulsibility See Figure 3
D-1298 API Gravity Matter of record
D-1500 Color Matter of record
D-3604 Elastomer Compatibility Weight change +2% -1%; Volume change +5% -2%
D-4172 4-Ball Wear Limit is 0.35 mm with 40 kg load
ISO 4606 ISO Cleanliness Cleaner than 21/18 on delivery
D-2893 Oxidation Test Viscosity increase less than 5% 312 Hours (13 days) at 100°C
D-664 Neutralization Number Not to exceed 1.0
D-2782 Timken Test Pass 60-pound load
D-2783 4-Ball EP Weld=250 kg; LWI=45 kg
FZG Gear Tooth Wear 9 stages; wear less than 10 mg
Figure 2. A typical performance specification for a gear oil
12 | November - December 2013 | www.machinerylubrication.com
volume used of each. If the results do not conform to the 80/20 rule, your plant might be a candidate for lubricant consolidation. In other words, if relatively equal volumes of many products are in use, duplication might exist.
Benefits and Disciplines of the Specification System
The most obvious benefi t of the specifi cation system is lower prices. This can be easily seen. What goes unseen is the high-quality
products you obtain while forcing oil companies to compete. However, by instituting a specifi cation system, plant maintenance people are compelled to learn what works and why. This may be a challenge in some plants.
The willingness to perform testing is critical. You do not need to have an onsite laboratory, but you must fi nd a quality offsite lab. While a few tests can be performed onsite with inexpensive equipment, most require expensive equipment and a qualifi ed technician. A few ways to reduce these costs are discussed below.
These two disciplines — learning what works and why, and the willingness to conduct testing — are essential.
Intangible BenefitsWhen you have a “system” in place for
purchasing lubricants, vendors tend to be more careful with your products’ quality. Knowing that you test and won’t hesitate to complain or have a bad load pumped out at their expense will keep everyone honest. Also, those vendors who live by “sharp” practices or high costs don’t even bother to solicit your business. My personal experience has proven this to me repeatedly.
TestingAs mentioned previously, it is recom-
mended to randomly test every truckload of bulk oil and drum shipments. The steel company did this because of the large volumes purchased. Tests are generally priced individually, and some are expensive. To lower costs, the steel company selected a few critical tests for each load and assumed the rest were OK. However, this may have been overkill. You could take a sample, label it and store it in case of future problems. As confi -dence in a vendor grows, this would be an acceptable practice.
COVER STORY
Maintenance Code No. ISO VG
Viscosity Limits (cSt @ 40° C)
Viscosity Limits (SSU @ 100° F)
Pour Point °F (Maximum ASTM D-97)
Demulsibility % Water in Oil (Maximum)
Characteristics Total mL Free Water (Minimum)
ASTM D-2711 mL Emulsion (Maximum)
MC-43 68 61.2-74.8 284-347 -15° F (-26° C) 1 80 2
MC-51 150 135-165 625-764 -10° F (-23° C) 1 80 2
MC-87 220 198-242 917-1121 -10° F (-23° C) 1 80 2
MC-21 320 288-352 1334-1631 0° F (-17.8° C) 1 80 2
MC-93 460 414-506 1918-2344 0° F (-17.8° C) 1 80 4
MC-71 680 612-748 2834-3465 10° F (-12° C) 1 80 4
MC-31 1000 900-1100 4169-5095 20° F (-6.7° C) 1 80 4
Figure 3. Examples of maintenance codes assigned for various lubricant tests
www.machinerylubrication.com | November - December 2013 | 13
Remember, buying lubricants by performance specifi cations puts lubrication on a professional base. Vendors would rather deal with people who understand lubricants and what makes them work. When the user’s understanding increases, the vendor may see the need to increase his or her own knowledge.
In the last 20 years, various organizations have devised certifi cation tests to evaluate vendor and user knowledge in the lubrication fi eld. This effort has vastly improved the knowledge of everyone involved. Now vendors know that if a problem occurs, they will receive a rational hearing rather than a screaming, emotional response. Vendors become more service-oriented and better prob-lem-solvers instead of mere order-takers.
At the same time, customers become better problem solvers when they have records that show the important parameters have not changed. They must probe deeper to see if the problem might have been caused by something they did or did not do.
Finally, by concentrating on performance specifi -cations, total fl uid management (TFM) will take on a whole new dimension. If you choose to go this route, no longer will you be at the complete mercy of the TFM manager. The knowledge gained by focusing on
the lubricant specifi cations will enable you to ask all the important questions and insist on critical reports.
14 November - December 2013 | www.machinerylubrication.com
PR
OD
UC
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EW
S
METALWORKING FLUIDThe new ArrowCool line of metalworking fl uids from Chem Arrow features bio-stability, low foam and high lubricity. The low-foam technology used to formulate the fl uids eliminates the need of anti-foam additives. Unlike traditional metalworking fl uids that have a ser-vice life of approximately 6 months, the new ArrowCool fl uids can be used for several years, reducing the costs associated with purchasing replacement fl uids and disposing of used coolant. The fl uids have also been enhanced to meet the latest environmental restrictions.
Chem Arrowwww.chemarrow.com626-358-2255
DRAIN PLUG TOOLThe Drain Plug Pro is a new tool for easily removing oil drain plugs. By keeping hands and fi ngers away from possibly hot draining oil, the one-size-fi ts-all tool makes the oil changing process a more effi cient, cleaner and safer operation. It attaches to any steel compo-nent, including an oil pan, to hold and keep the drain plug free from contaminants as oil is draining while also serving as a reminder that the drain plug is still out. The tool’s integrated magnets allow particles attached to the drain plug to be removed.
OTC Toolswww.otctools.com800-533-6127
FLUID DISPENSING/METERING PUMPThe PDS-100 from Fluid Metering Inc. is a programmable fl uid metering and dispensing system that integrates valve-less pump technology with precision, programmable drive motor control. The pump head internals are made from chemically resistant, sapphire-hard ceramics, which are ideal for dispensing a broad range of fl uids, including silicone lubricants. The PDS-100 is available in both single and dual pump head confi gurations. The displacement and speed of each pump head can be individually controlled. Duplex confi gurations can also provide two-channel dispensing, effectively doubling production capacity.
Fluid Metering Inc.www.fmipump.com800-223-3388
FOOD-GRADE GREASE Interfl on’s Food Grease HD00 is a semi-fl uid lubricant for industrial gearboxes and machine components using automatic oil and grease lubrication. Based on MicPol technology, the heavy-duty grease is
NSF H-1 accredited for use within the food industry and can also be utilized as a solvent-free corrosion inhibitor. The grease is suitable for
extreme high-pressure applications, dusty and wet environments, and high temperatures. During fi eld tests, it has shown an improvement in wear protection as well as a reduction in energy consumption.
Interflonwww.interflon.com877-346-5823
www.machinerylubrication.com | November - December 2013 15
METAL CONDITIONEREverrev is an anti-friction metal conditioner formulated to improve the performance of gas and diesel engines as well as hydraulics and most metal-to-metal transmissions. It treats ferrous-based metals through a molecular change within the metal surfaces. The chemical reaction forms a smoother and denser surface without residual buildup or change in the tolerances of working parts. It is activated by heat and pressure, and is carried by motor oil, transmission oil, hydraulic fl uid and greases to friction points, reducing heat and wear.
Everrevwww.everrev.com386-295-4343
SINGLE-POINT AUTOMATIC LUBRICATORSSKF’s new System 24 LAGD Series single-point automatic lubricators were created to deliver the proper preset amount of lubricant needed for bearings in machinery across industries. The gas-driven feed versions can per-form reliably on a 24-hour basis without manual inter-vention and can resolve issues typically associated with hard-to-access or poten-tially hazardous lubrica-tion points. Each lubri-cator features fl exible, user-adjustable dispense settings and transparent lubricant containers. The lubricators also integrate tool-free activation and are available in two sizes (60 and 125 milliliters).
SKFwww.skf.com267-436-6000
HYDRAULIC TESTERThe SDMKR reversible fl ow device from Stauff was developed for rapid and accurate monitoring of hydraulic components and systems. It provides simultaneous measurement of fl ow, pressure and temperature. Each tester includes a fl ow meter with a visual display and a built-in thermometer, as well as a loading valve. The loading valve makes it possible to safely increase the working pressure gradually and continuously for a realistic simulation of normal machine operation. The portable fl ow device can be installed in both pressure and return lines.
Stauffwww.stauffusa.com201-444-7800
ATOMIZING SPRAY NOZZLES Exair’s new external mix spray nozzles atomize fl uids in a range of spray patterns for a wide variety of uses, especially where a high volume of liquid is needed. The atomizing nozzles combine liquid and compressed air to create a coating of liquid that can be easily adjusted to meet the needs of the application. Air and liquid fl ow are controlled independently, while corrosion resistance and durability are provided by the stainless-steel con-struction. The adjustable nozzles are available in a variety of fl ow patterns.
Exair Corp.www.exair.com800-903-9247
ML
16 | November - December 2013 | www.machinerylubrication.com
LUBE-TIPS
Advice for Oil SamplingBefore taking a large number
of oil samples using pre-labeled bottles, mark the bottle caps with enough information to enable quick recognition of which bottle you need to pull out for sample points. This procedure enables you to go directly to the correct sample bottle without having to search through the entire box looking at labels to fi nd the right one. It also saves a lot of time and helps eliminate using the wrong bottle.
Magnet on a Dipstick for Quick InspectionFor better visual inspection of an oil’s color, paint a magnet
white and permanently attach it to the dipstick of a reservoir. If particles become stuck to the magnet, you know further investiga-tion is required.
Prevent Sample Bottle CollapseWhen you are sampling using a vacuum-type pump, hot oil or
exceptionally viscous oil can result in the plastic sample bottle co l-lapsing, making it diffi cult if not impos-sible to pull suffi cient vacuum to draw out the oil sample.
To prevent this, get a short piece of clear, rigid PVC pipe with an internal diameter that closely matches the outer diameter of the plastic sample bottle. Slide this over the
outside of the bottle before drawing a vacuum with the hand pump. The rigid plastic sleeve prevents the bottle’s collapse, and the clear plastic enables the sampler to see when the bottle is full.
The fi t or gap between the sleeve’s inner diameter and the sample bottle’s outer diameter does not need to be snug. However, the larger the gap, the less effective the sleeve is in preventing the bottle’s collapse.
Post Your Oil Cleanliness TrendsPlace a trend chart of ongoing oil cleanliness for all to see on the
front of all major reservoirs. Any change in the trend (up or down) can promote questions and actions within the maintenance team. Remember, cleanliness control is the responsibility of everyone, and having a visual representation of cleanliness prominently mounted will promote improved housekeeping by keeping reservoirs and equipment clean and sealed.
Safety Tips for Oil Storage AreasConsider the following safety tips for your oil
storage areas:
• Fire extinguishers should be located strategically throughout the lube room. They should also be inspected and tested on a regular basis.
• All spills should be cleaned up promptly.
• Used rags and absorbents should be placed in approved containers immediately after use. The container should be emptied at the end of each shift.
• Good ventilation is required in the lube room to vent hazardous fumes such as those related to solvents.
• Solvents should rest on a grounded surface to prevent sparks from static electricity.
Improving Oil Change ProceduresWhile quick-connect couplings may be considered best practice,
if they are not in the maintenance budget, you might try the following method to help keep a gearbox drain plug clean during an oil change. After capturing particles from the magnetic plug to examine later, clean and dry the plug, then place it in a zip-lock bag. Label the bag with a magic marker. If the gearbox case is ferrous, stick the bag on the case near the fi lling point. If the case is not ferrous, tie the bag with a strap or similar fastener near the fi ll point to remind you to put in the plug before fi lling the gearbox with oil. This will keep the drain plug clean, prevent it from getting lost and remind you to replace it before fi lling with fresh oil.
The “Lube-Tips” section of Machinery Lubrication maga-zine features innovative ideas submitted by our readers. Additional tips can be found in our Lube-Tips email news-letter. If you have a tip to share, email it to us at [email protected]. To receive the Lube-Tips newsletter, subscribe now at www.MachineryLubrication.com/page/subscriptions.
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18 November - December 2013 | www.machinerylubrication.com
BY WOJCIECH MAJKA AND TOMAS KLIMA, ECOL, POLAND
TURBINE LUBRICATION
Hydrodynamic Cleaning and
Flushing of Turbine
Oil Systems
OOne of the most important but underestimated factors impacting the operation of turbines (both steam and gas) and other machinery is the condition of the oil, especially its “mechanical” cleanliness (presence of solid particles). Although the need for appropriate oil care is commonly accepted among power plants with regular maintenance practices, the cleanliness of the oil system interiors (piping, tanks, coolers, etc.) remains an issue. Problems caused by dirty oil systems in machinery such as turbo-generators, turbo-compressors, turbo-pumps and other large-scale oil systems (hydraulics, large stationary diesel engines, etc.) are quite common.
The most reasonable and responsible maintenance strategy is to maintain the proper condition of the oil and oil system based on a correctly applied oil analysis program, determining not only basic oil parameters but also answering questions regarding the
potential of varnish forma-tion and other aging-related properties along with the general oil and component condition. Temporarily controlling the system’s interior is also advised (using endoscopy, visual inspection of friction nodes, control of used fi lter elements within their exchange process, etc.). Of course, the lubricant quality matters as well.
Unfortunately, from time to time, plants experience signifi cant problems related to lubrication. A big part
of these problems is associated with the purity of the oil. While many industry experts speak about the role of oil contamination, the issue of achieving purity of both the oil and oil system is often neglected or not discussed in detail.
