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JANUARY/FEBRUARY 2013 • VOL 14, NO. 1 • www.LMTinfo.com
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
WHAT WORKS FOR OTHERS CAN WORK FOR YOU 10
Building On Real-World Success This year, we explore lubrication trends, techniques and benefits using the scale of proven success. Ray Thibault, Contributing Editor
UTILITIES MANAGER ■ Big Money Talks William C. “Bill” Livoti
■ Efﬁciency Showcase
ICML CERTIFICATION SERIES 18
Industrial Lubrication Fundamentals: Friction Certification matters. The more certified lube professionals there are, the stronger the “voice” of lubrication will be throughout industry. Ken Bannister, Contributing Editor
SUPPLY CHAIN LINKS 22
Haas Automation: Turning Out 30 Years Of Innovation And Success A lot goes into being on the cutting edge of something. Here’s how a leading machine-tool manufacturer got there and stays there.
DEPARTMENTS 4 6 8 9 26 30
Publisher’s Notes My Take From Our Perspective Motor Decisions Matter Problem Solvers Supplier Index
Jane Alexander, Editor
The Maintenance & Reliability Technology Summit is: An annual, four-day educational experience and professional-development opportunity Created for plant and facility managers, maintenance leaders and crew members, reliability engineers, industrial technicians and all other capacity-assurance professionals Composed of two days of Conferences (60-minute sessions) and two days of Workshops (full-day sessions) presented by industry experts. Scheduled for April 30-May 3, 2013 at the Hyatt Regency O’Hare, Rosemont, IL.
For more information, visit www.MARTSConference.com today! JANUARY/FEBRUARY 2013
Achieving Efﬁciencies Through Practices & Products Apply for a free, one-year subscription at
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Bill Kiesel, Publisher
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
January/February 2013 • Volume 14, No. 1 ARTHUR L. RICE President/CEO email@example.com
What We Need
e begin 2013 with a number of challenges and opportunities. On one hand, some of the strongest headwinds we face are associated with government indecision (the debt ceiling, sequestration and wrangling over too many regulations vs. too few, for example). On the other hand, most of us are looking forward to what onshoring/ reshoring trends and improving economic conditions could hold for our businesses and communities. From my perspective, one of our biggest challenges (and something we’ve covered extensively) involves the changing workforce—and the thousands of industrial jobs going unfilled across our underemployed nation. For whatever reason, the message that the manufacturing and process sectors offer great opportunities and career benefits seems to have been lost on much of our society. This sad fact was reinforced for me on Christmas Day, in a New York Times article by Jack Healy. Entitled “Pay In Oil Fields Is Luring Youths In Montana,”* the article’s premise is that the state’s teenagers are selling themselves short by jumping off the college track to pursue good-paying trades and support-related jobs. It suggests that working “construction and repairing machinery,” or “first [seeking] training as welders or mechanics” are not worthy goals. To sum it up, being an apprentice, as the author puts it, “alongside men old enough to be their fathers,” is a risky choice for young people hoping to ensure meaningful futures. I agree that higher education is important. But then, all education is important, be it via universities, trade schools, apprenticeships or—if we’re really lucky—getting to work alongside our fathers, mothers and others of their generation. Improving our industrial base is among the most noble of pursuits. If enough of our children heed that call, we all could be enjoying better lives (with fewer lawyers, fewer bankers, fewer indecisive politicians…). We need more proud, skilled men and women keeping our energy sources flowing, our power grid working, our water-treatment facilities functioning, our transportation systems running and our plants humming safely, cleanly, efficiently, reliably and profitably. LMT firstname.lastname@example.org
Best Wishes for a Happy & Prosperous 2013!
*http://www.nytimes.com/2012/12/26/us/26 For more info, enter 63 at www.LMTfreeinfo.com montana.html?pagewanted=1&_r=0
LUBRICATION MANAGEMENT & TECHNOLOGY
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KENNETH E. BANNISTER RAY THIBAULT, CLS, OMA I & II Contributing Editors
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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 except Mar/Apr by Applied Technology Publications, Inc., 1300 S. Grove Avenue, Suite 105, Barrington, IL 60010. Periodical postage paid at Barrington, IL and additional 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 2013. 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: firstname.lastname@example.org. 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.
