LMT Jan/Feb 2012 by Applied Technology Publications

SUPERIOR PERfORMANCE. SUPERIOR EffICIENCy. SUPERIOR qUALITy.

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1.88ThinkNSK (888.446.5675) BALL BEARINGS

www.nskamericas.com ROLLER BEARINGS

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LINEAR MOTION PRODUCTS

TECHNICAL SERVICES

JAnUARY/feBRUARY 2012 • vOL 13, nO. 1 • www.LMTinfo.com

contents

AchIevInG effIcIencIeS ThROUGh PRAcTIceS & PRODUcTS

Features eQUIPMenT-SPecIfIc LUBe SeRIeS 10

Part I (Introduction): A Real-World Approach To Improved Lubrication

This practical series examines proven strategies and tactics from an equipment standpoint, one system at a time.

Ray Thibault, Contributing Editor

GeAReD fOR SUcceSS 16

extending The Life Of Gear Reducers Dip into these tips to get your lubrication practices up to speed. Don Miller, Baldor Electric Co.

DeLIveRInG The GOODS 20

The Anatomy Of A centralized Lubrication System: Single-Point Lubricator Technology These workhorses (aka SPLs) may not be right for every application, but they have a rightful place in every plant’s lube-management program. Ken Bannister, Contributing Editor

LUBRIcATIOn BASIcS 24

Get It Right: Respect the 5Rs

dePartMeNts 4

Publisher’s notes

My Take

from Our Perspective

Motor Decisions Matter

Problem Solvers

Supplier Index

Refreshing yourself and your team on lubrication “RIGHTS” can help prevent plenty of lubrication “WRONGS” around your operations. Jane Alexander, Editor, with Paul Michalicka, SKF USA Inc.

Achieving efﬁciencies Through Practices & Products Apply for a free, one-year subscription at

www.LMTinfo.com JANUARY/FEBRUARY 2012

www.lmtinfo.com | 3

PUBLISHER’s Notes

Bill Kiesel, Publisher

The Spirit Of The Resolution

t’s the time of year for resolutions. Have you resolved to enhance your professional development this year? If so, I want to remind you of a terrific way to stay on track with your goal and prevent the let-down feeling that comes when you allow the spirit of a New Year’s resolution to slip away. You can keep that spirit alive in 2012 by attending the information-packed, 9th annual Maintenance and Reliability Technology Summit (MARTS) March 12-15 in Rosemont, IL. MARTS’ robust schedule offers 10 full-day Workshops and 27 hourlong Conferences over the four days, including the following presentations created specifically for lubrication professionals like you: n Contributing Editor Ray Thibault’s “Certified Lubrication Specialist (CLS) Review” is a three-day Workshop aimed at preparing attendees to take the CLS certification exam (which is offered at the conclusion of the course). This Workshop will help refine, update and upgrade your understanding of lubrication, from evaluation and selection through surveys and analysis to application details for bearings and gears, pneumatics, seals and others. If you’re serious about your career in lubrication, this course is for you. n Two one-hour regular Conference presentations will target a range of critical lube issues. The first, “Leak-Detection and Lubrication Management Using Acoustical Ultrasonic Receivers,” by Mike Gilley of Fox River Systems, will discuss how ultrasonics can be used to improve lubrication-management programs, and its value in condition monitoring and detecting leaks in compressed air/gas systems. The second, “Maximize Oil Life With Condition Management,” by Jarrod Potteiger of Des-Case Corp., will explain the many ways lubricants can fail and how to identify the causes through analysis. The CLS Workshop runs Monday-Wednesday, March 12-14; regular Conference sessions are set for Tuesday, March 13 and Wednesday, March 14. Register today at www.martsconference.com to ensure your seat at MARTS—and an opportunity to excel in 2012 and beyond. Best wishes for success in this great new year. Our thanks to all readers, contributors and advertisers for your continuing support! LMT bkiesel@atpnetwork.com

PS: While not specifically lube-related, the MARTS Conference presentation, “Innovative Tips, Techniques and Ideas Guaranteed to Improve Maintenance Effectiveness,” by Contributing Editor Ken Bannister, should also be tagged as a “must-attend” session! 4|

lubrication management & technology

Achieving EffiCIencies THROUGH PRACTICES & PRODUCTS

January/February 2012 • Volume 13, No. 1 arthur l. rice President/CEO arice@atpnetwork.com

bill kiesel Executive Vice President/Publisher bkiesel@atpnetwork.com

Jane alexander Editor-In-Chief jalexander@atpnetwork.com

RICK CARTER Executive Editor rcarter@atpnetwork.com

Kenneth E. Bannister ray thibault, CLS, OMA I & II RAYMOND L. ATKINS Contributing Editors

RANDY BUTTSTADT

Director of Creative Services rbuttstadt@atpnetwork.com

GREG PIETRAS

Editorial/Production Assistant gpietras@atpnetwork.com

ellen sandkam

Direct Mail esandkam@atplists.com

jill kaletha

Reprint Manager 866-879-9144, ext. 168 jillk@fosterprinting.com

Editorial Office 1300 South Grove Ave., Suite 105 Barrington, IL 60010 847-382-8100 / FAX 847-304-8603 www.Lmtinfo.com

Subscriptions For inquiries or changes contact Jeffrey Heine, 630-739-0900 ext. 204 / Fax 630-739-7967 Lubrication Management & Technology (ISSN 19414447) is published bi-monthly by Applied Technology Publications, Inc., 1300 S. Grove Avenue, Suite 105, Barrington, IL 60010. Periodical postage paid at Barrington, IL and additional offices. Arthur L. Rice, III, President/CEO. Circulation records are maintained at Lubrication Management & Technology, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Lubrication Management & Technology copyright 2012. No part of this publication may be reproduced or transmitted without written permission from the publisher. Annual subscription rates for nonqualified people: North America, $140; all others, $280 (air). No subscription agency is authorized by us to solicit or take orders for subscriptions. Postmaster: Please send address changes to Lubrication Management & Technology, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Please indicate position, title, company name, company address. For other circulation information call (630) 739-0900. Canadian Publications Agreement No. 40886011. Canada Post returns: IMEX, Station A, P.O. Box 54, Windsor, ON N9A 6J5, or email: cpcreturns@wdsmail. com. Submissions Policy: Lubrication Management & Technology gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Printed in U.S.A.

JANUARY/FEBRUARY 2012

Reliability: Own It This MARCH... Save The Date For Keynote Address Tues. March 13, 2012:

MAINTENANCE and RELIABILITY TECHNOLOGY SUMMIT

Managing the Trends

The Capacity Assurance Conference!

MARCH 12-15, 2012

David Boulay, president, Illinois Manufacturing Extension Center

Conference Selections: Optimizing Pump-System Performance: The Link Between Energy Efficiency and Improved Reliability Roland McKinney, SKF Service Division

The Top 5 Best Maintenance Practices of World-Class Companies Enrique Mora, Mora International Consulting Services

Maintenance and Reliability Assessment: Is World Class Right For Your Facility? Dave Rosenthal, Jacobs Engineering

How a Community College Partnership Can Address the Skills Shortage Mark Combs, Parkland College

Leveraging PAS 55 to Optimize Asset Utilization and Increase Productivity

Now entering its ninth year, MARTS is an exciting learning event in a great location that helps reliability professionals at all levels improve their skills and excel on the job. Pricing and attendance options for every budget make it easy for individuals or groups to share the MARTS experience.

• A four-day educational experience created exclusively for reliability professionals • 27 hour-long Conferences over two days – Tuesday, March 13 and Wednesday, March 14 – kicked off by Keynote speaker David Boulay, president of the Illinois Manufacturing Extension Center, and followed by reliability experts in many disciplines

• 5 full-day Workshops on Monday, March 12 • 5 full-day Workshops on Thursday, March 15 • Two professional certification opportunities

Kris Goly, Siemens Asset Performance Management Services

Workshop Selections:

Energy and Sustainability Management

Eric Huston and members of SKF Service Division

From TPM to TPR: Move to the Next Level of Maintenance and Process Reliability

Enrique Mora, Mora International Consulting Services

Cause Mapping I: Effective Root Cause Analysis Mark Galley, ThinkReliability

Maintenance Planning and Scheduling: Increase Your Workforce Without Hiring R. D. (Doc) Palmer, Richard Palmer & Assoc.