So what can you do when severe deposits, sludge, varnish or rust formation occurs in an oil system, or when a newly assembled oil system is corroded or contaminated with chemical preservatives or machining debris? What can be done with large quan-tities of wear debris inside an oil system after severe seizure and breakdown of a bearing?
For trouble-free operation, contaminants must be removed from the oil system. However, in extreme cases, the level and type of impurities may exceed the separation capability of the system fi lters and threaten future equipment operation, resulting in loss of production. The standard maintenance approach then
Dirt in an oil system
N b D b 2013 || hihi ll b ib i ii
Hydrodynamic cleaning and fl ushing with oil at turbulent fl ow rates offers many advantages, such as:
• Long-term system and oil purity• Retention of the natural protective oxide layer on the inner
walls of the pipeline system• Reduced quantities of fl ushing oil • Reduced wear of lubricated parts and extended mean time
between repairs• Signifi cant increase in oil durability (reduced quantities of
replacement oil)• Higher equipment availability• Signifi cant reduction of fi lter insert consumption • No turbine outages due to dirt in the oil system• Reduced total operation costs
Benefits of Hydrodynamic Cleaning and Flushing of Oil Systems
20 November - December 2013 | www.machinerylubrication.com
is not enough. Immediate cleaning of the entire interior of the oil system with subsequent turbulent fl ushing should be performed. Often, if the oil doesn’t meet specifi c requirements, oil replace-ment (exchange) is also required.
Because proper cleaning of an oil system is not easy within an overhaul process or when assembling a new system, a variety of technologies and strategies have been used, such as mechanical cleaning with ramrods, chemical cleaning (with solvents, oil additives, etc.), steam blowing or utilizing different oil fl ushing procedures. In dirty oil systems, most of these practices do not produce the desired results within a reasonable amount of time and money. Frequently, positive results do not last long but diminish, resulting in the need for additional cleaning.
With the cost of operating dirty lubrication systems in turbines far too signifi cant to neglect, more effi cient solutions have been developed. One effective method of preparing new oil systems and restoring operated oil systems for future reli-able operation involves the technology of hydrodynamic cleaning and fl ushing of oil systems. This alternative to obso-lete or ineffi cient methods has become a preferred choice of many original equipment manufacturers (OEMs) and power-generation repair companies.
The Problem of Dirty Oil SystemsOne of the most expensive and underestimated problems
associated with the use of machinery is the inadequate cleanli-ness of the oil system. It results in low oil cleanliness, thus leading to most maintenance problems and to related extra expenses (production outages, repairs, penalties and loss of customers).
Impurities can enter the oil system during assembly, upon execution of overhauls or simply from the immediate surround-ings. They also are created during operation due to oil degradation and corrosion processes. In process machinery, compressed gas often carries different impurities and can interact with the base oil or oil additives while entering the oil system through wet seal glands. These contaminants accumulate in the oil system interiors, creating different deposits.
Impurities are the main cause of premature wear and can lead to equipment breakdown. The most vulnerable parts include bearings, hydraulic actuators and controllers, gear-
boxes, drive-shaft seals, pumps, oil coolers, fi lters and reservoirs.
The most common impurities are metal debris from machining, welding slag, sealants or other materials used during assembly or repairs, oil system corro-sion products (mainly rust), solid impurities, wear metal particles, and water from oil coolers or steam gland leaks and from ambient humidity. Impurities sometimes include gases (e.g., light hydrocarbons or ammonia) and cooling liquids. Other troublesome impurities involve oil degradation products from aging and thermal stress, which create insoluble chemical compounds that are responsible for varnish and sludge formation.
TURBINE LUBRICATION
A dirty oil pipeline (sludge and corrosion in the return line)
An oil cooler covered by sludge from oil-aging products
Impurities also lead to increased consumption of fi lter cartridges. During operation, these impurities are carried by oil to lubricated components, depositing on the inner walls of pipelines, coolers, tanks and other elements.
The presence of water accelerates the creation of corrosion inside the system. The current trend is to build oil systems from stainless steel. However, some parts that can corrode rapidly (armature, tanks, etc.) may still be made of carbon steel. In older systems, which are made mostly of carbon steel, the problem of corrosion is signifi cant. These systems are prone to corrode quickly, especially in parts that are not permanently fi lled with oil (gravity return lines, tank roofs, etc.), due to water condensation on these surfaces.
With oil such a key component of any mechanical device, problems related to the lubricant often turn into problems with the machinery. In most cases, impurities in the oil mean interrup-tions in machinery operation.
Particles in the oil that can be damaging to lubricated compo-nents may be very different in size, depending on the cleanliness requirements given by the component manufacturer. However, the dangerous size normally is smaller than the human eye can see (less than 40 microns). In practice, a machine consists of many components (e.g., bearings, sealing glands, hydraulics, etc.), so the purity of the oil and the system should meet the requirements of the most demanding component. In a typical turbine system, hydraulics require the highest oil cleanliness and the smallest average size of dangerous particles.
Is Flushing Always Enough?Most available standards, recommendations and industry
practices place a lot of attention on the fl ushing process before startup of the system. While turbulent fl ushing of danger-ous-sized contaminants will prepare an oil system for safe operation, only a well-designed fl ushing procedure will be effec-tive. In many cases, even the most turbulent fl ows will not remove well-attached/sticky deposits from the system walls. When fl ushing a system in which such deposits are present, reaching the required oil cleanliness can be diffi cult. Indeed, achieving reasonable oil cleanliness can take a long time.
In addition, during initial startup and regular operation of a turbine when conditions are quite different than when fl ushing (system vibrations from machinery, high temperatures, different fl ow velocities, shocks from pump starts, valves opening, etc.), it is common for new particles to detach from remaining (after fl ushing) dirt from the system walls. Dimin-ishing oil cleanliness is then usually observed. This type of situation is most often visible when severe deposits are present in the system, especially varnish, sludge and rust. Some of the mentioned impurities cannot be cleaned by means of turbulent fl ushing only. Prior to fl ushing, thorough cleaning of the system should be performed.
Hydrodynamic Cleaning TechnologyCleaning an oil system is not an easy process.
Many irregular and rough surfaces made of metal, narrow spaces, recesses between fl anges, etc.,
demand lots of effort and expertise to detach any deposits in order to remove them from the system with turbulent fl ushing.
Hydrodynamic cleaning with high-pressure water jets and subsequent high-velocity oil fl ushing of systems offers a viable alternative to other frequently insuffi cient and obsolete methods. This cleaning and fl ushing technology can be an effective method of preparing new oil systems and restoring operated systems regardless of their size and complexity.
The technology includes three phases: hydrody-namic cleaning using water at very high pressure, fl ushing of the system with oil at high (turbulent) fl ow rates and with full-fl ow absolute fi ltration, and post-as-sembly bypass oil fi ltration prior to equipment startup.
Magnetic ferrous particles attached to magnets from an oil system
Hydrodynamic cleaning and fl ushing of oil systems is quickly becoming a preferred choice of OEMs and maintenance/repair compa-nies. Since 1994, more than 450 different turbine oil systems have been serviced with this technology, including newly commissioned and refurbished machinery ranging from:
• Turbo-generators (steam and gas turbines)
• Process turbo-compressors and blowers (hydrocarbons, synthesis gas, hydrogen, air, ammonia, etc.)
• Boiler feed pumps with hydrokinetic couplings and gearboxes
• Large industrial diesel engines (including auxiliary power supply in nuclear power plants)
• Large marine diesel engines
• Large hydraulic and lubricating oil systems in steelworks and rolling mills
• Central lube oil distribution systems in plants
Practical Applications
www.machinerylubrication.com | November - December 2013 21
The core of this technology involves cleaning all the inner surfaces of the oil system with high-pressure water jets utilizing suitable nozzles, immediate drying and application of a protective turbine oil spray to the dried surfaces, followed by fl ushing with continuously fi ltered oil at suffi cient pressure and fl ow rates.
Step 1: HydroblastingDuring hydroblasting, the inner surfaces of the system are
blasted with high-pressure water in order to detach soft deposits (loose wear debris, sand and dust grains, products of the oil-aging process, sludge, biological deposits, resins, asphalts,
greases and corrosion-pro-tective layers), as well as hard deposits like corro-sion products, rust, welding slag, varnish residue and machining residue that is partially attached to the surface. The following activities are carried out in the course of the cleaning process:
• High-pressure water hydroblasting of all the interiors of pipelines and other elements of the oil system (coolers, reservoirs, bearing stands, etc.) using suitable equipment (elastic lances, nozzles, water guns, etc.).
• Immediate drying of cleaned surfaces using fi ltered, compressed air.
• Application of anti-corrosive protection on dried surfaces (spraying with lubricating turbine oil) until fl ushing occurs.
• Protection of open fl anges from environmental dust and dirt until the fl ushing process takes place.
This advanced technology allows disassembly of only neces-sary small parts of the oil system (pumps, valves, fi ttings, coolers, etc.). The goal of hydroblasting is to ensure all of the system’s interiors are free of corrosion, sludge, varnish and other deposits.
22 November - December 2013 | www.machinerylubrication.com
TURBINE LUBRICATION
An oil pipeline after hydroblasting
The hydroblasting process
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Turbulent flushing with full-flow absolute filtration
The pressurized water mechanically removes/detaches such deposits from the inner surfaces of the oil system and carries them outside the system by means of a water stream. The water used for cleaning is sweet, potable water or decarbonized water from the power plant, so the risk of system contamination by any chemicals is eliminated. Future fl ushing is then possible by oil that will be further operated in the turbine.
Immediate drying of the cleaned surfaces using fi ltered, compressed air and applying a protective layer of turbine oil (spray) prevent against secondary corrosion of the cleaned oil system. The system remains completely dry after the hydrody-namic cleaning phase, thus eliminating the risk of water ingression into the oil during fl ushing.
Step 2: Flushing with Filtered Oil at High Flow RatesDuring this step, all impurities that remain in the system after
hydroblasting are removed while ensuring the appropriate purity of the oil in the system. The system is fl ushed using special fi ltra-tion and pumping units with turbulent fl ows at rates ranging from 13,000 to 20,000 liters per minute. These units have appropriate operating parameters and are connected to the oil system with hoses, manifolds, bearings, servo-motors and other fl ow-restricting elements.
Flushing is performed using fresh turbine oil, which will
remain in the system for further use. A separate batch of fl ushing oil is not needed. The fl ushing process continues until the prede-termined purity criteria are reached in each location of the system. During this time, the oil temperature and direction of its fl ow are changed in order to move out remaining impurities.
Effective fl ushing of the oil system is based on the following three factors:
1. Flow rates at all pipeline sections should be suffi cient to invoke turbulence.
2. The oil cleanliness class measured in various locations of the system should be better than required by the turbine manufacturer (e.g., 17/15/13 according to ISO 4406). The oil’s purity is measured during the fl ushing process using appropriate instruments and according to a predetermined schedule. Cleanliness requirements can also be set higher upon request.
3. No solid particles greater than 150 microns are deposited on the 100-micron mesh strainers installed in strategic loca-tions throughout the system. Smaller particle sizes may also be warranted.
Depending on the custom-er’s requirements, the oil
purity criteria can be more stringent. However, in most cases, the typical result is much better than a cleanliness class of 14/13/10.
Step 3: Bypass Oil Filtering Before and During System StartupIn order to remove post-assembly impurities introduced after
fl ushing, bypass oil fi ltration in the main oil reservoir is performed before and during the system startup. The duration and fi ltration criteria are adapted to the specifi c operational requirements.
A flushing skid in operation
Bypasses on a turbine bearing of a large
steam turbine
TURBINE LUBRICATION
The process of drying an oil system (left) and application of a turbine oil spray as anti-corrosive protection
Hydroblasting of an oil system
24 November - December 2013 | www.machinerylubrication.com
Safe and EffectiveThe technology of hydrodynamic cleaning and fl ushing
with oil at turbulent fl ow rates provides a highly effective method for the renewal of dirty and corroded systems to “like new” condition while also being suitable for newly assembled oil systems.
Hydroblasting not only disinfects the system from aging products, old oil, protective layers or other chemicals that might contaminate fresh oil, but also shortens the future fl ushing process because most impurities are removed by water. The
small amount of contaminants
that remain in the system are then easy
to fl ush out. In addition, hydroblasting is quite useful
before an oil exchange and permits deep investigation of the oil system by endoscope prior to fl ushing.
Flushing after hydroblasting is fast and effi cient, allowing a completion date to be set and a schedule to be maintained with no extra time needed for prolonged fl ushing. With this technology, proactive maintenance based on oil analysis can be implemented.
The method is entirely safe for the natural environment, as pure water is the cleaning medium, and the wastewater contains only impurities detached from the inner system surfaces along with trace quantities of oil washed from the system. Long-term warranties in regards to the system cleanli-ness are also a possibility.
Manifolds and temporary connections on a small steam turbine
Offline oil re-filtration before startup
www.machinerylubrication.com | November - December 2013 25
PR
OD
UC
T S
UP
ER
MA
RK
ET
New! RHT FG-68 NSF H1 Food Grade Refrigeration Compressor lubricant will improve system effi ciency and productivity. It will meet the stringent requirements of closed-loop ammonia refrigeration systems in the food ser-vice industry.
Summit Industrial Products 800-749-5823
www.klsummit.com
RULER View™ provides the full pic-ture of a fl uid’s antioxidant health, is a window into lubricant health and a critical part of an effective condition-monitoring program, allowing better decision-making.
Fluitec Internationalwww.fl uitec.com
201-946-4584marketing@fl uitec.com
Distributor Inquiries Welcomed! Sublime Water Descaler is safe, biodegradable, environmentally friendly and changes color from yellow to purple when spent. U.S. Navy Approved & NSF A3 Regis-tered. Private labeling available.