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Jane Alexander, Editor-In-Chief
Go Ahead And Try It: A Little More Tenderness
he last Friday of 2012 found me listening to the Afternoon Shift, a program produced by Chicago’s WBEZ Public Radio station. In his wonderful voice, the host Rick Kogan was discussing New Year’s resolutions and how people tend to make them. Needing all the help I could get along those lines, I turned up the volume. The truth is that I’m a horrible resolution maker. Most of mine don’t stick, including those perennial pledges to “Get Skinny” and “Get Rich.” (Alas, I like to eat and shop just a little too much, and most of my associates will tell you that I’ve never met a casino I don’t like.) But back to the Afternoon Shift… Kogan detailed how he had gone about selecting his own 2013 resolutions and referenced several outside sources he used for inspiration. One of those ideas grabbed my attention: “Try,” as Otis Redding advised in the old Jimmy Campbell and Reg Connelly song, “a little tenderness.” Bingo! I had my resolution! I may never achieve my desired weight or bank balance, but I’m confident I can be nice (or nicer) to everyone in my life—from a personal, as well as a professional standpoint. Interestingly, many people don’t realize how empowering the right kind of tenderness can be for those on the receiving end, even when it’s extended in the workplace. I do. Several years ago, I sat in a room surrounded by a number of successful publishing executives who were vigorously interviewing me for a magazine job—a position for which I admittedly had neither training nor experience. In retrospect, I still don’t know how I got to that interview. Recently divorced after 25 years of marriage, my life was in shreds. I’d been floating from one dead-end job to another for the past two years, and my self-esteem (all of it) was long gone. Having convinced myself that I didn’t have the slightest shot at being hired as an editor, I was eager to creep out of the building and start my long, dismal drive home. Just as the session appeared to be wrapping up, however, one of the men in the room stepped forward to say he had a final question for me (according to him, “the most important question of all”): “What’s your favorite Elvis song?” All I could think of was “Love Me Tender.” It must have struck a chord with my interviewers. I later learned it was their policy to ask the same “most important” question of every applicant they grilled, but nobody had ever answered it the way I did. Long story short, I got the job. Furthermore, during the years I worked for the company, I was treated with a great deal of tenderness (i.e., nurtured, supported and respected). That, in turn, helped me grow professionally and eventually led me here. Perhaps it’s just my way of paying it forward: In 2013, I resolve to call on my better angels more regularly than last year, and to ensure that the “T-word” is a bigger influence in my life. I encourage you to give it a try as well. With all the bad, sad, mean-spirited things our country has seen of late, and all the ugly words we’ve been hearing, more than a little tenderness is certainly in order. LMT email@example.com Here’s Wishing Everyone An Awesome 2013!
lubrication management & technology
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Come Help Us Celebrate Our 10th Anniversary
As Always, You’ll Find Just What You Need: Training Networking Solutions Program Details & Registration Information Will Be Announced Soon
Plan Now To Attend MARTS 2013 The Hyatt Regency O’Hare Hotel, Rosemont, IL.