Motor System Management

Howard W. Penrose, Dreisilker Electric Motors, Inc.

Other Workshop Presenters: Mike Gilley, Fox River Systems Dave Krings, Consultant Jim Seffrin, Infraspection Institute Ed Stanek, LAI Reliability Systems Bob Williamson, Strategic Work Systems

For complete schedule and registration information, please go to

www.MARTSconference.com The Capacity Assurance Conference! MAINTENANCE and RELIABILITY TECHNOLOGY SUMMIT

Hyatt Regency O’Hare, Rosemont (Chicago), IL For more info, enter 62 at www.LMTfreeinfo.com

MY TAKE

Jane Alexander, Editor-In-Chief

Let’s Go, Team!

now coming down, a layer of ice on its way to Chicagoland…Can I be faulted for letting my thoughts wander off in the direction of spring? Of course, that gets me thinking about baseball, which in turn gets me thinking about teams—our team, to be exact! No, not the Sox or Cubs: I’m referring to LMT’s “LubeStarz Team.” It’s time to build this year’s roster, and you could be a big part of it—as a possible member yourself, or in nominating others from your organization’s lubrication team or elsewhere! How often do hardworking lube pros receive the positive recognition they deserve? Not very! Our LubeStarz Team is designed to change that to some extent: We want to put a face to— and also applaud—the maintenance and operations professionals who play pivotal roles in successful lubrication-management programs across industry. To our way of thinking, they’re unsung heroes in that never-ending battle for reliability. WE’RE BUILDING OUR 2012 TEAM... As Ray Thibault says in his introduction of a year-long series on equipment-specific lubrication strategies (see pg. 10), it’s the individuals who are charged with inspecting an operation’s equipment (including lube Let’s Build techs, oilers and operators) that make up the Our 2012 Team first line of predictive and proactive defense. We think it’s high time to bring those types of people into the spotlight, don’t you? So, please don’t hold back. We want to hear about you and/or other deserving lube pros. Henry Neicamp Steve Vaughan, Go to www.lubestarz.com for details—ASAP. Mark L. Graham, The sign-up process is easy. Then, as we did last year, we’ll select one or more applicants to feature in every 2012 issue of LMT. If you haven’t picked up on it by now, we’re really proud of our 2011 LubeStarz Team and Dave Maki Mike Graves, can’t wait to build our 2012 lineup. With your Sandor Mercz Kerek help, it’s sure to be a winner. For now, let me add my voice to those of L utbaerz S our Publisher Bill Kiesel and Contributing Editor Ken Bannister in wishing all readers, contributors and advertisers a very happy and prosperous new year. LMT jalexander@atpnetwork.com

Here Are Our 2011L uberz

Sta

MLT I

Field Services Manager, Polaris Laboratories, the well-known, full-service fluid-analysis provider, headquartered in Indianapolis, IN

CLS, CLGS, OMA

Maintenance Mechanic Alcoa – Mt. Holly Goose Creek, SC

Technical Services Manager, Lubricants O’Rourke Petroleum Products, based in Houston, TX

P.Eng.

Head Oiler, St. Mary’s Paper, a mill located in Sault Ste Marie, Ontario, Canada

Industrial Mechanical Technician, Ingenieria Proactiva Ltda., a consulting operation in Cali-Valle, Colombia

President, Coastal Engineering Services, a consulting Info firm based Company in New Brunswick, Canada Contact Info Here

www.websitehere.com

Our caps are off to all hardworking Lube Starz, who’ll receive their own baseball caps for making the team. Up for the game? Go to www.lmtinfo.com/lubestarz or www.lubestarz.com to tell us about yourself!

Follow the instructions for submitting your own application and photo and you might find your work-related profile in a future LMT issue. We look forward to hearing from you soon!

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

30 | LUBRICATION MANAGEMENT & TECHNOLOGY

NOVEMBER/DECEMBER 2011

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

6 | LUBRICATION MANAGEMENT & TECHNOLOGY

JANUARY/FEBRUARY 2012

99% of Americans have seen combat on TV.

Photo by Petty Officer 2nd Class Sandra M. Palumbo, U.S. Navy - Bahrain, November 6, 2007

1% of Americans have seen combat in Iraq or Afghanistan.

We know where youâ&#x20AC;&#x2122;re coming from. Weâ&#x20AC;&#x2122;ve got your back. Join the online community at IAVA.org

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FROM OUR PERSPECTIVE

Ken Bannister, Contributing Editor

Tiny Bubbles. . .

he welcoming of a brand-new year means most of us will have pledged to change our ways—hopefully for the better. I’ve always found the celebration of this holiday paradoxical: We lament our poor decisions and regrets of the past year, while hoping for transformation and a fresh start promised by the mere changing of date! This year’s celebratory toasting with friends prompted a lively discussion over how all those “tiny bubbles” got into our sparkling drinks. With a little on-the-spot, online research, we were shocked to learn the British—of all people— are credited with discovering that the presence of sugar causes wine to naturally carbonate during fermentation. This discovery, along with improved glass manufacturing and the use of cork bottle stoppers (an old Roman trick), allowed the Brits to enjoy “bubbly” wine (including that imported from the Champagne region of France) as early as the 17th century, well in advance of Dom Perignon and his band of merry monks. Reflecting on these details, my thoughts turned to how the effervescence of aerated fluid can be so delightful and benign with regard to “open systems” like the human tongue and digestive track, yet so dangerous in “closed-loop” arrangements like our blood’s circulatory system or a machine’s hydraulic/lubrication workings. In closed systems, tiny bubbles work in destructive ways, manifesting many types of damage. These include: 1) pump cavitation that rapidly erodes impellers and their seals, and leads to restricted fluid movement and poor component response; 2) shortened lube life, as additive packages are rapidly depleted fighting the foam and oxidization caused by excess air in the fluid, leading to the lubricant attacking the very bearings it’s supposed to protect; 3) excess working of the fluid, creating internal friction that heats the lubricant and reduces its working life; 4) line hammer or “banging” of lubricant lines caused as air compresses and decompresses when it changes direction in the system, leading to leaking joints

LUBRICATION MANAGEMENT & TECHNOLOGY

and additional air-entry points; and 5) air entrapment in hydraulic fluid that results in “spongy” and less-positive cylinder movements. If you’ve noticed such symptoms in your equipment, maybe you should start 2012 in a different way: Open your PM cupboard and review how to better combat the evils of tiny bubbles.

Keeping tiny bubbles out of your lube systems will pay dividends in the life of fluids and components and the efficiency of your equipment. For example, checking for correct reservoir fluid levels will ensure that air isn’t pulled into the pump suction through lack of fluid coverage or that air isn’t produced through “churning” of fluid when the reservoir is overfilled. Fluidtemperature checks will ensure that hydraulic fluids don’t exceed 180 F, burning seals to failure and opening up air-entry points. Check for compromised seals, as well as the condition of all pump suction lines, clamps and hoses to ensure system integrity and absence of air-entry points. Check, too, for poor system component response and banging noises—ask the operator to help with this one. These are all easy checks that can be performed by maintainers and/or operators. Keeping tiny bubbles at bay in your lubrication systems will pay dividends with the life of both fluids and components—not to mention the overall efficiency of your equipment systems. How resolute do you feel? Good luck and best wishes for a prosperous 2012! LMT kbannister@engtechindustries.com For more info, enter 02 at www.LMTfreeinfo.com

JANUARY/FEBRUARY 2012

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Tools and techniques to optimize equipment reliability...