Summit Industrial Productswww.sublimedescaler.com
800-749-5823
GARZO Model 108B controllers main-tain oil levels in engines and compressor crankcases to prevent equipment dam-age and save oil. The standard valve assembly works with atmospheric tanks or up to 15 psig oil supply pressures.
GARZO, Inc.www.garzoproducts.com/108.html
DuPont™ Krytox® Fluorinated Greases and Oils are chemically inert, insol-uble in common solvents. Tempera-ture range -103º to 800º F. Compat-ible with plastics, rubber, ceramics and metals. Nonfl ammable, oxygen compatible, no silicones or hydrocar-bons. H-1/H-2 food grades available.
Miller-Stephenson Chemical Company, Inc.
www.miller-stephenson.com 203-743-4447
Lightweight, rugged, carbon fi ber reinforced, powerful 3 Channel Simultaneous Vibration Analyzer, Shock Pulse for bearing analysis, laser tachometer with temperature, electronic stethoscope, balancing, laser alignment, and much more.
SPM Instrument Inc. www.leonovabyspm.com
Y2K FilterPak - Ideal for fl ushing small gearbox lube oil systems and hydraulic fl uids to control moisture and particulate contamination. Use wherever compressed air is available. Diamond-plate aluminum approx. weight 44 lbs.
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Because viscosity measurement should be simple, CANNON is excited to intro-duce the SimpleVIS™ portable visco-meter. Everything is included to get you started, minus your sample and solvent. Contact us for more information.
Cannon Instrument Companywww.cannoninstrument.com
26 November - December 2013 | www.machinerylubrication.com
New Clear View oil reservoirs are lightweight, durable, and econom-ical. Polycarbonate endplates have a slim profi le and broad chemical compatibility. Capacities from 2 ½ ounces to 1 gallon. Many styles, all made in the USA.
Oil-Rite Corporationwww.oilrite.com 920-682-6173
Manage your fl uids to target ISO cleanliness levels with the integrated/cost-effective LUBE ROOM from Fluidall. Dedicated pump and dual fi ltration per tank with closed-loop circulation and auto tap or quick disconnect dispensing.
Fluidall LLCwww.fl uidall.com
800-849-0591 pete@fl uidall.com
One Eye Industries for all your magnetic and industrial fi ltration needs. Our fi ltration solutions have applications in all industries. We manufacture an extensive product line utilizing new magnet technology.
One Eye Industries, Inc.www.oneeyeindustries.com
This DVD includes instructive videos and animations to give viewers a better understanding of electric motor bearings and how to lubricate them properly.
Noria Corporationstore.noria.com 800-597-5460
www.machinerylubrication.com | November - December 2013 27
28 November - December 2013 | www.machinerylubrication.com
GREASES
BY WES CASH AND RICK JAMES, NORIA CORPORATION
Using a Grind Gage for In-Service
OOil analysis is commonly used across industry not only to analyze oil health but also machine health. Recently, advances have been made in grease analysis. With the increasing demand for machines to operate fault-free, it has become even more crit-ical to understand what is occurring inside of them. Although technologies such as vibration, thermography and motor-cur-rent analysis can offer early signs of machine failure, analyzing in-service oil and grease can help refi ne your detection ability.
By periodically sampling the oil in a machine, you can obtain information about its health. The same is true for grease-lubri-cated components. With 90 percent of bearing applications being grease lubricated, it makes sense to apply the same meth-odology for analyzing the lubricant in these cases.
The value of grease sampling has been recognized and is now even an ASTM standard (D7718-11). This standard describes a method for taking a representative grease sample from an in-ser-vice bearing. While this is the fi rst step in grease sampling, the second phase involves conducting tests on the sample.
Several laboratories can perform grease analysis and check for contamination, changes in viscosity or consistency, as well as
test other properties of the grease and its constituents. Some of these tests can be expensive and may take several days before results are received. This has created a need to analyze in-service grease in the fi eld and obtain instant feedback on condition, contamination and wear debris content.
A study published by SKF indicates that roughly 70 percent of bearing failures are due to contamination. Another study by NSF found that contamination caused nearly 50 percent of bearings to fail. By applying the Pareto principle (the 80/20 rule), you can see that addressing contamination in bearings should prevent some if not most failures. Accessories such as shields and bearing isolators can be added to make bearings last longer, but you must be able to analyze the amount of contaminants in the lubri-cant to know how clean or dirty they are.
Field tests for oil analysis are readily available for almost any property you want to test, including acid number, viscosity, water content, etc. While there are some fi eld tests for greases, they are primarily limited to rough estimations of consistency and oil content. Whether in the fi eld or lab, few practical methods of analyzing particle concentration exist for in-service grease. In fact, there are only three methods available: micro-scopic analysis (FTM 3005.4), scratched acrylic plates (ASTM D1404) and fi neness-of-grind gages (Hegman gages). This article will discuss the fi neness-of-grind gage as a practical tool for both lab and fi eld applications.
Gage DesignThe gage’s design features a large block of steel (typically stain-
less or chromium plated) and tapered grooves or “raceways” machined into the surface. One groove may range from a depth of 0 to 250 microns, with a second groove from 0 to 50 microns.
A wiper blade is fabricated from the same material as the block. It draws the sample across the block’s surface for analysis. The wiper blade and the surface of the block are milled as smooth as possible to allow for zero clearance between them during the testing process. After many uses, the wiper may lose its profi le and may need to be retooled.
Grease Analysis
Freshly purged grease should be collected and analyzed for wear debris and contaminants.
GREASES
30 November - December 2013 | www.machinerylubrication.com
ApplicationsEarly applications of these gages were seen in the pharmaceu-
tical and paint industries, which had issues determining the fi neness of particles in suspension. For example, in the paint industry, the earliest method for inspecting dispersion quality involved obtaining a small sample of the product to test for particle fi neness. Testing in this manner had its drawbacks because it required considerable experience and agreement between testers to predict the fi nal product quality. To assist testers in determining dispersion quality, the North Standards were developed. These were actual pigment dispersions covering a broad range of grind quality. A sample was checked by comparing it to the selected standard on a glass plate.
In order to eliminate the dependence on standard samples, the Hegman grind gage was developed in 1938. It is now used in a variety of fi elds, including the food, pharmaceutical, pigments, plastics and paint industries. In all of these applications, Hegman gages (sometimes referred to as grind gages or grindometers) are utilized to produce, store and apply dispersion products.
Using the GageTo use the gage, start by placing the device on a fl at surface.
This will allow even pressure to be applied on the wiper blade during the testing process. Spread the grease to be tested on the deep end of the channel and be sure to use enough grease
so that it can be distributed evenly over the length of the block. Hold the wiper blade perpendicular to the block and pull the blade down the length of the channels with a smooth, even stroke. Once the grease has been spread down the channels, hold the block at an angle to a light source to check for particle concentration and type.
The grease sample is deposited at the deep end of the gage block.
The wiper blade is used to wipe the sample down the block.
The wiper is pulled down the length of the block with even pressure.
The raceways are examined for evidence of contamination.
Skid marks left in used grease indicate hard contaminants.
www.machinerylubrication.com | November - December 2013 31
Not only does this fi eld test provide a way to quantify particle concentration in grease, but it also offers a crude indication of
particle size. When the test has been completed, inspect the channels for streaks left behind. Where the streaks begin relative to the depth of the channel will give you an esti-mation of the particle size.
In a recent experi-ment, two tests were conducted: one with new grease applied
directly from a grease gun and another test with in-service grease taken from a wheel bearing. When the results were compared, a few differences were observed, including the amount of streaks found in the samples. The new grease spread evenly down both channels with little to no streaks, indicating no hard particles in the grease. On the other hand, the used grease sample showed obvious signs of hard contaminants.
Although knowing the size and concentration of particles suspended in grease is benefi cial, this test can be taken a step further to analyze the particles and identify the contaminants. By looking at the particles under a microscope, you can begin to distinguish environmental contaminants from wear debris originating in the bearing/race/cage assembly. These fi ndings can then be used to determine wear patterns and modes as well as give feedback on any contamination control devices being utilized.
This test offers the most information on grease that has been directly purged from the bearing’s core. If the grease can be sampled, either through a grease purge trap or a grease sampling device, it will provide direct information on the current state of
the grease in the bearing. However, dry, old grease that is simply scraped from the shaft/seal interface will have more ambient contamination (airborne particles), making it harder to obtain any current information about the state of the bearing. This type of grease is historical data from the bearing and doesn’t repre-sent what is happening currently.
Be sure to conduct this test on new grease to fi nd out what its “streak” profi le looks like in the raceways. Keep in mind that some solid additives such as graphite, moly, etc., may appear in both new and used grease samples and should be accounted for when evaluating a sample’s total contamination.
As the demand increases for machines to operate without failure for longer and longer periods, the need for accurate infor-mation on the operating condition of these machine parts will continue to become more important. This simple test should not be used to replace laboratory testing but rather to supple-ment it and provide more immediate information.
ReferencesDoubleday, D. & Barkman, A. (1950). Reading the Hegman
Grind Gage. Paint, Oil and Chemical Review.
Lafferty, G.J. & Gross, H.M. Application of the Hegman Gage to Medicinal Particle Fineness in Ointments. Journal of the American Pharmaceutical Association, Vol. XLIV, No. 4.
About the Authors Wes Cash is a technical consultant with Noria Corporation. He is a mechanical engineer who holds a Machine Lubrication Technician (MLT) Level II certif ication and a Machine Lubricant Analyst (MLA) Level I certif ication through the International Council for Machinery Lubrication (ICML). Contact Wes at [email protected].
Rick James is an industrial services technician with Noria Corporation. He holds a Machine Lubricant Analyst (MLA) Level I certifi cation and a Machine Lubrication Technician (MLT) Level I certifi cation through the International Council for Machinery Lubrication (ICML). Contact Rick at [email protected].
Hard particles will leave behind streaks in the grease and can be
given a rough size estimation based upon where they appear
on the scale.
This is an example of a hard particle found in a grease sample.
This magnified sample particle appears to be
a metal chunk possibly caused by overloading and
poor lubrication.
Cutting wear particles (top) are generally indicative of hard, solid contaminants.
A spherical wear particle is typically seen from fatigue cracks in rolling-element
bearings.
ML
This month, Machinery Lubrication continues its “Test Your Knowledge” section in which we focus on a group of questions from Noria’s Practice Exam for Level I Machine Lubrication Technician and Machine Lubricant Analyst. The answers are located at the bottom of this page. The complete 126-question practice test with expanded answers is available at store.noria.com.
1. Adhesive wear can be described as:A) The adhesion of wear debris to a layer
of varnish
B) The adhesion of a layer of oil to the metal surface
C) The transfer of silicon particles from one metal surface to another
D) The transfer of metal from one surface to another through a localized welding process
E) None of the above
2. Oil samples from an off-line (kidney-loop) filtration circuit should be taken:A) Downstream of the pump, upstream of the fi lter
B) Downstream of the reservoir, upstream of the pump (before the pump)
C) Downstream of the fi lterD) From the sumpE) From the drain plug
3. Compatibility of different greases:A) Is only a minor issue and often can be ignoredB) Is a major issue that is dependent on the
thickener used
C) Is independent of the thickeners used
D) Can be linked to the age of the grease involved
E) Is dependent only on the base oil used
Answers: 1. DOther names for adhesive wear include galling, scuffing, seizing and severe sliding. Adhesive wear normally occurs during machine starts, loss of film strength and overload/overspeed conditions. Proper lubricant selection is essential to control this wear mode.
2. AThis is to assess the actual condition of the oil before it gets filtered.
3. BCompatibility of different greases is a serious issue that mainly depends on the thickener type. In general, most grease thickeners are incompatible, so extreme caution is required when switching from one grease type to another.
TEST your KNOWLEDGE
32 | November - December 2013 | www.machinerylubrication.com
34 November - December 2013 | www.machinerylubrication.com
BY CARY FORGERON, ANALYSTS INC.
OIL ANALYSIS
OOrganizations have used oil analysis for decades to identify lubrication problems that could require equipment repair or even shut down an entire line of heavy machinery. Although the technique for sample collection remains predominantly unchanged, technology has revolutionized the information avail-able once the sample is analyzed. Improved technology, however, can mean a sea of data, which may be overwhelming to even the most business-savvy customer. There are many oil analysis soft-ware programs that promise to process complicated data, interpret results and offer recommendations. Additionally, beyond traditional sample analysis, software programs now offer systems for managing maintenance schedules, advanced data graphing and data-mining applications.
Not surprisingly, today’s plant engineers and fl eet managers have several options when selecting software to manage their oil analysis needs. Choosing the proper software and maximizing its features can provide a huge payback for the user through reduced machinery maintenance expenses.
For more than 50 years, oil analysis has been used to help diagnose the internal condition of oil-wetted components. Orig-inal testing methods focused on visual inspection coupled with a simple smell test. First used in the railroad industry in 1946, laboratory analysts detected problems in diesel engines through evaluation of metals in used oils. By 1955, the United States Naval Bureau of Weapons had adopted oil analysis procedures to predict aircraft component failure.
Testing and evaluation practices have evolved dramatically over the last fi ve decades, making oil analysis one of the most effective predictive maintenance technologies available. Monu-mental changes have taken place within the laboratory in the areas of sample evaluation and more importantly in how the data is reported and managed.
As recently as 10 years ago, customers collected an oil sample, hand-wrote information on a label and mailed the sample to the laboratory via traditional mail services. Two or three weeks later, the customer would receive a hard copy of the laboratory report in the mail. Today, improved instrumentation, streamlined delivery
services and enhanced technology put comprehensive results in a customer’s hand within 24 hours. This shortened result cycle is essential in the identifi cation of critical samples and can prevent expensive equipment repairs and costly downtime.
Additional benefi ts of a properly executed oil analysis program include reduced lubricant costs, decreased energy consumption, enhanced equipment effi cacy, improved produc-tion, and reduced risk of injury and environmental damage.
Technology EnhancementsAs research and technology have advanced over the years,
progress in lubricant testing has kept pace. The following are some of the key areas of technology enhancement in the oil anal-ysis industry:
Information DeliveryOnce limited to a single hard copy of a distinct sample,
customers can now review results online, download reports and
Ways to Maximize Your
Oil Analysis6Software Value
36 November - December 2013 | www.machinerylubrication.com
OIL ANALYSIS
share them with colleagues. The delivery cycle has also been condensed from several weeks to within 24 hours.
“I can do oil analysis 24 hours a day, seven days a week, 365 days a year,” says industry expert and consultant John Under-wood. “I used to have to wait for weeks for the paper to show up in the mail two weeks after I submitted the sample.”
Sample IdentificationWithin the last decade, technology has allowed fi eld techni-
cians to use the Internet to input comprehensive data about each oil sample. This improvement has reduced the risk of incorrect information gleaned from hand-written forms as well as increased the amount of information technicians can provide to laboratories about each sample.
Enhanced FunctionalityCurrent oil analysis software programs offer improved
reporting capabilities that extend far beyond the examination of a single sample. In addition to maintenance program management tools, software developments have enabled cross-comparison of makes, models and lubricant types within the asset population. Maintenance administrators can manage equipment information online and provide it to laboratory experts, which in turn enables data-mining capabilities that can identify critical trends. Graphing tools can also give a visual representation of the results.
Selecting an Oil Analysis Software ProgramChoosing a laboratory and technology partner for your
predictive maintenance program is not a decision to be taken lightly. Rather, it is important for this strategic evaluation to consider several essential factors:
Third-Party StatusBy selecting an independent lab, customers are assured
non-biased information from an organiza-tion that encourages total access and utilization of all the data and management tools available. Brand-specifi c laboratories may be experts on their own products, but they may not be trained on a variety of equipment or lubricants. While independent sources are always fee-based, these organi-zations offer the most state-of-the-art technology and services available. The bottom line is that it’s your data, and you should have access to as much information as possible.
Professionals Behind the SoftwareWhile technology is ever evolving, the
importance of expert human involvement cannot be overstated. Search for a lab with depth of knowledge and experience as well as important industry credentials.
Ability to Proactively Manage EquipmentLook for a system that allows you to
proactively manage equipment records, including location, name or identifi cation, make, model and lubricant information.
User Administration ToolsNot every member of a team needs access
to every piece of information. The best soft-
Online labeling offers the ability to print pre-registered sample labels for quick and proper processing.
ware programs allow maximum fl exibility, enabling mangers to self-administer and control customized permissions. Choose a system that lets administrators add and delete users, establish and manage groups of users, and grant individualized access permissions. Other benefi cial tools include customizable views and layouts, which put the most useful and important informa-tion right where you need it when you need it most.
Varied Data-Mining CapabilitiesOne of the most recent and helpful technological develop-
ments is customized graphing and result capability. Gone are the days of pouring over spreadsheets searching for tenden-cies and clues. Trend graphs utilize user-defi ned criteria to provide a visual representation of general wear, contamina-tion and other common problems. Comparison graphing allows users to compare specifi c pieces of equipment against like machines or an entire population of equipment. Providing complicated information in an easy-to-understand format, these reports deliver useful information for maintenance and purchasing decisions.
6 Tips for Getting the Most from Your Oil Analysis Software
The return on your oil analysis program depends greatly on what you put into it. Industry research indicates that most main-tenance programs achieve only 10 percent of the benefi ts available from oil analysis. User adoption of a more technolog-ical marketplace has been slow, and many fear information overload. However, by employing a few key strategies, you can maximize your oil analysis software for maximum results.
Conduct TrainingAt its most basic level, training can consist of the proper tech-
nique for sampling. Even with just simple computer skills, users
can learn to navigate software programs and take full advantage of their services and benefi ts.
“Training is critical to helping users understand what the programs can do to make their jobs easier and more effective,” Underwood says.
Many programs provide training via workshops, online videos, webinars, onsite training, newsletters or download-able PDFs. Encourage your team to utilize these educational modalities. As users become comfortable with the basics, they can add to their learning based on their role or the company’s needs. For example, lubrication technicians can learn more about sampling techniques and data input, while engineers can explore more technical graphing tools. If the software program offers ongoing customer service, don’t hesitate to
contact the hotline for product-specifi c guidance.
Utilize Program Management ToolsCustomizable features make managing an oil analysis
program easier and more effective than ever. Beyond tracking and storing results, modern systems help users record mainte-nance events such as sampling dates, usage hours and time in service. You can also create customized alarms to routinely collect samples on a prescribed basis. Whether your mainte-nance practices require collection every 500 hours or every quarter, these predictive samplings can prevent condition-based situations that may signal imminent failure. Also, look for scal-able programs that adjust to your individual needs.
Ensure Information is CompleteThe adage “garbage in, garbage out” never rang more true
than when collecting a lubricant sample.
Dashboards provide users with easy-to-understand graphs regarding sampling program performance.
Equipment management functions enable users to fully register critical information about each piece
of equipment.
www.machinerylubrication.com | November - December 2013 37
“Technology cannot make up for a bad sample,” Under-wood warns.
Incomplete or illegible information can lead to data-entry errors and limited testing that yields suboptimal reporting. Once restricted to whatever information could be scribbled on a small label, the latest software programs allow maintenance techni-cians to input critical information, including equipment (make, model, identifi cation number, location, etc.), hours of operation, maintenance activities, drain interval and more.
While incomplete information doesn’t affect the test results, it signifi cantly impacts the analyst’s ability to draw conclusions or detect trends. Therefore, it is essential that users provide
repetitive, information-rich and credible samples to ensure quality and meaningful reports. When more data points are given during the sampling process, laboratory analysts can deliver more comprehensive reports. With consistent and complete sample information, labs can ensure normalization of results based on the organization’s result history.
Take Advantage of Data MiningA highly technical area of computer science, data mining
extracts information from a set of data and transforms it into understandable and actionable information. In oil analysis, this process uses data management and complex metrics to detect
abnormalities in single samples or groups of samples.
While laboratory experts excel in extracting comprehensive information from a sample, end users may fi nd it diffi -cult to put technical information into practical terms. The average manager typi-cally isn’t interested in particle counts or the presence of iron or metals in a single piece of equipment. However, the ability to recognize trends across a population of equipment can signal a bigger problem that could result in lost revenue from downtime or expensive repairs.
According to Underwood, data mining is particularly helpful when managing fl eets.
“The ability to compare units and equiv-alent services helps companies determine what the best product on the market is for their particular business,” he says.
It is important to note that data mining is not the end user’s responsi-bility but rather an important and integrated component of any effective software program.
Use Graphical ComparisonsGraphs and other visual representations
highlight the severity of non-conforming data far better than tables and spread-sheets. Keep in mind that if a report isn’t readable, it won’t get read.
“A picture is worth a thousand words,” Underwood says. “People understand a graphical data presenta-tion much more readily than a bunch of numbers, so it is a critical component to any software program.”
Users should be able to select different graphing styles (line, bar, area, spider, etc.) based on preference and need. Especially helpful in comparing a pre-defi ned set of
OIL ANALYSIS
Comparison graphing offers a visual comparison of equipment performance against a population of data, allowing plant personnel to
determine which makes and models are best suited for each site.
Graphing sample conditions enables users to easily spot trends in specific units, equipment types, makes or models.
38 November - December 2013 | www.machinerylubrication.com
parameters, graphs can use data normalization to identify wear rates and predict equipment failures. Beyond looking at a single piece of equipment or sample, graphs can provide a cross-com-parison that allows users to compare units regardless of make, model or other specifi cations.
Graphs also present a visual picture of a single piece of equip-ment when compared to the entire population of machinery. While graphing tools should be easy to use, getting the most out of this new technology may require additional training.
Collaborate and CommunicateManaging a plant or fl eet and its maintenance program is
a collaborative effort requiring a team of technicians, engi-neers, administrators and manufacturers. Communication between team members, especially in a critical situation, is vital. Today’s software programs allow administrators to authorize which users can view information, manage equip-ment and more. It’s even possible to share information with equipment and lubricant manufacturers, leveraging all avail-able resources for maximum results. By establishing alerts, messaging, preferences and access for all essential team members, administrators can create a highly specialized network of shared information.
Maximizing Your Maintenance BudgetIn this extremely competitive era of
reduced profi t margins, companies are forced to squeeze the most out of their maintenance budgets. People, equipment and systems are expected to do more with fewer resources. Information technology is necessary for any organization’s preventa-tive maintenance program. With increased access to information, oil analysis software companies are helping maintenance managers spot trends, compare equipment and identify dangerous problems before they happen. Yet only 10 percent of users maximize their software programs. Ongoing training will help managers and administra-tors make the most of the ever-changing tools available.
Through the use of program manage-ment tools, proper sample registration, data-mining tools, graphical interpreta-tions and data sharing, organizations can ensure the longevity of their equipment and a more robust bottom line. Tech-nology will continue to advance, providing additional tools to the analysts, manufac-turers, service providers and end users. How effectively that technology is lever-aged will determine the ultimate success of the company.
About the AuthorCary Forgeron is the national fi eld service manager for Analysts Inc.
He has more than 10 years of experience in developing oil sampling programs for end users to meet their organization’s maintenance and reliability goals. Contact Cary at [email protected].
www.machinerylubrication.com | November - December 2013 39
From Page 42
40 | November - December 2013 | www.machinerylubrication.com
ML GET TO KNOW
Q: What types of training have you taken to get to your current position?
A: I have had training in precision maintenance, PdM technology, lubrication best practices, root-cause analysis, troubleshooting and precision alignment.
Q: What professional certifications have you attained?
A: In terms of lubrication, I currently hold the following certifi -cations from the International Council for Machinery Lubrication (ICML): Machine Lubrication Technician (MLT) Level I and Machine Lubricant Analyst (MLA) Level I, II and III. I also hold multiple certifi cations in different predictive maintenance technologies.
Q: Are you planning to obtain additional training or achieve higher certifications?
A: I plan to increase my knowledge in every predictive mainte-nance technology to the maximum certifi cation level allotted in each fi eld. I feel that doing so will benefi t both me and my
company, since each technology complements the other in relevance to the P-F curve. Faults or early discrepancies within machinery can be identifi ed, monitored and fl agged with better accuracy.
Q: What’s a normal work day like for you?
A: My average work day fi rst consists of performing preventive and predictive maintenance tasks. Once those tasks are fi nished, I continue to develop the predictive maintenance programs and projects to help increase the reliability of the facility. From time to time, I troubleshoot issues in the fi eld and perform root-cause analysis.
Q: What is the amount and range of equipment that you help service through lubrication/oil analysis tasks?
A: I service all of our facility’s equipment, ranging from our oven machinery to our belt conveyors. I also handle all lubrication tasks that are of a precision nature, including pulling oil samples. We conduct condition-based oil changes, so proper sampling practices must be followed accurately to evaluate the health of our machinery and lubricants. I also perform the lubrication on all of our electric motors and high-speed bear-ings using airborne ultrasonic technology to apply lubricant with precision.
Q: What have been some of the biggest project successes in which you’ve played a part?
Suncoke’s Lisch Developing World-Class Lubrication Program
Throughout his career, Brandon Lisch has held a number of positions, such as industrial cleaner, scaf-
fold erector/inspector, maintenance mechanic and lead lubrication technician. Now as a predictive maintenance (PdM) technician for Suncoke Energy, he is developing a world-class lubrication program. Lisch’s facility in Middle-town, Ohio, has been making strides in changing its culture in terms of lubrication best practices. This includes building a lubricant storage facility, training, 5-S princi-ples, equipment modifi cations, a color-coding system and standard operating procedures. Suncoke is also exploring options for an in-house oil laboratory to complement its lubrication program.
Name: Brandon LischAge: 28Title: Predictive Maintenance Technician
Years of Service: 2 yearsCompany: Suncoke Energy Location: Middletown, Ohio
www.machinerylubrication.com | November - December 2013 | 41
A: The biggest success has been the development of the PdM programs, including the lubrication program here at Suncoke Energy Middletown Operations. The strides the company has made and the full support of reliability are helping make these programs fl ourish. At the rate of development, it will not be long before Suncoke is named a world-class facility. That is the overall goal for us all.
Q: How does your company view machinery lubrication in terms of importance and overall business strategy?
A: Machinery lubrication is one of the most important, if not the most important, aspect in machine reliability. All other proactive activities performed would be in vain if the lubri-cation aspect of the machinery is neglected or improperly performed. Lubricants are the lifeblood of a machine. Suncoke fully supports this statement and understands the value of implementing this program to better serve our customer, community and the environment with the reduc-tion of unexpected failures.
Q: What do you see as some of the more important trends taking place in the lubrication and oil analysis field?
A: The most important trend I see is the increase in lubrication knowledge. Industries are steering away from the “grease monkey” persona and beginning to believe in the skilled lubri-cation professional. It has been proven time after time that a fully developed lubrication program is one of the keys to success when it comes to machine reliability. Strides in these fi elds are taking the lubrication profession to a new level.
Q: What has made your company decide to put more emphasis on machinery lubrication?
A: In the coke-producing industry, the dust from the process is extremely harmful to our equipment. Coke is a carbon-based product that has a hardness ranking of 10 on the Mohs scale. Intrusion of coke dust or any foreign particle into an asset could be detrimental to our equipment and operation. Proac-tive measures like the prevention of ingression by following lubrication best practices is more economical than being in a reactive mode and replacing machinery due to an unexpected failure caused by improper lubrication practices.