Part I (Introduction):

A Real-World Approach To Improved Lubrication This practical series examines proven strategies and tactics from an equipment standpoint, one system at a time. Ray Thibault CLS, OMA I, OMA II, MLT, MLT II, MLA II, MLA III Contributing Editor

EQUIPMENT-SPECIFIC LUBE SERIES

any of my articles (including those in the recent “Certification Matters” series that ran in LMT throughout 2011) have concentrated on the selection of the correct lubricant and maintaining oil cleanliness as major factors in enhancing equipment reliability. This year, we introduce a series on improving your lubrication approach with regard to the specific equipment systems in your plant. The focus will be on equipment categories—not on the lubricants that you use. The schedule for various equipment types we’ll discuss in 2012 is as follows: ■ March/April — Electric Motors ■ May/June — Pumps ■ July/August — Fans and Blowers ■ September/October — Compressors ■ November/December — HVACR Considerations

Among The Topics To Be Discussed In This Series Highlighting straightforward advice for enhancing your equipment’s reliability

Each of these equipment systems will be discussed in detail with regard to their respective lubrication concerns. Particular emphasis will be put on correct application of lubricants and troubleshooting techniques to identify problems with the lubricated system—earlier than later. The importance of application Regardless of your industry sector, correct application of lubricants is vital to the reliability of your equipment systems: Too much or too little lubricant in a system can cause serious problems. The following are application categories: ■ Manual ◆ Grease guns ◆ Grease cups ◆ Hand packing ◆ Brush ◆ Oil cans ■ Natural ◆ Oil bath ◆ Oil splash ◆ Slinger ring/flinger/disc ■ Gravity ◆ Drip/wick feed oilers ◆ Constant level oilers ■ Automated ◆ Single-point ◆ Centralized system ◆ Oil mist ◆ Air-line oilers ◆ Pressure circulation

As noted, this series will focus on equipment issues, correct lubricant application and troubleshooting (i.e., diagnostic tools and techniques) for early problem identification. Topics will include (but won’t be limited to): ◆ Comparison of similarities/differences in

lubrication of different equipment types. ◆ Advantages/disadvantages in use of

slinger rings and determination of correct oil levels. ◆ When to use sealed-for-life bearings

for electric motors. ◆ Use of ultrasonic greasing of electric motors

versus traditional practices.

JANUARY/FEBRUARY 2012

◆ Advantages of oil mist (both purge

and dry) for bearing lubrication. ◆ Troubleshooting use of bottle oilers. ◆ Correct placement. ◆ Maintenance of proper oil levels. ◆ Advantages of bull’s-eye oilers

for proper oil level control. ◆ Proper use of infrared thermography (IR)

as an indicator of equipment problems. (Example: Can IR detect leaking valves in a reciprocating compressor?) ◆ Troubleshooting and advantages/disad-

vantages of various air blower types.

www.LMTinfo.com | 11

EQUIPMENT-SPECIFIC LUBE SERIES

The importance of troubleshooting Do you listen when your equipment is “speaking” to you, and do you understand the language being spoken? These articles will update you on the knowledge and tools you need to effectively communicate with your equipment. Scores of early problems can usually be detected by observing your equipment. Condition-monitoring techniques, such as vibration analysis, ultrasonics, infrared and oil analysis (and how they relate to one another as diagnostic tools) will also be covered. Again, this series will be highlighting useful information and solutions to problems from the real world— not just from academia. While many of these methods may seem simple, they’ve proven to be very effective in plant environments. For example, people observing equipment need access to infrared thermographic technology (and must be trained on its benefits and how to use it). Furthermore, these articles are being written with the following in mind: The key to enhancing system reliability is the people who inspect the equipment, including your lubrication technicians, oilers and operators— they make up the first line of defense in a site’s ability to be predictive and proactive about equipment problems. Given that fact, consider these additional questions: ■ Have you trained these people properly

(and adequately)?

Lube techs, oilers and operators are key to system reliability. They’re a site’s first line of predictive and proactive defense.

■ Do they have guidelines on what to look for to

identify problems at an early stage? ■ Is your team of technicians and oilers a consistent

group, and thus familiar with the equipment these individuals are responsible for maintaining, or do you keep changing assignments? ■ Do operators communicate with each other about

similar problems? Articles in this series will propose a checklist to follow and the appropriate tools and techniques to use when inspecting equipment. Drawn from a real-world knowledge base Much of the knowledge to be presented in these articles will come courtesy of real-world, end-user experts. One such expert is Mark Kavanaugh, who has more than 42 years of experience in large manufacturing operations and is currently responsible for coordinating the lubrication of thousands of pieces of rotating equipment. He’s also responsible for collecting and performing all of the on-site oil 12 | LUBRICATION MANAGEMENT & TECHNOLOGY

analysis for his plant. More important, he has extensive equipment knowledge—as both a millwright and a machinist. Mark holds a number of lubrication certifications, including: Certified Lubrication Specialist from The Society of Tribologists and Lubrication Engineers (STLE), and Machinery Lubrication Technician Level I and Machinery Lubrication Analyst Level II from the International Council of Machinery Lubrication (ICML). His type of equipment and lubrication knowledge/expertise and practical plant-floor perspective should help make this series especially valuable. Coming up The March/April installment will focus on oil- and greaselubricated electric motors and application techniques. LMT Ray Thibault is based in Cypress (Houston), TX. An STLECertified Lubrication Specialist and Oil Monitoring Analyst, he conducts extensive training for operations around the world. Telephone: (281) 257-1526; email: rlthibault@msn.com. For more info, enter 03 at www.LMTfreeinfo.com JANUARY/FEBRUARY 2012

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W O R R Y- F R E E

IT TAKES ONE TO KNOW ONE... There’s more than just bragging rights at stake...

The Innovators Of

Are Proud To Sponsor The Maintenance & Reliability Innovator Of The Year Award

Inpro/Seal Rock Island, IL www.inpro-seal.com Presented By Applied Technology Publications

The Clock Is Ticking Down... All Entries Are In And The 2011 Competition Is Closed.

Now, It’s Up To The Judges... The Grand Prize And 3 Category Winners* Will Be Announced On February 15th. To Learn Who Won, Visit: www.mt-online.com/innovatorwinners Our Thanks To Everyone Who Took The Time To Submit An Innovation. Good Luck To All Of You.

(To everyone else, stay tuned for details of our 2012 competition!)

Inventor of the original Bearing Isolator, Inpro/Seal has been delivering innovative sealing solutions and superior customer service for more than 30 years. Now part of Waukesha Bearings and Dover Corp., Inpro/Seal is stronger and more innovative than ever and continues to invest in technology and product development. This brand built its reputation on the outstanding performance of the original Bearing Isolator, which increases the reliability of rotating equipment and provides cost savings by improving mean-time-betweenrepair (MTBR). Plus, Inpro/Seal offers same- or next-day shipments, even on new designs. But Bearing Isolators were just the start. In response to customer needs, Inpro/Seal now offers the Air Mizer®, for sealing a variety of product-handling equipment; the Current Diverter Ring™ (CDR®), which protects motor bearings and coupled equipment by diverting damaging electrical currents to ground; and the Motor Grounding Seal (MGS®) that combines CDR technology with the complete protection of a Bearing Isolator to safeguard bearings from electrical currents and contamination.

The innovators of INPRO/SEAL will provide individual iPads and cases to the Grand Prize winner and 3 Innovation Category winners. *Categories include innovative devices, gizmos and gadgets; innovative processes and procedures; and innovative use of outside resources. For more info, enter 10 at www.LMTfreeinfo.com

14 | LUBRICATION MANAGEMENT & TECHNOLOGY

JANUARY/FEBRUARY 2012

...AN INNOVATOR, THAT IS! The Innovators Of

The Innovators Of

Are Proud To Sponsor The Maintenance & Reliability Innovator Of The Year Award

Royal Purple Porter, TX www.royal-purple-industrial.com

Scalewatcher North America, Inc. Oxford, PA www.scalewatcher.com

Lubricant performance can vary greatly between competing mineral-based and synthetic products. According to the innovators of Royal Purple, since quality differences can signiﬁcantly impact the cost of operating and maintaining equipment, your lube purchases can’t be effectively managed as a commodity: Lubricant excellence is paramount. The company notes that beneﬁts attainable across a broad population of rotating equipment from upgrading to Royal Purple lubricants include, among other things, energy savings greater than 3%, and a reduction in the need for equipment repair by at least 30%. Although Royal Purple products may cost more per gallon, an operation’s annual cost for lubricants changes little, due to greatly extended drain intervals and the elimination of oil changes associated with equipment repairs. Initiatives to reduce maintenance and improve equipment reliability often are time- and people-intensive. Royal Purple offers substantial improvements and savings simply through replacement of a product you already buy and use. It doesn’t get any easier than this.