How You Can Be Featured in the Next ‘Get to Know’ Section
Would you like to be featured in the next “Get to Know” section or know someone who should be profi led in an upcoming issue of Machinery Lubrication magazine? Nominate yourself or fellow lubrication professionals by emailing a photo and contact information to [email protected].
42 | November - December 2013 | www.machinerylubrication.com
ML CROSSWORD PUZZLERGet a Printable Version
of This Puzzle Online at: MachineryLubrication.com/puzzle
Get the solution on page 39
44 | November - December 2013 | www.machinerylubrication.com
BENNETT FITCH | NORIA CORPORATION
This is the fi fth part of a series of “anatomy” lessons within Machinery Lubrication. In this issue, a specifi c device or object
will not be dissected but rather the content provided in a typical oil analysis report, including how to interpret the data and other fi nd-ings. These interpretations may decide either the cost or avoidance of machine failure and downtime.
Interpreting an oil analysis report can be overwhelming to the untrained eye. Oil analysis isn’t cheap, and neither is the equipment on which it reveals information. Every year, industrial plants pay millions of dollars for commercial laboratories to perform analysis on used and new oil samples. Unfortunately, a majority of the plant
personnel who receive these lab reports do not understand the basics of how to interpret them.
Typically, an oil analysis report comes with a written summary section that attempts to put the results and recommendations in
layman’s terms. However, since the laboratory has never seen the machine or know its full history, these recommended actions are mostly generic and not precisely tailored to your individual circumstances. Therefore, it is the responsibility of the plant personnel who receive the lab report to take the proper action based on all known facts about the machine, the environment
and recent lubrication tasks performed.
Why Perform Oil Analysis An obvious reason to perform oil analysis is to understand the
condition of the oil, but it is also intended to help bring to light the condition of the machine from which the oil sample was taken. There are three main categories of oil analysis: fl uid properties, contamination and wear debris.
Fluid PropertiesThis type of oil analysis focuses on identifying the oil’s current
physical and chemical state as well as on defi ning its remaining useful life (RUL). It is designed to answer questions such as:
• Does the sample match the specifi ed oil identifi cation?
• Is it the correct oil to use?
• Are the right additives active?
• Have additives been depleted?
• Has the viscosity shifted from the expected viscosity? If so, why?
• What is the oil’s RUL?
ContaminationBy detecting the presence of destructive contaminants and
ANATOMY of an Oil Analysis REPORT
O i l A n a l y s i s
LESSONS IN LUBRICATION
Interpreting an oil analysis report can be overwhelming
to the untrained eye.
| N b D b 2013 || hihi ll b ib i ii
1. Read and check the data on the oil type and machine type for accuracy.
2. Verify that reference data is shown for new oil conditions and that trend data is at an understood frequency (preferably consistent).
3. Check the measured viscosity.
4. Verify elemental wear data and compare to reference and trended data. Use a wear debris atlas to match elements to their possible source.
5. Check the elemental additive data and compare to reference and trended data. Use a wear debris atlas to match elements to their possible source.
6. Verify elemental contamination data along with particle counts and compare with reference and trended data. Use a wear debris atlas to match elements to their possible source.
7. Check moisture/water levels and compare to reference and trended data.
8. Verify the acid number and base number and compare to reference and trended data.
9. Check other analyzed data such as FTIR oxidation levels, fl ash point, demulsibility, analytical ferrography, etc.
10. Compare any groups of data that are trending toward unacceptable levels and make justifi cations based on these trends.
11. Compare written results and recommendations with known information on the oil and machine, such as recent changes in envi-ronmental or operational conditions or recent oil changes/fi ltration.
12. Review alarm limits and make adjustments based on the new information.
What to Look for When Reviewing an Oil Analysis Report
www.machinerylubrication.com | November - December 2013 | 45
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narrowing down their probable sources (internal or external), oil analysis can help answer questions such as:
• Is the oil clean?
• What types of contaminants are in the oil?
• Where are contaminants originating?
• Are there signs of other types of lubricants?
• Is there any indication of internal leakage?
Wear DebrisThis form of oil analysis is about determining the presence and
identifi cation of particles produced as a result of mechanical wear, corrosion or other machine surface degradation. It answers a number of questions relating to wear, including:
• Is the machine degrading abnormally?
• Is wear debris produced?
• From which internal component is the wear likely originating?
• What is the wear mode and cause?
• How severe is the wear condition?
Ultimately, you need to know if any actions should be taken to keep the machine healthy and to extend the life of the oil. Oil analysis for machines can be compared to blood analysis for the human body. When a doctor pulls a blood sample, he puts it through a lineup of analysis machines, carefully studies the results and reports his conclusions based on his education, research and detailed questions
asked to the patient. Likewise, with oil analysis, careful oil samples are taken, and elaborate machines yield the test results. Laboratory personnel interpret the data to the best of their ability, but without crucial details about the machine, a diagnosis or prognosis can potentially be inaccurate. Some of these important details include:
• The machine’s environmental conditions (extreme tempera-tures, high humidity, high vibration, etc.)
• The originating component (steam turbine, pump, etc.), make, model and oil type currently in use
• The permanent component ID and exact sample port location
• Proper sampling procedures to confi rm a consistently repre-sentative sample
• Occurrences of oil changes or makeup oil added, as well as the quantity of makeup oil since the last oil change
• Whether fi lter carts have been in use between oil samples
• Total operating time on the sampled component since it was purchased or overhauled
• Total runtime on the oil since the last change
• Any other unusual or noteworthy activity involving the machine that could infl uence changes to the lubricant
Oil Analysis Tests For a standard piece of equipment undergoing the normal recom-
mended oil analysis, the test slate would consist of “routine” tests. Alternatively, if additional testing is needed to answer advanced ques-
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www.machinerylubrication.com | November - December 2013 | 47
tions, these would be considered “exception” tests. Routine tests vary based on the originating component and environmental conditions but should almost always include tests for viscosity, elemental (spec-trometric) analysis, moisture levels, particle counts, Fourier transform infrared (FTIR) spectroscopy and acid number. Other tests that are based on the originating equipment include analytical ferrography, ferrous density, demulsibility and base number testing.
The table above shows how tests are utilized in each of the three main oil analysis categories.
ViscositySeveral methods are used to measure viscosity, which is
reported in terms of kinematic or absolute viscosity. While most industrial lubricants classify viscosity in terms of ISO standard-ized viscosity grades (ISO 3448), this does not imply that all lubricants with an ISO VG 320, for example, are exactly 320 centi-stokes (cSt). According to the ISO standard, each lubricant is considered to be a particular viscosity grade as long as it falls within 10 percent of the viscosity midpoint (typically that of the ISO VG number).
Viscosity is a lubricant’s most important characteristic. Monitoring the oil’s viscosity is critical because any changes can lead to a host of other problems, such as oxidation, glycol ingression or thermal stressors.
Too high or too low viscosity readings may be due to the presence of an incorrect lubri-cant, mechanical shearing of the oil and/or the viscosity index improver, oil oxidation, anti-freeze contamination, or an infl uence from fuel, refrigerant or solvent contamination.
Limits for changes in the viscosity depend on the type of lubri-cant being analyzed but most often have a marginal limit of approximately 10 percent and a critical limit of approximately 20 percent higher or lower than the intended viscosity.
Acid Number/Base NumberAcid number and base number tests are similar but are used to
interpret different lubricant and contaminant-related questions. In an oil analysis test, the acid number is the concentration of acid in the oil, while the base number is the reserve of alkalinity in the oil. Results are expressed in terms of the volume of potassium hydroxide in milligrams required to neutralize the acids in one gram of oil. Acid number testing is primarily performed on non-crankcase oils, while base number testing is mainly for over-based crankcase oils.
An acid number that is too high or too low may be the result of oil oxidation, the presence of an incorrect lubricant or additive depletion. A base number that is too low can indicate high engine blow-by conditions (fuel, soot, etc.), the presence of an incorrect lubricant, internal leakage contamination (glycol) or oil oxidation from extended oil drain intervals and/or extreme heat.
FTIRFTIR is a quick and sophisticated method for determining
several oil parameters including contamination from fuel, water, glycol and soot; oil degradation products like oxides, nitrates and sulfates; as well as the presence of additives such as zinc dial-kyldithiophosphate (ZDDP) and phenols. The FTIR instrument
OIL ANALYSIS CATEGORY TESTS
Fluid PropertiesViscosity, Acid/Base Number, FTIR, Elemental Analysis
ContaminationParticle Counting, Moisture Analysis, Elemental Analysis
Wear DebrisFerrous Density, FTIR, Elemental Analysis
of lubrication professionals would not understand how to interpret an oil analysis report from a commercial laboratory,
based on a recent poll at MachineryLubrication.com
32%
48 | November - December 2013 | www.machinerylubrication.com
LESSONS IN LUBRICATION
recognizes each of these characteristics by monitoring the shift in infrared absorbance at specifi c or a range of wavenumbers. Many of the observed parameters may not be conclusive, so often these results are coupled with other tests and used more as supporting evidence. Parameters identifi ed by shifts in specifi c wavenumbers are shown in the table above.
Elemental Analysis Elemental analysis works on the principles of atomic emission
spectroscopy (AES), which is sometimes called wear metal anal-ysis. This technology is designed to detect the concentration of wear metals, contaminants or additive elements within the oil. The two most common types of atomic emission spectroscopy are rotating disc electrode (RDE) and inductively coupled plasma (ICP). Both of these methods have limitations in analyzing particle sizes, with RDE limited to particles less than 8 to 10 microns and ICP limited to particles less than 3 microns. Nevertheless, they are useful for providing trend data. Possible sources of many common elements are shown in the table on the right.
The best way to monitor this type of data is to fi rst determine what is expected to be in the oil. An effective oil analysis report will provide reference data for the new oil so any amounts of addi-tive elements can be easily distinguished from those of contaminants. Also, because many types of elements should be expected at some level (even contaminants in certain environ-ments), it is better to analyze trends rather than focus on any specifi c measurement of elemental analysis data.
Particle Counting Particle counting measures the size and quantity of particles in
the oil. Many techniques can be used to assess this data, which is typically reported based on ISO 4406:99. This standard designates three numbers separated by a forward slash providing a range number that correlates to the particle counts of particles greater than 4, 6 and 14 microns. To view an illustration of how different particle counts are assigned specifi c ISO codes, visit http://www.machinerylubrication.com/Read/29525/sample-new-oil.
Moisture AnalysisMoisture content within an oil sample is commonly measured
with the Karl Fischer titration test. This test reports results in parts per million (ppm), although data is often shown in percentages. It can fi nd water in all three forms: dissolved, emulsifi ed and free. The crackle test and hot-plate test are non-instrument moisture tests for screening before the Karl Fischer method is used. Possible reasons for a moisture reading being too high or too low would include water ingression from open hatches or breathers, internal condensation during temperature swings or seal leaks.
Interpreting Oil Analysis ReportsThe fi rst thing to check on an oil analysis report is the informa-
tion about the customer, originating piece of equipment and lubricant (see Section A of the sample report on page 49). Including these details is the customer’s responsibility. Without this informa-tion, the effectiveness of the report will be diminished. Knowing which piece of equipment the oil was sampled from affects the ability to identify potential sources of the measured parameters,
WAVENUMBER OIL PARAMETER
1750 Oxidation (for mineral oils)
3540 Oxidation (for organic ester)
815 Oxidation (for phosphate ester)
1150Sulfation (possibly from high-sulfur fuel contamination)
1630 Nitration (typically with natural gas engines)
3625 Water ingression (for organic ester)
3400 Water ingression (for mineral oils)
2000 Soot (combustion chamber blow-by contamination)
880, 3400, 1040, 1080
Glycol ingression
800 Diesel fuel ingression
750 Gasoline fuel ingression
795-815 Jet fuel ingression
3650 Phenol inhibitors additive depletion
980 ZDDP anti-wear/antioxidant additive depletion
ELEMENT POSSIBLE SOURCESAluminum Pistons, bearings, pumps, thrust washers
Antimony Bearings, grease
Barium Rust and oxidation inhibitor additives, grease
Boron Anti-corrosion additives in coolant, dust, water
Calcium Detergent/dispersant additives
Chromium Piston rings in internal combustion engines
CopperBearings, brass/bronze alloys, bushings, thrust washers
Iron Shafts, rolling-element bearings, cylinders, gears, piston rings
Lead Bearings, fuel additives, anti-wear additives
Lithium Grease, additives
Magnesium Transmissions, detergent additives
Molybdenum Piston rings, electric motors, extreme-pressure additives
Nickel Bearings, valve train, turbine blades
Phosphorus Anti-wear additives, extreme-pressure gear additives
Potassium Coolant additives
Silver Bearing cages (plating), gear teeth, shafts
Silicon Dust/dirt, defoamant additives
Sodium Detergent or coolant additives
Tin Journal bearings, bearing cages, solder
Titanium Bearing hub, compressor blades
Zinc Neoprene seals, grease, anti-wear additives
www.machinerylubrication.com | November - December 2013 | 49
especially wear particles. For example, the originating piece of equipment can help associate reported wear particles with certain internal components. The lubricant information can provide a baseline for several parameters, such as the expected viscosity grade, active additives and acid/base number levels. These details may seem straightforward but are often forgotten or illegible on the oil sample identifi cation label or request form.