Scalewatcher™ is a no-maintenance environmentally friendly descaler that does not change water composition. Scales and stains disappear gradually and completely, without further action required, guaranteed. The Scalewatcher products work by way of magnetic and electric ﬁelds and a continuously changing frequency. The process forces dissolved minerals such as calcium and magnesium to crystallize before mineral ions (the cause of hard scale) can settle on surfaces. This stops or reduces ne buildup of hard scale, and because the water is better able to dissolve minerals, existing hard-scale layers are softened and eventually disappear. The Scalewatcher technology has been used by more than 250,000 satisﬁed customers worldwide. These products prevent corrosion in pipework; prevent settlement of zebra mussels in plants using sea or river water for cooling; reduce bacterial counts in cooling systems; reduce water and energy bills; extend the life of water-using equipment (especially boilers); can be installed without plant shutdown; are maintenance-free; and last 20+ years.

The innovators of ROYAL PURPLE will provide individual cases of Royal Purple products to the Grand Prize winner and 3 Innovation Category winners.

The innovators of SCALEWATCHER will provide individual water treatment units to the Grand Prize winner and 3 Innovation Category winners.

*Categories include innovative devices, gizmos and gadgets; innovative processes and procedures; and innovative use of outside resources.

For more info, enter 11 at www.LMTfreeinfo.com

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JANUARY/FEBRUARY 2012

www.LMTinfo.com | 15

GEARED FOR SUCCESS

Lubrication is the key...

Extending The Life Of Gear Reducers Dip into these tips to get your lube practices up to speed.

mproper lubrication is among the leading causes of gearbox failure. Thus, it makes sense that proper lubrication plays a key role in achieving satisfactory performance and extending the life of gear (or speed) reducers. Letâ&#x20AC;&#x2122;s review some important points. Don Miller Baldor Electric Co.

16 |

LUBRICATION MANAGEMENT & TECHNOLOGY

JANUARY/FEBRUARY 2012

GEARED FOR SUCCESS

OIL VISCOSITY EQUIVALENCY CHART

A big step toward success is choosing the proper lubricant from one of two basic types: mineral-based or synthetic (with the most common synthetic types being hydrocarbon polyalphaolefins [PAOs] and polyalkylene glycols [PAGs]). That choice should be predicated on a product’s characteristics—i.e., viscosity, viscosity index, pour point and additive package. Conversely, choosing and/or using the wrong product, wrong viscosity, wrong additives, etc., are steps toward improper lubrication. Likewise, not maintaining the correct oil-fill level, operating the gearbox with dirty or contaminated oil and other poor lube practices also can be the kiss of death for your equipment.

KINEMATIC VISCOSITIES cSt/ 40°C 2000

1000

cSt/ 100°C

ISO VG

AGMA GRADES

SAE GRADES GEAR OILS

8000

1000

680

460

320

1500

220

1000

800

600

250

10 9 8 7

200

3000 140

2000

100

150

6000 5000 4000

200

300

1500

400

100

SUS/ 210°F

600

300

SUS/ 100°F 10,000

800

500

SAYBOLT VISCOSITIES

100

85W

80W

500 400 300

60 55 50

50 6 46 1 Lubricant function in gear reducers 200 75W 40 In all speed reducers or gear drives, friction is 45 32 150 5 30 created between internal moving components. VISCOSITIES CAN BE 22 The primary function of the lubricant is to RELATED HORIZONTALLY 40 100 20 4 ONLY. minimize the friction caused by the sliding and VISCOSITIES BASED ON 15 80 96 VI SINGLE GRADE rolling action of the gears and bearings and to 70 OILS. 10 ISO ARE SPECIFIED AT 60 10 dissipate heat by providing a thin layer of oil 40°C. 8 AGMA ARE SPECIFIED AT between moving components. With a typical 7 50 40°C. 6 SAE 75W, 80W, AND 85W thickness of just 0.00005 of an inch, this layer of SPECIFIED AT LOW 5 5 TEMPERATURE. EQUIVALENT oil, known as elastohydrodynamic (EHD) film, 40 4 VISCOSITIES FOR 100°F separates the mating surfaces of components, AND 200°F ARE SHOWN. 3 SAE 90 TO 250 SPECIFIED 3 preventing metal-to-metal contact and mini35 AT 100°C. mizing wear. If the EHD film is insufficient for 2 2 32 the transmitted load, metal-to-metal contact of the mating surfaces occurs and causes pitting of gear teeth. No EHD film—or an insufficient By ISO grading standards, the viscosity range of a lubricant is usually amount of it—can also cause scuffing of the gear narrower than that found in the SAE grading system. teeth and leads to bearing and gear failure. The most important properties to consider standards, is usually narrower than that used by SAE. As when choosing the correct lubricant for a gear reducer are shown in the “Oil Viscosity Equivalency” chart above, viscosity, viscosity index and pour point. the viscosity of SAE 90 gear oil overlaps the ISO 150 and ■ Viscosity, a lubricant’s ability to resist free flowing when the ISO 220 viscosity grades and partially overlaps the subjected to a force, helps determine the thickness of the ISO 320 viscosity grade. oil film throughout the expected operating temperature. This resistance to free flowing is what produces the elas■ Viscosity index (VI) indicates the ability of the lubritohydrodynamic film between the moving components. cant to resist viscosity change as the temperature of The International Standards Organization (ISO) viscosity the lubricant changes. The higher the VI, the wider classification system and the Society of Automotive the operating temperature range of the oil while still Engineers (SAE) grading system specify the viscosities of being able to maintain its rated viscosity. Synthetic industrial lubricants. The ISO and SAE viscosity of a given lubricants have a much higher VI than mineral-based lubricant is measured at both 40 C (100 F) and 100 C products and can be used in very cold or very hot (210 F). The viscosity range of a lubricant, by ISO grading ambient conditions.

JANUARY/FEBRUARY 2012

www.LMTinfo.com | 17

GEARED FOR SUCCESS

Changing out a lubricant too frequently is a waste of time and resources. Not changing it out as needed can lead to premature reducer failure or worse. ■ Pour point is the lowest temperature at which a lubricant will pour. Temperatures lower than the pour point will cause the lubricant to solidify. For proper lubrication, the pour point of a lubricant should be 10-15 degrees F lower than the coldest expected ambient temperature. The lubricant chosen for a specific application should have an ISO viscosity suitable for the ambient temperature in which the reducer is expected to operate. The lubricant must be able to maintain the EHD film when subjected to the forces created by the application. Insufficient viscosity will cause metal-to-metal contact and premature wear— and even possible catastrophic failure. As the operating loads on a gear reducer increases, the reducer operating temperature and required viscosity increases. Gear reducer maintenance The correct amount of oil must be maintained in a gear reducer to ensure long and satisfactory performance. If the reducer operates with an insufficient amount of oil, premature gear or bearing failure can occur due to oil starvation. Overfilling the reducer, however, will create excessive churning that leads to excessive air entrapment. If this occurs, overheating will most likely result due to the reduced ability of the air and oil mixture to dissipate heat. To get the most accurate reading, the oil level should be checked with the reducer not operating and after the reducer has had sufficient time to cool. On new applications, the reducer should be operated under normal loads for approximately two weeks. During this “breakin” period, fine particles of metal will be removed from the mating surfaces of the internal components and gears. After the two-week break-in period, the oil should be drained and the reducer flushed to remove all metal particles. The drain plug must also be cleaned prior to re-installation. To reduce cost and waste, the break-in oil can be filtered and re-used in the reducer. The reducer oil level should always be maintained to the proper level as indicated by the manufacturer. Considering oil life As a gear reducer operates, the lubricant begins to break down and oxidize. This process, along with the starting and stopping of the reducer, causes sludge and varnish deposits to form along with acids. The acids can attack yellow metals such as bronze gears or bearing cages. Sludge formation prevents effective lubrication and interferes with the elastohydrodynamic oil film and can cause metal-to-metal contact between moving components. 18 |