The next section (Section B) of the oil analysis report to examine is the elemental analysis or FTIR breakdown. This data can help identify contamination, wear metals and additives present within the oil. These parameters are reported in parts per million (ppm). Nevertheless, this does not mean a contamination particle, for example, can only be indicated by sodium, potassium or silicon spikes. In the example above, the rise in silicon and aluminum could potentially indicate dust/dirt contamination as
the root cause. One likely explanation for these spikes is that as dirt (silicon) enters the oil from an external source, three-body abrasion occurs within the machine, causing wear debris including aluminum, iron and nickel to increase.
With a better understanding of the metallurgy within the system’s components, any spikes in wear metals can be better associated, allowing a proper conclusion as to which internal components are experiencing wear. Keep in mind that for trend analysis, it is important that samples are taken at an appropriate and uninterrupted frequency.
With elemental data related to contaminants and wear metals, alarms are set for upward trends in the data. For elemental data pertaining to additives, alarms are set for downward trends. Having a baseline of new lubricant reference data is critical in assessing which additives are expected and at what levels. These baselines are
Ref. Fluid Life
50 | November - December 2013 | www.machinerylubrication.com
then established to help determine any signifi cant reduction in specifi c additives.
Another section of the oil analysis report presents previously identifi ed sample information from the customer such as oil manu-facturer, brand, viscosity grade and in-service time, as well as if an oil change has been performed. This is important data that can provide an explanation for what could be false positives in alarming data changes.
The “physical tests” section of a report offers details on viscosity at both 40 degrees C and 100 degrees C, along with the viscosity index and percentage of water. For common industrial oils, the viscosity measurement at 40 degrees C is usually given, since this correlates to the oil’s ISO viscosity grade. If the viscosity index must also be calculated, such as for engine oil, then these additional viscosity measurements will be identifi ed. The viscosity for engine crankcase oils is typically reported at 100 degrees C.
Water contamination, which commonly is measured by the Karl Fischer test, is presented in percentages or ppm. While some systems are expected to have high levels of water (more than 10,000 ppm or 10 percent), the typical alarm limits for most equipment are between 50 to 300 ppm.
The “additional tests” section shows two fi nal tests: acid number (AN) and particle size distribution (aka, particle count).
When analyzing the acid number, you should have both a refer-ence value and the ability to trend from past analysis. The acid number often will jump considerably at some point. This may be your best indicator for when the oil is oxidizing rapidly and should be changed.
The last section of the oil analysis report generally provides written results for each of the fi nal few test samples along with recommendations for required actions. Typically, these recom-mendations are entered manually by laboratory personnel and based on information provided by the customer and the data collected in the lab. If there is an explanation for the data that stems from something not explicitly stated by the customer, the results must be reinterpreted by those familiar with the machine’s history of environmental and operating conditions. Under-standing the information given here is critical. Remember, there is always an explanation for each exceeded limit, and the root cause should be investigated.
In addition to the raw data shown throughout the oil analysis report, graphs can help illustrate notable trends in the data. Below is an example of trended data points from analyzed data, with the water test having the most notable unfavorable spike. Along with the trend data, graphs should show typical averages, warning (marginal) limits and alarm (critical) limits. These limits
LESSONS IN LUBRICATION
Graphs in an oil analysis report can help illustrate notable trends in the data. (Ref. Fluid Life)
www.machinerylubrication.com | November - December 2013 | 51
should be modifi ed depending on the type of data collected, the type of lubricant and the machine’s known operating conditions.
Standard alarm limits will be set by the oil analysis laboratory. However, if there is any reason to adjust these limits higher or lower, they should be identifi ed properly. Examples of limits that should be lowered would be those for highly critical assets or assets that are consistently healthy. A small spike in data would be cause to run an exception test or an immediate second sample for analysis. In such cases, a second sample would ensure the data received is representative of the oil conditions and not simply a
human error in sampling or analysis. If exception tests are needed, the chart above shows which tests would be appropriate when a given routine test limit has been exceeded.
About the AuthorBennett Fitch is a technical consultant with Noria Corporation. He is
a mechanical engineer who holds a Machine Lubricant Analyst (MLA) Level II certifi cation and a Machine Lubrication Technician (MLT) Level II certifi cation through the International Council for Machinery Lubrica-tion (ICML). Contact Bennett at bfi [email protected].
SELECTING OIL ANALYSIS TESTS BY APPLICATION
Test or Procedure
Paper Machine Oils
Motor and Pump Bearings
Diesel and Gas Engines Hydraulics
Air and Gas Compressors
Chillers and Refrigeration
Transmissions, Final Drives, Differentials
Industrial Gear Oils
Steam Turbine Oils
Gas Turbine Oils
EHC Fluids***
1. Particle Count2. Viscosity
a. 40º C b. 100º C
3. AN4. BN
R
R-R-
R
R-E(5a)-
R
-R-R
R
R-R-
R
R-R-
R
R-R-
R
R-R-
R
R-R-
R
R-R-
R
R-R-
R
R-R-
5. FTIR a. Ox/Nit/Sul b. Hindered Phen c. ZDDP d. Fuel Dil./Soot
6. Flash Point
R-
---
RR
R--
R-
-RR
RR
R--
RR
R-R*
R-
---
R-
R--
RR
R--
RR
---
R-
--E(2b,5d)
--
---
7. Glycol-ASTM Test
8. Ferrous Density9. Analytical
Ferrography10. RPVOT
-
E(1)E(8,14 a)
-
-
E(1)E(8,14a)
-
E(14b)
RE(8,14 a)
-
-
RE(8,14 a)
-
-
RE(8,14a)
R
-
RE(8,14a)
-
-
RE(8,14a)
-
-
RE(8,14a)
-
-
E(1)E(8,14a)
R
-
E(1)E(8,14a)
R
-
RE(8,14a)
-
11. Crackle12. Water by KF13. Water Separability
RE(11)R
RE(11)-
RE(11)-
RE(11)-
R**E(11)**R**
RE(11)-
RE(11)-
RE(11)-
RE(11)R
---
RE(11)-
14. Elemental Analysis a. Wear Metals b. K, Na, B, Si c. Additives
R, E(1)RR
R, E(1)RR
RRR
R, E(1)RR
R, E(1)RR
R, E(1)RR
RRR
R, E(1)RR
R, E(1)RR
RRR
R,E(1)RR
*Gas compressors only ** Air compressors only ***For phosphate ester fluids, consult the fluid supplier and/or turbine manufacturer.
R = Routine testing
E = Exception test keyed to a positive result from the test in parentheses
52 | November - December 2013 | www.machinerylubrication.com
ML
Find more great articles and content from Machinery Lubri-cation magazine online. From Web exclusives and industry
news to videos, white papers, buyer’s guides and more, every-thing that relates to machinery lubrication is available now on MachineryLubrication.com.
The Importance of Machine CriticalityCriticality is very much a part of making informed decisions on
scheduling, whether it be a simple sight-glass inspection or as complex as a turbine rebuild. Critical equipment most defi nitely should be checked more often than non-critical equipment. These assets deserve the focus of your limited time, money and energy. Of course, it is important to know how you defi ne an asset as critical. Discover how to determine the criticality of an asset by reading this article on the ML site.
Understanding the Re-refining ProcessRe-refi ning is a process employed to refurbish used oil and
return it to a high-quality base oil. In the United States, approxi-mately 40 percent of used oil is captured and recycled in some manner, while 60 percent is lost. Nearly 14 percent of the captured and recycled oil is re-refi ned. Read this article on the ML site to understand the various processes used by re-refi ners to remove contaminants, water, spent additives and any of the original remaining additives from the used oil.
How to Repack, Grease and Adjust Car Wheel Bearings
This video demonstrates the proper way to repack, grease and adjust vehicle wheel bearings. Watch as a brake caliper on a car is removed by compressing the caliper piston in order to release hydraulic pressure. Access this 2-minute, 51-second video at www.MachineryLubrication.com.
An Introduction to the Principles of LubricationThis video explains the importance and methods of mechanical
lubrication for various equipment. In order to use lubricants correctly, you need to know some of the key terms describing their specifi c char-acteristics, such as viscosity, viscosity index, pour point, fl ash point and fi re point. Access this 4-minute, 2-second video at www.MachineryLubrication.com.
Advantages of Synthetic Base OilsPetroleum-based mineral oils function very well as lubricants
in 90 percent of industrial applications. They are cost-effective and provide a reasonable service life if used properly. However, they have some limitations. Synthetic base oils are expensive because of the processing involved in creating these pure chemical base oils. Their use must justify the additional cost. In other words, there should be a fi nancial benefi t to using them. Find this article on the ML site to learn the two main advantages of using synthetic base oils.
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Check out the full list of white papers by visiting www.Machin-eryLubrication.com and clicking on the “White Papers” link.
54 November - December 2013 | www.machinerylubrication.com
BO
OK
ST
OR
E
Oil Analysis Basics – Second Edition
Publisher: Noria Corporation
The new second edition includes more detailed information on oil sampling, fi ltration and contam-inant removal, base oils and additives, water-in-oil contam-ination and removal, ASTM standards, glycol testing, fl ash point tests, and 14 additional oil analysis tests.
Lubrication Fundamentals – Second Edition
Authors: D.M. Pirro and A.A. Wessol
This newly revised and expanded reference book emphasizes the need for lubri-cation and careful lubricant selection. Thoroughly updated and rewritten, the second edition of Lubrication Fundamen-tals discusses product basics, machine elements that require lubrication, methods of appli-cation, lubrication, lubricant storage and handling, lubricant conservation and much more.
Lubrication Basics for Machinery Operators Training Video
Format: DVDPublisher: Noria Corporation
Train your team on the basics of lubrication and how to
recognize early signs of lubrication-related prob-lems with this convenient video training DVD. Your operators will learn the
basics of operator-based
lubrication inspections and gain the knowledge to ensure that routine inspections and top-offs are performed with precision and accuracy.
Chemistry and Technology of Lubricants – Third Edition
Authors: R.M. Mortier, M.F. Fox and S.T. Orszulik
This updated and revised third edition describes the chemical components that contribute to the formulation of liquid lubri-cants and includes a discussion of lubricant technology for specifi c applications. It is of particular rele-vance for those in industry who are involved with lubricant additives, formulation and testing, as well as those who are concerned with the use and specifi cation of lubricants.
Lubrication Awareness Poster SetPublisher: Noria Corporation
This set of fi ve posters effectively uses humorous illustrations and bulleted tips and pointers to communicate critical lubrica-tion advice. Posters included in the set are Home Sweet Home, Keep Our Machines Clean, Overgreasing Doesn’t Pay, Use the Correct Oil and Watch Your Aim.
Handbook of Lubrication andTribology – Volume II: Theoryand Design – Second EditionAuthor: Robert W. Bruce
Sponsored by the Society of Tribol-ogists and Lubrication Engineers, this handbook incorporates up-to-date, peer-reviewed information for tackling tribological problems and improving lubricants and tribological systems. It demon-strates how the principles of tribology can address cost savings, energy conservation and environ-mental protection.
Welcome to Machinery Lubrication’s Bookstore, designed to spotlight lubri-cation-related books. For a complete listing of books of interest to lubrication professionals, check out the Bookstore at store.noria.com.
For descriptions, complete table of contents and excerpts from these and other lubrication-related books, and to order online, visit: store.noria.com or call 1-800-597-5460, ext. 204.
56 | November - December 2013 | www.machinerylubrication.com
BY SUZY JAMIESON, ICML
ML
When it comes to developing, implementing and sustaining a reliability-improvement program, long-term success ulti-
mately depends on a solid foundation. Indeed, it is the foundation that will determine whether the current initiative will be just another
fad or actually achieve the results you have set out to accomplish. It is also important to know the elements that are in place will with-stand the test of time and weather the storms that will inevitably come your way.
Sometimes we overlook the obvious. As a society, we invest considerable
time and energy aiming for great heights yet often forget that crucial ingredient for making sure we do not
fall fl at on our faces once we have reached the top. In other words, you have to crawl before you can walk. No matter how great an idea seems in theory, it is a long, uncertain journey from design to actual results, especially for anything worthwhile.
As with most other things in life, you must start at the bottom. In the case of reliability programs, this means the hands-on personnel, the shop-fl oor staff or the technicians. They are the human foundation of any reliability-im-provement program. Without them, their buy-in and a solid foundation of technical skills, no amount of reliability theory, philosophy or trendy gadgetry will make the program stand when it is shaken — and it will be shaken. After all, as any maintenance and reliability professional knows, things do not always go according to plan.
Be sure to value and respect the tech-nicians and the crucial role they play in the outcome of any plant reliability-im-
CERTIFICATION NEWS
World-Class RELIABILITY STARTS with a Solid FOUNDATION
b D b 2013 || hihi ll b ib i ii
Quality certifi cation programs not only can provide standards and guidelines for profes-sional recognition but also a multitude of benefi ts for individuals, organizations and industry.
For IndividualsEarning an ICML certifi cation acknowledges your expertise in machinery lubrication
and/or oil analysis to troubleshoot and ensure reliability of lubricated equipment. The lubri-cation and oil analysis community, your employer, clients and peers will recognize your ICML credential as a symbol of the skills and knowledge you’ve gained through experience. ICML certifi cation shows that you are a professional with the ability to successfully utilize machinery lubrication and/or oil analysis for your organization or client.
As an ICML-certifi ed professional, you also receive the following benefi ts:• Industry recognition of your knowledge and profi ciency in machinery lubrication
and/or oil analysis techniques.• Logos and a certifi cate to enable you to identify your ICML-certifi ed status to
colleagues or clients.