LUBRICATION MANAGEMENT & TECHNOLOGY

That’s why gear reducers—like any other types of mechanical equipment—should have a preventive maintenance (PM) schedule for changing the lubricant. The schedule is dependant on the local conditions in which the speed reducer operates and the type of oil selected. The lubricant should be changed every 2500 hours under normal operating conditions. In extremely harsh environments, the lubricant must be changed more frequently. In helical or spur-gear speed reducers, the operating hours between oil changes can be extended with the use of synthetic lubricants. Typically, when extremely cold or hot ambient conditions exist, a synthetic should be selected. An added benefit of synthetic oil is that it tends to reduce the overall operating temperature of the reducer. For worm-type speed reducers, PAGs are very effective in reducing sliding friction and extending the operating hours before a lubricant change is required. Extreme pressure (EP) additives—such as graphite or sulfur-phosphorus—are highly effective in reducing friction. These types of lubricants, however, generally should not be used with internal backstops or brakes that rely on friction to operate correctly. The manufacturer of the speed reducer should be contacted if there’s any doubt about the suitability of EP lubricants. In addition to decreased lubricant life, excessive operating temperatures can lead to increased lubricant contamination. The surface temperature of a heavily loaded speed reducer can exceed 200 F degrees. Once the reducer is shut off, it starts to cool, and condensation begins to form on the inside of the gear case. Over time, depending on ambient conditions, the amount of water forming on the inside of the gear reducer housing can be substantial. This type of contamination can lead to bearing and gearing failure. The condensation displaces the lubricant and results in an insufficient oil film between mating components. Depending on the severity of the water contamination, the frequency of servicing the lubricant may need to be as short as 250 hours. Proper selection of desiccant filters and breathers will help minimize condensation damage. Gear reducers operating under heavily loaded conditions at slow speeds will generate high operating temperatures. This high operating temperature decreases the useful life of the lubricant and results in more frequent lube changes. This is true for both mineral-based and synthetic lubricants. In fact, the useful life of a typical mineral-based product at 200 F can be as short as 2000 hours. JANUARY/FEBRUARY 2012

Bottom lines Selecting the proper lubricant and maintaining and implementing a good oil sampling and analysis program will help to determine the proper servicing intervals of your gear reducers. Changing out a lubricant more frequently than necessary will result in wasted resources and drive up maintenance cost. Not changing the oil when needed, however, will lead to premature reducer damage and possible catastrophic failure. Keep in mind that the proper selection of a lubricant and establishment of a routine PM program will result in less equipment downtime and higher productivity. LMT

                                                                         

 m

Don Miller is Customer Order Engineering Manager for Baldor’s Dodge Mechanical Gear products. Email: dbmiller@baldor.com.

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

California - Illinois - Connecticut - Canada e-mail: support@miller-stephenson.com www.miller-stephenson.com m For more info, enter 66 at www.LMTfreeinfo.com

Repurposing Industry Byproducts And Waste

Repurposed Materials, Inc. Denver, CO

JANUARY/FEBRUARY 2012

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SPONSORED INFORMATION

epurposed Materials, Inc., is looking for byproducts and waste from industry that would be candidates for “repurposing.” This company defines “repurposing” as the use of assets that have value “as is” for a second, unrelated application. If an end-user organization can find a second life for an unneeded asset, it can create great opportunities no matter the corporate objective (i.e., investment recovery, landfill diversion, etc.). While traditional recycling involves re-manufacturing processes, mass participation and significant energy, repurposing gives used products new lives without changing them. This not only adds life to the materials by keeping them out of the waste stream, it also provides sustainable products that do the job at a fraction of the cost. If Repurposed Materials determines there’s a repurpose market for an asset(s), it negotiates the transfer of the item(s) for eventual re-sale. Examples include turning used rubber roofing membrane into pond liners; turning old Tyvek super sacks into sandbags for levees; turning retired wine barrels into trash cans; turning worn heavy-duty equipment tires into stock tanks; and turning scrap conveyor belting into truck bed liners and anti-fatigue mats, among other things.

Gadgets

Green

Next Issue:

Efficient Gadgets

They’ll be showcased regularly in our pages over the course of the year. Watch for them. These sections are designed to put a big spotlight on all types of products to help you do your jobs better. Lots better.

N T GREIE IEN C EFFLIABLE RE NOTE TO ADVERTISERS:

Got a Gadget to Spotlight? Call Your Sales Rep Today, Or Contact Kathy Jaros 847.382.8100 x 117 kjaros@atpnetwork.com

www.LMTinfo.com | 19

DELIVERING THE GOODS

The Anatomy Of A Centralized Lubrication System

Single-Point Lubricator Technology These workhorses (aka SPLs) may not be right for every application, but they have a rightful place in every plant’s lube-management program. Ken Bannister Contributing Editor

nyone who has visited the engine room of an old steam ship or watched an old steam engine run will have seen a beautiful brass and glass chamber full of oil sitting directly atop each major bearing point. These pioneering single-point automatic lubricating devices were elegantly simple—the majority of them operated by cracking open a tapered valve to a determined point to allow oil to flow by gravity onto a transfer wick or brush in contact with the bearing surface.

In 1872, while working as an oiler for the Michigan Central railroad, Elijah McCoy changed the lube game considerably when he invented the world’s first automatically pressurized (non-gravity activated) lubricator that used steam from the engine to activate and force-feed lubricant from the device to the bearing surface. So successful was McCoy’s patented device that the railroad companies shunned all other designs in favor of it, coining the phrase by wanting only “the real McCoy!” Incorporating a similar design, grease can also be successfully dispensed using gravity and the aid of a spring-tensioned follower plate inserted in the lubricant chamber. Grease is filled from the bottom of the reservoir via a nipple that allows grease to hydraulically push against the follower plate and spring to load the chamber. Once loaded, the grease is expelled by the spring-loaded chamber pushing the grease against the hydraulic back pressure set up by the bearing 20 | LUBRICATION MANAGEMENT & TEChNOLOGy

clearance. The bigger the bearing, the bigger the clearance— and the more grease expelled into the bearing area. Although expressly designed as a one-bearing, one-point system, the gravity lubricator could be (and often was) coupled to a single-inlet, multiple-outlet manifold to lubricate multiple points simultaneously, albeit in a nonmetered manner. As a testament to their design, these early Single-Point Lubricators (SPLs) are still available for sale, with many original lubricators still in use today largely due to their simplicity, quality of manufacture and ability to be refilled easily by the user (see Fig. 1). Their successors are in a different league, however. Today’s models are sophisticated units that use chemical, electro-chemical and electro-mechanical pumps controlled by built-in electronics to move oil and grease at pressures great enough to use progressive-styled metered divider-block delivery systems. JANUARY/FEBRUARY 2012

DELIVERING THE GOODS

a pulsed electrical current is sent through a contained electrolyte causing an electro-chemical reaction. This reaction creates an inert nitrogen gas to form inside a hermetically sealed bellow that pushes against the oil or grease charge contained in the lube reservoir section of the unit. Unlike the chemical-activated style, the discharge on this unit can be controlled or turned off completely by the circuit-board selector switches. Like its chemical-activated cousin, this is also a single-use disposable unit, as the bellows cannot be collapsed. Modern modified variations of this design now allow for a refillable reservoir with only the power unit and bellows requiring replacement when exhausted. Offered in many reservoir sizes, the most popular size continues to be the 4oz (120ml) unit.

Fig. 1. Filling a late-1800s single-point lubricating device with oil. The unit is still in use today. (Courtesy Engtech Industries, Inc.)

How the System Works Chemical-activated SPLs… One of the earliest innovators of the modern styled SPLs was the German company Perma, which developed an inexpensive disposable chemical-activated design in the early 1960s. This simple unit uses a chemical reaction to develop a gas contained within a sealed expandable bellows unit. The maintainer activates the unit by releasing a fixed chemical charge pellet into the bellows that is forced to react with an electrolyte to produce an expandable gas. As the gas slowly expands within the bellows, it pushes the lubricant out of the unit into the bearing area. Different chemical charge amounts are used to vary the dispensing time from days to months, depending on the bearing’s needs. With a 4oz (120ml) reservoir, this style of unit—in its current updated version—continues to be one of the most popular SPL units for the dispensing of grease. Electro-chemical-activated SPLs… Almost 20 years later, in the early 1980s, we saw the first electronic-controllable SPL from ATS Electrolube. Using an electro-chemical reactor cell, the user activates the unit via a series of time-selector switches connected to a batteryoperated electronic circuit board (see Fig. 2). Once activated, JANUARY/FEBRUARY 2012

Fig. 2. Time-selector switches on an electro-chemical type of SPL (Courtesy Engtech Industries, Inc.)