For Employers and OrganizationsThrough certifi cation, organizations can maximize their return on investment in oil
analysis. ICML certifi cation delivers the following benefi ts:• A standardized method of determining training needs and measuring results• A reliable benchmark for hiring, promoting and career planning• Employee recognition and rewards that validate their expertise• Improved employee ability to ensure machine reliability• Quality assurance for outsourced oil analysis and lubrication services
For IndustryCertifi cation brings much-needed credentials to an up-and-coming lubrication and oil
analysis community. Benefi ts to the community include:• Respect for oil analysis and lubrication professions• Increased professionalism within the community
Benefits of ICML Certification
www.machinerylubrication.com | November - December 2013 | 57
provement program. It is in your best interest to recognize the direct impact they have on the culture change. Respecting and supporting them in their professional development and teaching them not only what they should or need to be doing but also why will make all the difference.
Common sense and mutual respect can go a long way, even in our plants. Give technicians a solid start by providing them with the proper tools they need to succeed. This means ensuring they have
the appropriate job description and pre-established procedures that are clearly taught and monitored through proper supervision.
The importance of skills development cannot be overempha-sized. This will require technical training for tradesmen as well as
operators, followed by an audit of their skill set, i.e., competency testing in the technologies they will utilize when monitoring the condition of your assets.
As you develop technicians to be future leaders within your program, new mentors will emerge. Empowering them with career potential and recognition of their worth and contribu-tions to the overall health of the plant’s reliability and availability will instill the pride everyone deserves in his or her professional role. Suddenly you will fi nd yourself with in-house experts eager to make a difference. The intangible benefi ts you will see are the same as those experienced and documented by many world-class operations.
The crucial fi rst step is to understand where you are currently. Establish your starting point, not only in relation to your practices and your team’s skill level (be it in lubrication, for example, or other areas), but also where you aim to be, such as a benchmarked world-class parameter. Knowledge of the steps needed to get where you want to go is an obvious necessity, as is knowing where your limited resources are best spent — and everyone has limited resources. Ulti-mately, wherever your higher return-on-investment opportunity lies, that is where your focus should be.
To learn more about ICML’s certifi cation programs, please visit www.lubecouncil.org.
Recognize that the technicians are ultimately
the foundation of your reliability-
improvement program.
Need to train your team, but it’s always been too expensive?
More and more companies are realizing the value of bringing training onsite.
Lubrication is the lifeblood of your machinery. Bring us onsite or to the facility of your choice for private team training.
The benefits are obvious and rewarding:
• Tailored curriculum to address your company’s needs
• Learning in a more personable and familiar environment
• Confidential issues and solutions may be discussed freely • Flexible course scheduling • A unified learning experience
www.noria.com (918) 392-5033
58 | November - December 2013 | www.machinerylubrication.com
Ron Francis, MLT ISheldon Brown, MLT IWilliard Popplestone, MLT I
A.W. ChestertonMark Guenther, MLT II
AESDavid Rossler, MLA IAnthony Woods, MLA IIGregory Lilley, MLA IIHeather Mawhinney, MLA IIKevin Perrin, MLA II
Allied ReliabilityMelissa Woodward, MLT I
Alto ParanaGonzalo Gatti, MLA IIJuan Fortuny, MLT I
AMRRIBobby Kennedy, MLT I
Apache Corp.Matthew O’Brien, MLT I
AtlasPradeep Nair, MLA II
Axiall Corp.Chester Guidry, MLT IDaniel Miller, MLT IDonnie McDonald, MLT IHenry Verbick, MLT IJace Dickerson, MLT IJeffrey Eastwood, MLT IKyle Bowman, MLT ILionel Bonin, MLT ISeth Cannon, MLT ITaylor Richard, MLT ITodd Haydel, MLT I
BACTS Pablo Savall, MLT I
Baxter HealthcareCarlos Falu-Vazquez, MLA I
Bayer CropScienceJeffrey Levin, MLT I
Boehringer IngelheimGary Helmink, MLA IJohn Adams, MLT I
BungeCarlos Oliveira, MLT IEdivaldo Junior, MLT IJoel Fernandes, MLT IJosinaldo de Melo, MLT IRicardo Romao, MLT I
Bureau of ReclamationKeith Cooper, MLT I
Cargill Doug Leischner, MLT ITanner Rix, MLT I
Catalyst PaperBrian Lundberg, MLT I
Ceng LLCBrian Koscielniak, MLA II
Central Motor Wheel of AmericaHal Hastings, MLT IRon Mosley, MLT I
ChevronMd. Alam, MLA IIMinhaj Ahmad, MLA IIMohammad Chowdhury, MLA IISadeaque Ul Islam, MLA II
Chicago Bridge and Iron Co. Charles Ray, MLT IMarcus Duhe, MLT I
Cirra ConsultantsCharly George, MLA II
City of LargoGarry Rice, MLA I
CPS EnergyRyan Mcdonnell, MLT I
Croda ChemicalsShantanu Das, MLA III
DaimlerChryslerMichael Leggett, MLT I
Dalrymple Bay Coal TerminalAndrew Marshall, MLA I
DTZBarton Dewey, MLT IChris Hanna, MLT IDonald Haapapuro, MLT IEamon Reilly, MLT IJason Jensen, MLT IKyle Maack, MLT IPaul Manock, MLT IScott Erickson, MLT IStephanie Wyum, MLT ITyler Roberts, MLT I
Duke-EnergyRyan McKillip, MLA I
E&J Gallo WineryEverett Young, MLT I
Eastman ChemicalTravis Bledsoe, MLT I
EcoElectricaJulio Colon, MLT I
Ethicon LLCJoel Delgado, MLT IJulio Rodriguez, MLT I
Excell B EnterprisesPalanisamy Duraisaamy, MLT II
FateGastón Argañaraz, MLT I
FilterMag Inc.Randy Yount, MLA I
Flint Hills ResourcesMike Davis, MLA I
Florida Power & LightMichael Schilling, MLA II
FuchsAlexander Franke, MLT I
G&G SalesHank Gilley, MLA I & MLT I
General MillsBen Rosenbauer, MLT IChak Man Chan, MLT IJoe Pequignot, MLT IWade Falconberry, MLT I
Georgia-PacificAaron Swoyer, MLT IAndrew Overton, MLT IChad Marcell, MLT ICorey Marcell, MLT IDaniel Massie, MLT IGlenn Noack, MLT IJames Marcusen, MLT IJoel Krause, MLT IJoshua Nackers, MLT IJulie Longtin, MLT IMark Wnuk, MLT IMike Maciejewski, MLT IMitch Sokolski, MLT IPeter Stengl, MLT IRandy Malcore, MLT IRon Wilde, MLT ISteven Chada, MLT I
GlencoreJosef Dopsa, MLA IBarnard Jimenez, MLT I
GlucovilSebastián Lombardi, MLT II
Green Country Energy LLCLee Garell, MLT I
HankookYangseok Son, MLA II
Harley Davidson Motor Co.Gregory Coligan, MLT I
Holcim Michael Fink, MLA ITyler Reed, MLT I
HyundaiSung-Ho Hong, MLT I
Industrial Oils UnlimitedKyle Kress, MLA II & MLT I
InterflonGerd Hulsmann, MLA II
JD Irving Jacques Theriault, MLT I
Jimah O&M Kathiresan Maniam, MLT I
Johnson ControlsRichard McKenzie Jr., MLA IHarley Register, MLT I
Jones EngineeringArthur McCarthy, MLA II
Kaiser AluminumRich Hoy, MLT I
KatechJonghyuck Park, MLT I
Korea Midland Power Co. Jae-Gun Hwang, MLT I
La Plata CogeneraciónAdrián Lella, MLA I
Laboratorio Dr. LantosGabriel Lucchiari, MLT II
Lagan CementDavid O’Rourke, MLA IIStephen Beirne, MLA II
Lartex SRLRoberto Zapata, MLT I
Laurentide ControlsMagali Jarry, MLA II
Lilly del CaribeJorge Arroyo, MLA IJuan Marquez, MLA ISamuel Barreto, MLA I
Juan Figueroa, MLT I
Lubrication Engineers Inc.Gary Jacobs, MLT ISteven Hays, MLT ISteven Petrehn, MLT IAdam Serwinski, MLT II
McCain FoodsJonathan Allen, MLT IJoshua Lesniak, MLT IMichael Monteith, MLT I
MichelinAl Arnette, MLT I
MillerCoors Brewing Co.Carroll Wyant, MLT II
Monition Robert Webster, MLA II
Mosaic Co.Sean Greenlee, MLA IBilly Gunter, MLT I
MRG LaboratoriesLisa Williams, LLA IRichard Wurzbach, MLA II
NAES Corp.Mike Walker, MLA I
New Gold Inc.Clinton Burton, MLA I
Noria CorporationGerald Putt, MLA I & MLT IILoren Green, MLT II
CERTIFICATION NEWS
RECENT RECIPIENTS OF ICML CERTIFICATIONSThe International Council for Machinery Lubrication (lCML) would like to congratulate professionals worldwide who have recently achieved certifi ed status through ICML’s certifi cation programs. ICML offers certifi cation in the areas of oil analysis and machinery lubrication. The following is a list of recently certifi ed professionals in the area of machinery lubrication who have attained their status as a certifi ed Machine Lubricant Analyst (MLA), Machine Lubrication Techni-cian (MLT) or Laboratory Lubricant Analyst (LLA).
ICML CertificationsLLA I = Laboratory Lubricant Analyst Level IMLA I = Machine Lubricant Analyst Level IMLA II = Machine Lubricant Analyst Level IIMLA III = Machine Lubricant Analyst Level IIIMLT I = Machine Lubrication Technician Level IMLT II = Machine Lubrication Technician Level II
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.
www.machinerylubrication.com | November - December 2013 | 59
NV EnergyKasey Davis, MLT I
Oil Filtration Systems John Bonner, MLA I
Pall Corp.Ki Kook Yoon, MLT IYoung Min Lee, MLT I
Pattison Sand Co.Steven Janes, MLT I
Petro-CanadaNeil Buchanan, MLA III
PetrolabsRajinder Negi, MLT IVenkata Suresh Pedasingu, MLT I
Petroleum DevelopmentMohammad Uddin, MLA II
Prüftechnik CanadaBenoit Marcotte, MLT II
Reliability Technology ServicesStephen Pianka, MLT I
Rock Tenn Co.Barry Smith, MLA I & MLT IBrian Mounce, MLA I &
MLT IDavid Story, MLA I & MLT IJamie Marquis, MLA I & MLT IKenneth Roberts II, MLA IAlan Lindner, MLT IJames Vencill, MLT IMark Stone, MLT IRobert Garcia, MLT ITroy White, MLT I
Samsung Techwin Co.Seongjun Kim, MLT I
SappiSeth Washburn, MLT I
Sarawak Energy BerhadNurfaizal Wahi, MLT I
Schaeffler GroupSeemant Joshi, MLA I
Schreiber FoodsBrent Page, MLT IBret Morris, MLT IChad Williams, MLT IGerard Curti, MLT IJoe Anderson, MLT IJosh Behrendt, MLT IKenneth Kanc, MLT I
Kenneth Puckett, MLT ILarry Orethun, MLT IRaymond Grissom, MLT IRichard Reeves, MLT ISteven Foster, MLT ITravis Berney, MLT I
ShellJong Lok, MLA I
SILClaudinei Gabriel Gabriel, MLT I
Sinto Inc.Daniel Lafl amme, MLA II
SkanskaJaime Torres Huamani, MLT I
SKFPaul Doherty, MLT I
Southern Gardens CitrusBrendon Russ, MLA II
Sugar Australia Pty. Gary Burgess, MLA IJai Cavka, MLA IPaul Roddy, MLA I
Sun Up Co.
Sang Chul Park, MLT ISuk Yoong Jung, MLT I
SunCoke EnergyJack McCoy, MLT I
T.E. Laboratories Edward Elder, MLA II
Tamko Building ProductsMichael Hoover, MLT I
Tampa ElectricTeal Trombetta, MLT I
Tata SteelAjit Verma, MLT I
TECO Westinghouse Motor Co.David Wilson, MLA I
TekforChristopher Lawrence, MLT I
Total AustralGastón Delgado, MLT INicolas Gatto, MLT I
Total Lubrication Management Co.Lloyd Funchess, MLT IMichael Dougay, MLT I
Tractors India Saugata Roy, MLA I
Transportadora de Gas del SurDiego Ramborger, MLA IIJulián Zottola, MLA II
Universidad del TuraboJuan Marquez, MLA I
US LubricantsDavid Kemps , MLT IKyle Redjinski, MLT I
Vedanta Aluminum Ipsita Hota, MLA I
WeyerhaeuserPaul Watson, MLA I
Wolf Creek Nuclear Operating Corp. Crettion Taylor, MLT I
YCRTJuan May, MLA IManuel Gerez, MLA IRaúl Choque, MLA I
Yemen LNG Co.Venkatesan Narayanan, MLA II
ICML certification testing is available after most of the courses listed. Please visit www.lubecouncil.org for more information on certification and test dates.