Electro-mechanical-activated SPLs… One major drawback of the two previously described designs is their inability to deliver controlled lubrication to multiple points. The original gravity lubricators had but a single point of control and residual line pressure; the chemical and electro-chemical lubricators only developed between 50 and 60 psi. The latest generation of SPLs addresses these issues with a battery-operated rotary mechanism driving a positive displacement pump that delivers output pressures from 350 psi to 900 psi—more than enough to move a small, multiple-outlet series-progressive divider valve built into or piped remotely to the pump. www.LMTinfo.com | 21

DELIVERING THE GOODS

Unlike previous designs, the core units on the latest models are reusable with refreshed lubricant and batteries. Still very affordable, these new-style devices offer a viable centralized-lubrication-system alternative to the bigger systems with which they now compete. Pros & Cons The early gravity units were developed to relieve the continuous attention required from the lubricator, whose job was to check the units’ reservoir levels and fill them as needed while the bearings reaped the benefit of continued lubrication in small amounts. The advent of automated units allowed out-of-sight bearings—such as those found on overhead cranes or roof-top units—to receive continued lubrication for weeks or months, again relieving the burden on the lubricator whose role changed to checking and marking the lubricator reservoir and performing a unit change-out when required. For no capital outlay, these low-cost units have extended the life of many bearings over the years. Because individual units are inexpensive and convenient, many maintenance departments fall into the trap of using them on every bearing with a grease nipple. Performance notwithstanding, widespread indiscriminate use can get very expensive, very quickly. Their use should be monitored against the cost of implementing the more expensive electro-mechanical SPL with hard-piped-divider delivery systems, or one of the more robust standard types of centralized systems that can

Because viscosity measurement should be simple � Simple to Use: Graphical Touch Screen � Rapid Automated Analysis: ~3 min. � Reliable: Only 2 Moving Parts � Small Sample Volume <1 mL � Range: 10 to 700 mm2/s at 40 or 100°C

Watch a video of the new SimpleVIS at www.cannoninstrument.com 2139 High Tech Road • State College • PA • 16803 814-353-8000 • 800-676-6232 Fax 814-353-8007

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22 | LUBRICATION MANAGEMENT & technology

deliver lubricant to hundreds of points simultaneously. Tips for Use n Tip #1: Disposal of “disposable” units and cores must follow all applicable guidelines for hazardous waste (chemicals and batteries). n Tip #2: When using chemical- and electro-chemical-activated units, users should understand that both styles rely on atmospheric back-pressure to control the flow from the lubricator. An OEM’s recommended settings are fine for units used below 1000 feet elevation. Above 1000 feet, the settings change approximately 5% for every 1000 feet. As air thins at higher elevations, the back pressure is reduced and these units flow at a faster rate— which can mean over-lubrication of the bearing and an empty reservoir sooner than you anticipated! Know your elevation and refer to the OEM’s charts for the appropriate settings. n Tip #3: Working in northern climates means hot summer weather and cold winter weather that will affect lubricant viscosity in all styles of SPLs. Using a #2 grade grease on a cold day in an outside location (e.g., rooftop and fan units), will stall the device and starve the bearing of its lubrication. Enter a seasonal PM in the CMMS to change out #2 grease units to #1 or #0 grease units in the late fall, and a second seasonal PM to change back to #2 grease units in the spring. n Tip #4: Always prime the lines with fresh lubricant to the bearing on any new installation before screwing the lubricator in place. n Tip #5: All SPL units require switching on and priming to the outlet point prior to installation to ensure continuity of lubricant to the bearing. This may mean switching on the unit JANUARY/FEBRUARY 2012

DELIVERING THE GOODS

Coming Up The next article in this delivery-systems series will focus on Pump-to-Point designs. Look for it in the March/April issue. LMT For more info, enter 06 at www.LMTfreeinfo.com

Keeping contamination under control.®

Education is only one part of the Transformation Fig. 3. An electro-chemical lubricator with “Date in Service” clearly indicated (Courtesy Engtech Industries, Inc.)

12-24 hours prior to its scheduled use. Check the OEM’s recommendations for correct startup of these devices. n Tip #6: It’s important to always clearly mark the date of installation on the SPL in large visible letters (see Fig. 3). Startup dates allow a maintainer to check actual delivery time versus setting time and adjust accordingly. n Tip #7: At each PM check of the SPL, mark the reservoir level to ensure the unit has actually delivered lubricant since the last check. Staying Power Single-Point Lubricator technology is an example of a very real (and long) industrial success story. SPLs are here to stay—not for every application, of course, but as a valuable tool in every plant’s lubrication-management program. JANUARY/FEBRUARY 2012

Des-Case’s Lubrication Transformation training and services are designed to help companies develop world-class lubrication practices in as little as 12 months. TM

Visit www.descase.com or call 615-672-8800 to learn about a variety of on-demand education options, including ICML certification.

sales@descase.com • (615) 672-8800 • www.descase.com For more info, enter 68 at www.LMTfreeinfo.com

www.LMTinfo.com | 23

LUBRICATION BASICS

Ensuring successful plant-wide lube programs...

Get It Right: Respect The 5Rs

Refreshing yourself

anufacturers looking to save money in a grueling economy can profit from the following advice: If you want to boost the bottom line, turn to your plant’s lubrication program. Opportunities almost certainly exist that will cut your grease and oil disposal costs, improve rotating-equipment productivity, modernize lube replenishment practices and increase the likelihood that operating machines are safeguarded from costly lube-related downtime.

and your team on the “RIGHTS” of lubrication can help prevent plenty of lubrication “WRONGS” around your operations. Jane Alexander, Editor with Paul Michalicka SKF USA Inc.

This is especially true for small and mid-size manufacturers of everything from metals to chemicals to food. The latest technologies, such as lubrication planning software and high-capacity automatic lubricators, enable smaller manufacturing plants to launch lubrication programs. Such programs were previously limited to larger operations for costrelated reasons.

24 | LUBRICATION MANAGEMENT & TECHNOLOGY

JANUARY/FEBRUARY 2012

LUBRICATION BASICS

Employing a plant-wide strategy For most plants, a comprehensive lube strategy works best. The approach gives maintenance and lubrication managers an overview of all plant activities and allows them to readily identify and capitalize on cost-saving opportunities. It fosters communication between different departments and among workers on different shifts, and encourages employees to work collaboratively rather than at crosspurposes. A plant-wide program can also promote changes in ingrained attitudes, habits and practices that often lead to costly inefficiencies. Plant-wide lube programs maximize a site’s lubricating effectiveness and cut costs. They usually incorporate: lubricant selection, point identification and mapping, proper re-lubrication practices, tool selection, lubricant analysis, staff training and continuous-improvement goals. Typically, the most effective programs are based on the “5Rs” concept. As most readers know, this emphasizes supplying the RIGHT lubricant to the RIGHT points in the RIGHT quantity, and doing so at the RIGHT time using the RIGHT method. 1.The RIGHT lubrication points… When starting or expanding a lubrication program, the first step is to identify all lubrication points in your plant. This includes machine points on all critical, secondary and backup machinery. The task is made easier with the latest lubrication software programs, which are available from lubricant and rotatingequipment technology providers. These software programs manage plant lubrication activities, replacing paper lists and basic spreadsheets. One newly introduced lubricant-planning program, for example, documents the lubrication history and status of all machine points, extending to location, lubricant type, quantity and re-lube intervals. Its capabilities include importing previous maintenance or lubrication actions and incorporating them into revised routines. JANUARY/FEBRUARY 2012

Lubricant planners manage plant lubrication activities, document the status of lube points and generate task lists for employees. (Photo courtesy of SKF USA Inc.)