Global Training Calendar
November 2013
ADVANCED MACHINERY LUBRICATION Daegu, South Korea • November 11-14, 2013
PRACTICAL OIL ANALYSIS Tampico, Mexico • November 12-14, 2013
PRACTICAL OIL ANALYSIS Bangalore, India • November 14-16, 2013
FUNDAMENTALS OF MACHINERY LUBRICATION Raipur/Vizag, India • November 17-19, 2013
ADVANCED MACHINERY LUBRICATION Montreal, Quebec Canada • November 19-21, 2013
OIL ANALYSIS/MACHINERY LUBRICATION I Bangkok, Thailand • November 19-22, 2013
HOW TO INTERPRET A LUBRICANT ANALYSIS REPORT Bogota, Columbia • November 20-22, 2013
December 2013
FUNDAMENTALS OF MACHINERY LUBRICATION Phoenix, AZ, United States • December 3-5, 2013
PRACTICAL OIL ANALYSIS Phoenix, AZ, United States • December 3-5, 2013
FUNDAMENTALS OF MACHINERY LUBRICATION Trinidad and Tobago • December 3-5, 2013
HOW TO INTERPRET A LUBRICANT ANALYSIS REPORT Lima, Peru • December 3-5, 2013
FUNDAMENTALS OF MACHINERY LUBRICATION León, Mexico • December 10-12, 2013
HOW TO INTERPRET A LUBRICANT ANALYSIS REPORT Santiago, Chile • December 10-12, 2013
60 November - December 2013 | www.machinerylubrication.com
BY RANCE HERREN, IFPS
HYDRAULICS
Expert through
Certification Become an
IIn today’s highly competitive manufacturing and service envi-ronment, machine and equipment uptime is critical. More often than not, it is a determinant of a company’s success and surviv-ability. Downtime is the death knell of profi tability. Perhaps the most important people in this metric are the mechanics and technicians. The wide range of skills required from the individual to keep a machine operational or to get it running after a break-down is signifi cant. This person must have an understanding of mechanics, hydraulics, pneumatics, and increasingly, electric and electronic controls. That is a tall order by any standard.
Some of the best engineers are those who have an extensive background or started their careers in troubleshooting and repair. They have seen what works, what doesn’t and what to do about it. They have a keen understanding of what it means to design and package an energy-effi cient and safe system for minimal maintenance, reduced downtime and repair with the fewest tools. They understand fi rsthand the need for and the
value of proper and thorough documentation.In other words, the engineer designs, the test technician tests
and troubleshoots, and the mechanic fi xes. All of these skill sets are critical. In the context of the overall success of the project, none is exclusive or more important than the other. Experts must be knowledgeable in the many aspects of fl uid power: hydraulic, pneumatic, and basic electric and electronic controls.
Becoming a well-rounded fl uid power expert does not end at a particular destination; it is a continuing, career-long journey. It requires the self-challenge to constantly seek out the opportunity to learn by engaging others with more or different knowledge and skills than your own. It demands stepping outside of your comfort zone and taking on the challenges that others may avoid. It involves extra time and effort that perhaps you would rather spend doing something else. You must read from text-books, fl uid power periodicals and component manufacturer catalogs to gain knowledge of the types of hydraulic and pneu-matic hardware in the marketplace, how they work and how they do not. To gain additional knowledge, consider taking a commu-nity-college course or attending a technical seminar in a discipline
www.machinerylubrication.com | November - December 2013 | 61
where your skills are weak. It doesn’t matter if you have been in the industry six months or 30 years. To advance your career and become that well-rounded fluid power expert, you must have some skin in the game.
To keep pace with the broad and ever-changing needs of industry, the International Fluid Power Society (IFPS) provides many specific and complementary certifications to demonstrate core and advanced competencies. And though some of the content from one certification to another is necessarily overlapping, each offering is targeted to meet the particular needs of the individual and to establish his or her qualifications. Getting certified and holding multiple certifications demonstrates that you take your career seriously and can be the key component to increasing your worth to your employer.
So, what exactly is a fluid power expert? It is the individual who can satisfactorily address the particular need at that moment and one who also has a demonstrable, broad base of knowledge. If you are well-rounded in multiple aspects of fluid power, prove it. Take the time and make the effort to get certified in all of those areas. Then that expert can and will be you.
Lastly, are you an employer or manager asking yourself, “What can I get out of certifi-cation?” You can assure your customers that your employees possess an industry-wide accepted level of competence and that your mechanics, technicians and engineers have the skills necessary to perform their tasks confidently, efficiently, reliably and safely. It shows you encourage employee pride and are willing to invest in the development of their careers. Tell the world that as a business owner or manager, you care about the image your company and employees put forth and how it reflects on the larger fluid power, manufacturing and service communities.
So now you might be thinking, “OK, but why should I spend all of this money in training and certifying my employees and risk them leaving and going to the competition?” Well, I have some bad news for you. When it comes to the talent pool, the fluid power industry is in a crisis. The number of individ-uals coming into and staying in the industry compared with those leaving or retiring is strikingly disproportionate. If you don’t invest in the development of your employees, including in training and certification, you are inadvertently promoting the industry’s demise
— and maybe even your own company’s downfall. At some point, it will not be a matter of if you lose that employee but when.
In the words of motivational speaker and sales coach Zig Ziglar: “The only thing worse than training an employee and having them leave is not training and having them stay.” On the subject of employee training and development, no truer words have ever been spoken.
For more information on IFPS certifications, visit www.ifps.org or call 800-308-6005.
62 | November - December 2013 | www.machinerylubrication.com
In many of the training courses Noria provides, we discuss how a culture change is required in most cases to achieve a
world-class lubrication program. This is by far the most diffi cult part of the process. The assessment is easy. A technical consultant walks through your plant or facility and looks for opportunities. Most often the low-hanging fruit is obvious and simply overlooked by plant personnel because it has become part of the standard scenery. With a fresh set of eyes specifi cally looking for these opportunities, they are generally not too diffi cult to fi nd.
Frequently, the facilities being assessed are operating in an “unconscious incompetence” stage, as shown in the diagram below. This simply means that the workforce is doing the wrong things and isn’t even aware that they are wrong. After training or an assessment is conducted, the facility moves to the second stage. Personnel at the plant are no longer ignorant of the right way to do business. Eyes have been opened, and innocence has been lost. Now they can pursue the optimum reference state (ORS) of lubrication excellence.
This is where things get diffi cult. Knowing the right things to do and actually doing them are obviously not the same thing. This is known as the knowing-doing gap. So now that you know what is right and wrong, how do you get that “culture shock” to take place?
During my career in the U.S. Navy, I was told repeatedly that an organization takes on the traits of its leadership. In other words, what the boss wants, generally the boss gets. If it is important to the boss, it is going to be important to the rest of the organization as well. Therefore, the easiest way to achieve a culture change is to get the boss onboard. Sometimes it is not always easy. You may have to be the champion of change and fi ght in the trenches alone. The following tips can help you affect the change you are seeking.
First, use the Pareto principle or the 80/20 rule. You may have been taught the 80/20 rule in terms of 20 percent of the workers do 80 percent of the work, but at Noria we apply it to contamination. Twenty percent of the causes of failure are responsible for 80 percent of the occurrences of failure. By and large the greatest percentage of
damage to equipment is due to partic-ulate contamination. So if particles are the largest source of contamina-tion, this prioritizes how you should invest your time and efforts.
Particles can get into machines in a few ways. They may be built in, ingressed or generated. The cost of excluding contaminants is less than 10 percent of what it will cost you once they are allowed to ingress into your fl uid (see http://www.machin-er ylubrication.com/Read/28574/justifying-cost-of-excluding-a-gram-of-dirt-). If you want to get your boss onboard, you will need to put this in terms of cost savings. There are several case studies that show the cost bene-fi ts of fi ltration, breathers, keeping shaft seals in good shape, etc. These
L u b r i c a t i o n P r o g r a m s
LOREN GREEN | NORIA CORPORATION
How to CHANGE YOUR Lubrication CULTURE
BACK PAGEBASICS
Drivers:• Crisis• Profitability• Aspiration
Drivers:• Measurement• Peer Pressure• Sustained Management
Support• SuccessLoss of
Innocence
Ignorance is Bliss
TIME
EFFO
RT/
OR
GA
NIZ
ATIO
NA
L R
ESIS
TAN
CE Culture Shock
ConsciousCompetence
ConsciousIncompetence
UnconsciousIncompetence
Old Business as Usual
UnconsciousCompetence
New Business as Usual
Looking for new strategies to increase operational efficiency? Searching for the moving target that drives leaner production while increasing safety and long-term profitability? Noria has your solution. Noria’s Lubrication Program Development is delivering bottom-line results for others just like you. We begin with a holistic survey of your facility viewed through the lens of
“vendor neutrality.” This model of unbiased recommendation offers an enterprise-wide value proposition with concrete returns in operational excellence and profitability. We’d love to tour your facility and show you why companies around the globe consult Noria for world-class service in lubrication-enabled reliability!
www.noria.com 800.597.5460 [email protected]
Contact One of Our Experts Today!
64 | November - December 2013 | www.machinerylubrication.com
studies address the savings in lubricants, bearings, downtime and many other areas that you can use to form a sound argument.
Secondly, you must get other team members onboard. In my experience, explaining the “why” is the most effective method to accomplish this. Why are we doing this? Talking about saving the organization money may or may not be your best approach. Detailing the benefi ts of keeping the oil clean, cool and dry in terms of reduced downtime and workload may help.
I recently conducted a training course where one of the students was skeptical of the advantages of oil analysis. He was a fan of vibration analysis and thermography but questioned the benefi ts of oil analysis. I explained that in order for vibration and thermography technologies to be used, you must either have
vibration or a higher than normal temperature condition. On the other hand, with a good oil analysis program, you can detect potential issues before they get to the point of registering on either vibration or thermography equipment. The ideal situation is to match all of these technologies. After taking the time to
explain the “why” of oil analysis, he began to come around and see the benefi ts.
This leads us from the “conscious incompetence” stage to the “conscious competence” stage. Now you know the proper proce-dures, quantities, frequencies, etc., and are putting this information to use. This is when the magic happens and the organization begins to change. You as the champion have made an impression, and the staff is following your example. When you start seeing evidence of this transformation taking place, you should take a moment to congratulate yourself and your team. Many organizations don’t make it this far.
Keep striving to make improvements and eventually you will reach the fourth and fi nal stage, “unconscious competence.” In this stage, personnel perform procedures correctly and aren’t even sure why. When asked why things are done a certain way, they might answer, “I don’t know; we’ve always done it that way.” Better yet, perhaps they can explain why everything is done the way it is. If so, you are well on your way to having a world-class lubrication program.
About the AuthorLoren Green is a technical consultant with Noria Corporation, focusing
on machinery lubrication and maintenance in support of Noria’s Lubrica-tion Program Development (LPD). He is a mechanical engineer who holds a Machine Lubrication Technician (MLT) Level II certifi cation and a Machine Lubricant Analyst (MLA) Level II certifi cation through the International Council for Machinery Lubrication (ICML). Contact Loren at [email protected].
BACK PAGE BASICS
67%of lubrication professionals say their facility has attempted to change its lubrication culture,
based on a recent poll at MachineryLubrication.com
1. Publication Title: Machinery Lubrication2. Publication Number: 021-6953. Filing Date: October 24, 20134. Issue Frequency: Bi-monthly5. Number of Issues Published Annually: 66. Annual Subscription Price: Free to qualifi ed subscribers7. Complete Mailing Address of Known Offi ce of Publication: Noria Corporation,
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Average No. Copies Each Issue During Preceding 12 Monthsa. Total Number of Copies (Net press run): 28,615 b. Legitimate Paid and/or Requested Distribution (By Mail and Outside the Mail) (1) Outside County Paid/Requested Mail Subscriptions stated on PS Form 3541: 21,427 (2) In-County Paid/Requested Mail Subscriptions stated on PS Form 3541: 0 (3) Sales Through Dealers and Carriers, Street Vendors, Counter Sales, and Other Paid or Requested Distribution Outside USPS®: 0 (4) Requested Copies Distributed by Other Mail Classes Through the USPS (e.g., First-Class Mail®): 0 c. Total Paid and/or Requested
Circulation: 21,427 d. Nonrequested Distribution (By Mail and Outside the Mail) (1) Outside County Nonrequested Copies Stated on PS Form 3541: 6,639 (2) In-County Nonrequested Copies Stated on PS Form 3541: 0 (3) Nonrequested Copies Distributed Through the USPS by Other Classes of Mail: 0 (4) Nonrequested Copies Distributed Outside the Mail: 183 e. Total Nonrequested Distribution: 6,822 f. Total Distribution: 28,249 g. Copies not Distributed: 365 h. Total: 28,614 i. Percent Paid and/or Requested Circulation 76%
16. No. Copies of Single Issue Published Nearest to Filing Date a. Total Number of Copies (Net press run): 31,165 b. Legitimate Paid and/or Requested Distribution (By Mail and Outside the Mail) (1) Outside County Paid/Requested Mail Subscriptions stated on PS Form 3541: 24,568 (2) In-County Paid/Requested Mail Subscriptions stated on PS Form 3541: 0 (3) Sales Through Dealers and Carriers, Street Vendors, Counter Sales, and Other Paid or Requested Distribution Outside USPS®: 0 (4) Requested Copies Distributed by Other Mail Classes Through the USPS (e.g., First-Class Mail®): 0 c. Total Paid and/or Requested Circulation: 24,568 d. Nonrequested Distribution (By Mail and Outside the Mail) (1) Outside County Nonrequested Copies Stated on PS Form 3541: 6,133 (2) In-County Nonrequested Copies Stated on PS Form 3541: 0 (3) Nonrequested Copies Distributed Through the USPS by Other Classes of Mail: 0 (4) Nonrequested Copies Distributed Outside the Mail: 100 e. Total Nonrequested Distribution: 6,233 f. Total Distribution: 30,80 g. Copies not Distributed: 364 h. Total: 31,165 i. Percent Paid and/or Requested Circulation: 80%
17. Total circulation includes electronic copies. Report circulation on PS Form 3526-X worksheet.
18. Publication of Statement of Ownership for a Requester Publication is required and will be printed in the NOV/DEC 2013 issue of this publication.
19. Signature and Title of Editor, Publisher, Business Manager, or Owner: Mike Ramsey, October 24, 2013. I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading information on this form or who omits material or information requested on the form may be subject to criminal sanctions (including fi nes and imprisonment) and/or civil sanctions (including civil penalties).
Machinery Lubrication Statement of Ownership 2013