The program generates daily lubrication task lists for maintenance personnel and can produce lists based on machine criticality, lubricant type or other criteria. Tools required for each lubrication task

are also displayed. The program tracks the performed tasks and saves the last 500 records for each activity in its database. The completed tasks can be archived for future reference. www.LMTinfo.com | 25

LUBRICATION BASICS

2. The RIGHT lubricant… After identifying lubrication points, it’s a good time to review your lubricant choices. Over 80% of rotating equipment applications are lubricated with grease, and many plants—especially smaller facilities—traditionally use a single all-purpose grease for a variety of applications. Although acceptable in some cases, this practice can waste grease and harm productivity in others. Demanding applications often require specialized lubricants to optimize performance. Machines that experience high temperatures or high pressures, for example, normally call for greases that are specially formulated to meet these operational requirements. Compared with general-purpose greases, specially formulated varieties can often prolong relubrication intervals and dramatically reduce overall grease consumption. One way to avoid lubricant mix-ups is to use fitting caps with labels that identify the correct lubricant and refill quantity for each machine point. Fitting caps also protect machine points from external sources of contamination. 3. The RIGHT quantity… Comprehensive lubrication programs facilitate the delivery of correct lubricant amounts to each lubrication point. Both under- and over-lubrication have harmful effects and should be avoided. Under-lubrication can cause metal-to-metal contact between rotating components, resulting in premature bearing and machine failure. Over-lubrication leads to lubricant churning, increasing operating temperatures and damaging lubricant viscosity. The result is a decline in operating efficiency. At the macro level, over-lubrication can waste lubricant and increase lubricant-related expenses. For every dollar of lubricant purchased, plants spend three dollars in lube disposal costs. Plant-wide programs can track and control lubricant usage and reduce disposal costs. For plants that manually re-lubricate, grease meters can help prevent over- or under-greasing by accurately measuring refill amounts. Most grease meters can be connected either to electrically driven or hand-operated grease guns. 4. The RIGHT method… Manufacturing plants have a choice of manual or automatic lubrication. Often, the best solution is a combination of manual and automatic lubrication, depending on application type and location. Automatic dispensing technologies, such as singlepoint lubricators (like those discussed in Ken Bannister’s “Delivering the Goods” feature on page 20 of this issue), find use in hard-to-access or dangerous locations, or where a large number of lubrication points make manual lubrication less feasible. 26 | LUBRICATION MANAGEMENT & TECHNOLOGY

In a recent case, a food manufacturer in the Midwest totaled annual savings of $332,800 by switching from manual to automatic lubrication. The company installed single-point lubricators on a number of food-processing production lines. The lubricators are equipped with canisters that hold up to 250 milliliters of grease. The electromechanically driven units supply a steady, regulated flow of grease directly to machine points. In a 12-month period, the facility was able to eliminate 62,400 manual re-lubrication events, each requiring about 10 minutes of labor. The plant’s labor costs were then reduced by $208,000 annually. In addition, because automatic lubricators gauge lubricant flow precisely, the plant reduced its lubricant consumption by $124,800/yr. Machine repairs also declined due to the lubricators’ effectiveness. Higher-capacity, multi-point lubricators have been introduced for heavy-duty applications where single-point lubricators would be ineffective. These include hot-gas fans and calendar rolls in paper mills, conveyor systems and some cement, farming and forestry applications. One such system distributes grease or oil to separate lubrication points via as many as eight feed lines. The lines measure up to 16’ in length. The lubricator’s outlets can supply from 0.1 to 10 cubic centimeters of lubricant per day to machine points. 5. The RIGHT time… According to lubrication studies, the best practice is to lubricate frequently in small quantities, rather than less often using a large amount of lubricant. This practice results in optimal machine performance. Plant-wide lubrication programs, supported by planning software, help maintenance personnel adhere to correct practices regarding re-lube intervals. Lubrication software can prompt maintenance personnel to re-lubricate when necessary. Single- and multi-point automatic lubricators can also effectively supply a steady flow of lubricant according to a preset schedule. Don’t forget lubricant analysis Periodic lubricant analysis can help provide consistent lubricant quality. During operation, lubricants deteriorate over time due to contamination, heat, contact with process fluids or other factors. New, inexpensive testing technologies allow maintenance technicians to test samples of used lubricant on the factory floor and make an assessment of lubricant quality. Problem samples can be flagged and sent out for expert analysis. LMT Paul Michalicka, SKF’s North American Area Sales Manager for Maintenance Products, is based in Lansdale, PA. Telephone: (416) 299-2894; email: Paul.Michalicka@skf.com. For more info, enter 07 at www.LMTfreeinfo.com JANUARY/FEBRUARY 2012

BOOSTING YOUR BOTTOM LINE

Make Repair A Priority And Achieve Savings

ince the electrical cost to operate a motor over its lifetime is many times greater than its original purchase price, even a small decrease in motor efficiency can cause a significant increase in operating costs. The first step to avoid unnecessary operating costs is to establish efficiency as a priority in your purchasing, maintenance and repair decisions. When it comes to rewinding motors, work with your motor service provider to ensure best-practice repairs are done following the ANSI/EASA AR 100 standard1 that defines the process to rewind motors to preserve efficiency. Record this repair policy and other repair-replace, maintenance and purchase considerations in a motor management plan. Take a look at two success stories on how prioritizing motor repair and planning can lead to cost savings. Repair Specifications Save Money and Energy—Kennewick Wastewater Treatment Plant When faced with the threat of rising energy prices and possible brownouts, the Kennewick Wastewater Treatment Plant took action to increase efficiency plant-wide. After developing a motor inventory and identifying opportunities to make cost-effective equipment upgrades, the operations also established a motor-repair spec with detailed best-practice procedures to be followed in rewinding eight motors, ranging in size from 40 hp to 150 hp. It’s estimated this repair specification alone generated approximately $4500 in annual cost savings, totaling an estimated $25,000 over the motor life.2 Weyerhaeuser Saves $2.5 Million by Developing Motor Plan Weyerhaeuser, one of North America’s largest forest product companies, runs 57,000 motors in its plants across the U.S. and Canada. It had become clear that increasing motor efficiency and planning for repair-replace decisions was key in optimizing production and reliability. A cross-functional

JANUARY/FEBRUARY 2012

team of engineers was formed to investigate opportunities to lower motor operating costs. The team identified best-practice motor rewinds as an important strategy and developed a specification that standardized repair across all operational motors. Focusing on motor repair and management strategies ultimately produced $2.5 million in savings.3 Making best-practice repair specifications a priority has a demonstrated ability to generate cost savings. Get started today by checking out the following helpful resources: ANSI/EASA AR 100 (www.easa.com/energy) available through the Electrical Apparatus Service Association (EASA), defines recommended practices for the repair of rotating electrical equipment. MDM Motor Planning Kit (www.motors matter.org/tools/mpk.html) is a free booklet that provides a comprehensive overview of motor management. It describes how to pursue a variety of plans ranging from generic purchasing policies to total motor inventory. LMT 1. ANSI/EASA AR 100 Recommended Practice for the Repair of Rotating Electrical Apparatus, 2010, www.easa.com/energy 2. Repair Specifications Save Money and Energy— Kennewick Wastewater Treatment Plant, 2001, www.motorsmatter.org/case_studies/Kennewick.pdf 3. Weyerhaeuser, Weyerhaeuser Saves $2.5 Million by Developing Motor Plan, 2002, www.motorsmatter.org/case_studies/Weyer.pdf For more info, enter 69 at www.LMTfreeinfo.com

The Motor Decisions Matter (MDM) campaign is managed by the Consortium for Energy Efficiency (CEE), a North American nonprofit organization that promotes energysaving products, equipment and technologies. For further information, contact MDM staff at mdminfo@cee1.org or (617) 589-3949.

www.LMTinfo.com | 27

PROBLEM SOLVERS

Packaged Oil-Skimming Systems

banaki’s Discrete Security Oil Skimmer Groundwater Remediation Packages are for use where there’s a need to keep the skimmer from being tampered with or in applications where the operation of oil-removal equipment may be deemed unsightly. These lockable poly-shelters are available in two sizes to accommodate various oil skimmers and option configurations. A 30- or 55-gal. drum can be used for oil collection depending on the size of enclosure. The systems incorporate endless belts in 1”, 2” or 4” widths that fit in 2”, 4” and 6” or larger diameter well casings. Abanaki Corp. Cleveland, OH For more info, enter 30 at www.LMTfreeinfo.com

Microbial-Resistant Machining Coolant

ustlick Ultracut 380R from ITW Rocol is a semi-synthetic, microbial-resistant coolant suited for a range of machining and grinding applications. According to the company, it provides long-lasting performance without additives. The coolant contains no DCHA (dicyclohexamine), chlorine, boron, phenol, nitrites, triazines, sulfur, copper or SARA 313-reportable chemistry. Available in 5- or 55-gallon containers, the product is recommended for ferrous & nonferrous metals, aluminum, titanium, brass, bronze, copper and other high-nickel alloys. ITW Rocol North America Glenview, IL

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

Hydraulic Oil For Injection Molding Equipment

lüber Lubrication’s Klüberfood 4 NH1-46 is the only NSF H1-registered, fully synthetic hydraulic oil approved for use on Husky injection molding equipment. According to Klüber, the oil can reduce contaminant build-up and valve blockages, resulting in longer oil-change intervals and lower operating costs. It also provides good oxidation stability and overall stability from -40 to 135 C. Husky has approved the oil’s use on all generations of its machines. Klüber Lubrication Londonderry, NH For more info, enter 32 at www.LMTfreeinfo.com

28 | LUBRICATION MANAGEMENT & TECHNOLOGY

JANUARY/FEBRUARY 2012

PROBLEM SOLVERS

Comfortable, Disposable Respirators

enkel’s Loctite® Nordbak® 7255TM is a two-part, sprayable ceramic coating designed to protect metal surfaces on industrial equipment from wear, abrasion and corrosion. Packaged in a reusable dual-cartridge dispenser, it may be quickly and evenly applied to large surfaces and complex or intricate areas. The coating features a solvent-free, thixotropic formulation and is suited for use on tank linings, mixing vessels, pump housings, impellers, chutes, troughs and centrifuge components.

agid Glove & Safety’s Precision Safety® Disposable IR1970P95 Respirators are designed to filter at least 95% of airborne particles, protect against certain oil and non-oil based particles and provide nuisance relief from acid gas and organic vapors. According to Magid, these NIOSH 42 CFR-approved products can standardize on one filtering face mask what may have previously taken three separate respirators. Comfort-enhancing features include adjustable nosepieces and full face seals.

Henkel Corp. Rocky Hill, CT

Magid Glove & Safety Mfg. Co. LLC Chicago, IL

Sprayable Ceramic Coating

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

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

7-Step Best Practice Lubrication Program Professional Self-Directed Implementation ToolKit

Tap into your Liquid Gold for less than $20 per day!* Whether you’re looking to increase asset utilization and maintainability, reduce contamination, downtime, energy consumption and/or your carbon footprint, or simply cut your maintenance and operating costs, you’re ready for a 7-Step Best Practice lubrication program! For more information on this “expert in a box” approach to successful lubrication programs, contact ENGTECH Industries at 519.469.9173 or email info@engtechindustries.com * Amortized over one year

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

JANUARY/FEBRUARY 2012

www.LMTinfo.com | 29

Index ADVERTISER

JANUARY/FEBRUARY 2012 Volume 13, No. 1 •

WEBSITE

CIRCLE #

PAGE #

ATP Lists ....................................................www.atplists.com ............................. 71................... 30 Baldor Electric Company.........................www.baldor.com .............................. 73................... 32 Cannon Instruments ................................www.cannoninstrument.com ........ 67................... 22 CIM ............................................................www.cim.org/edmonton2012 ........ 64..................... 9 Des-Case Corporation .............................www.descase.com ............................ 68................... 23 Engtech Industries Inc..............................www.engtechindustries.com........... 70................... 29 IAVA............................................................IAVA.org............................................ 63..................... 7 MARTS ......................................................www.martsconference.com ............ 62,72 ..........5,31 Miller-Stephenson Chemical Co. ............www.miller-stephenson.com.......... 66................... 19 NSK Corporation .....................................www.nskamericas.com.................... 61..................... 2 U.S. Tsubaki Power Transmission, LLC ..www.LongLifeLambda.com ........... 65................... 13

Access LMTfreeinfo.com and enter the circle number of the product in which you are interested, or you can search even deeper and link directly to the advertiser’s Website. Submissions Policy: Lubrication Management &Technology gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish, and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned.

ATP List Services

ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS

1300 South Grove Avenue, Suite 105 Barrington, IL 60010 PH 847-382-8100 FX 847-304-8603

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SALES STAFF OH, KY, TN 135 N. Rocky River Road Berea, OH 44017 440-463-0907; Fax 440-891-1254 JOHN DAVIS jdavis@atpnetwork.com AL, DC, DE, FL, GA, MD, MS, NC, NJ, PA, SC, VA, WV 1750 Holmes Drive West Chester, PA 19382 610-793-3093; Fax 610-793-3094 JIM HANLEY jhanley@atpnetwork.com IA, MN, NE, ND, SD 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 847-382-8100 x116; Fax 847-304-8603 BILL KIESEL bkiesel@atpnetwork.com CT, ME, MA, NH, NY, RI, VT, ON, QC P.O. Box 1059 Osterville, MA 02655 508-428-3331; Fax 508-428-2545 VINCENT LeGENDRE vlegendre@atpnetwork.com IL, IN, MI, WI 1173 S. Summit Street Barrington, IL 60010 847-382-8100 x108; Fax 847-304-8603 TOM MADDING tmadding@atpnetwork.com AR, KS, LA, MO, NM, OK, TX 5930 Royal Lane, Suite E #201 Dallas, TX 75230 972-816-6745; Fax 972-767-4442 GERRY MAYER gmayer@atpnetwork.com

www.atplists.com Contact: Ellen Sandkam 847-382-8100 x110 800-223-3423 x110 info@atplists.com esandkam@atplists.com 1300 S. Grove Ave., Suite 105, Barrington, IL 60010 For more info, enter 71 at www.LMTfreeinfo.com

30 |

LUBRICATION MANAGEMENT AND TECHNOLOGY

AZ, CA, CO, ID, MT, NV, OR, UT, WA, WY, AB, BC, MB, SK 3605 N. Tuscany Mesa, AZ 85207 480-396-9585 JERRY PRESTON jpreston@atpnetwork.com CLASSIFIED ADVERTISING 3605 N. Tuscany Mesa, AZ 85207 480-396-9585 JERRY PRESTON jpreston@atpnetwork.com

JANUARY/FEBRUARY 2012

Reliability: Own It This MARCH... Save The Date For Keynote Address Tues. March 13, 2012:

MAINTENANCE and RELIABILITY TECHNOLOGY SUMMIT

Managing the Trends

The Capacity Assurance Conference!

MARCH 12-15, 2012

David Boulay, president, Illinois Manufacturing Extension Center

Conference Selections: Optimizing Pump-System Performance: The Link Between Energy Efficiency and Improved Reliability Roland McKinney, SKF Service Division

The Top 5 Best Maintenance Practices of World-Class Companies Enrique Mora, Mora International Consulting Services

Maintenance and Reliability Assessment: Is World Class Right For Your Facility? Dave Rosenthal, Jacobs Engineering

How a Community College Partnership Can Address the Skills Shortage Mark Combs, Parkland College

Leveraging PAS 55 to Optimize Asset Utilization and Increase Productivity

• 5 full-day Workshops on Monday, March 12 • 5 full-day Workshops on Thursday, March 15 • Two professional certification opportunities

Kris Goly, Siemens Asset Performance Management Services

Workshop Selections:

Energy and Sustainability Management

Eric Huston and members of SKF Service Division

From TPM to TPR: Move to the Next Level of Maintenance and Process Reliability

Enrique Mora, Mora International Consulting Services

Cause Mapping I: Effective Root Cause Analysis Mark Galley, ThinkReliability

Maintenance Planning and Scheduling: Increase Your Workforce Without Hiring R. D. (Doc) Palmer, Richard Palmer & Assoc.

Motor System Management

Howard W. Penrose, Dreisilker Electric Motors, Inc.

Other Workshop Presenters: Mike Gilley, Fox River Systems Dave Krings, Consultant Jim Seffrin, Infraspection Institute Ed Stanek, LAI Reliability Systems Bob Williamson, Strategic Work Systems

For complete schedule and registration information, please go to

www.MARTSconference.com The Capacity Assurance Conference! MAINTENANCE and RELIABILITY TECHNOLOGY SUMMIT

Hyatt Regency O’Hare, Rosemont (Chicago), IL For more info, enter 72 at www.LMTfreeinfo.com

For decades, ABB variable speed drives and Baldor motors have set the standard for quality, reliability and energy savings. Now, industrial customers in the U.S. can buy these products and receive expert support from a single source. Call 479-646-4711 to locate the district office nearest you. Two trusted names. One local source for sales and support. Only from ABB and Baldor. baldor.com

• Local Sales & Support • Energy Efficiency • Industrial Motors & Drives • Unmatched Customer Service

Scan with your smartphone to watch a motor and drive energy efficiency video or go to http://bit.ly/mSM0JV.

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