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FROM OUR PERSPECTIVE
Ken Bannister, Contributing Editor
Making A List And Checking it Twice
ver the holidays, I was one of the thousands upon thousands of passengers who boarded planes on the busiest air-travel day of the year and flew across the country or globe to visit family and friends. It takes a hectic day like that to truly appreciate how much we (both as travelers and maintenance professionals), as well as other industries, owe the aviation industry—and how well the airlines’ systems and processes work when stressed to the max. Despite my personal lack of control over the situation, my plane departed on time, flew smoothly and arrived safely at the right destination. Moreover, even my luggage showed up exactly when and where it should have! In life, there are often times when we must relinquish control. Such is the case when I must fly to a client’s site or event. Unlike Tom Cruise or John Travolta, who own personal jet aircraft and are licensed to pilot themselves around the world, I need to rely on commercial aircraft and pilots. To reduce my risk as much as possible, I put myself in the hands of reputable organizations and people, and choose carriers based not on their ticket prices, but their safety records. Thanks largely to the efforts of F. Stanley Nowlan and Howard H. Heap, travelling by air these days is much safer than in decades past. In the 1960s, Nowlan and Heap headed an industry group to develop a maintenance methodology that could reduce airline accident rates while increasing (and sustaining) the reliability of ever-more complex future-generation aircraft. The result, based on a simple seven-question process, was MSG-1—or what we now refer to as Reliability Centered Maintenance (RCM). This methodology has been responsible for greatly increasing equipment reliability across all industries, while simultaneously simplifying levels of maintainability. Going back even further in history, to those “magnificent flying machines” of World War I, we also can credit aviation with the advent of true
LUBRICATION MANAGEMENT & TECHNOLOGY
scheduled maintenance: That was introduction of 30-, 60-, 90- and 120-hour airframe checklists for combat aircraft along with staggered scheduling— providing planes lasted that long in combat!
Other industries, along with maintenance and reliability pros everywhere, have plenty to thank the aviation industry for: Aviation helped birth RCM and pioneered the use of checklists. In his recent book, The Checklist Manifesto: How to Get Things Right, Dr. Atul Gawande describes the first military test flight of the B17 bomber in the 1930s. Ending in a crash due to a simple pilot oversight, this flight led to the aviation industry pioneering operational and maintenance checklists. As head of the World Health Organization’s Safe Surgery Saves Lives program, Dr. Gawande adapted the aircraft checklist and credits use of this simple, innovative tool for a dramatic reduction in hospital and surgical deaths, regardless of hospital conditions. Designed correctly, a checklist can overcome both ignorance and ineptitude. Such a tool can be particularly effective in the field of lubrication where, so often, the wrong lubricant can be placed in the wrong place, in the wrong amount. . . For more on the effective use of checklists, be sure to read the March 2013 installment of my Maintenance Technology magazine column “Don’t Procrastinate…Innnovate.” In the meantime, I wish all readers a very happy and prosperous 2013! LMT firstname.lastname@example.org
BOOSTING YOUR BOTTOM LINE
Tools To ‘Drive’ Your Motor Energy Savings
oday’s marketplace is full of voices promoting adjustable speed drives (ASDs) with competing claims of savings and benefits. What’s all this discussion about? An ASD controls the speed of an induction motor by adjusting the voltage and frequency that supply the motor. Afﬁnity laws—which show that change in power consumption is proportional to the cube of the change in speed—illustrate energy-savings potential through the use of adjustable speed technology. What you may not have heard, however, is that in addition to saving energy, ASDs can improve operational processes and reduce motor maintenance costs. Is ASD Technology Right for You? Adjustable speed drives can be very useful in applications with variable torque loads like centrifugal pumps, fans and blowers, as well as in HVAC and compressed air systems. However, ASDs are not a plug-in solution. In some cases, such as constant-power or constant-speed applications and high-static-pressure pumps, ASDs will NOT save energy. How can you ﬁnd out if ASDs will be a boon to your facility budget? Motor Decisions MatterSM (MDM) has you covered. On the MDM Website (www.motorsmatter.org), you’ll ﬁnd an entire section focused on this topic. Two resources, in particular, can help you assess whether ASDs are appropriate for your operations and also help you develop a preliminary estimate of your energy savings and payback to identify and screen potential projects. Get Answers to Your Questions The National Electrical Manufacturers Association (NEMA) Application Guide for AC Adjustable Speed Drive Systems is the first resource you should review. Key selection and application factors include the motor, drive type, electrical supply, mechanical insulation and controls. The Guide also includes important safety and
| MAINTENANCE TECHNOLOGY JANUARY/FEBRUARY 2013 32
operational considerations that help you make a smart decision.
What you may not have heard is that ASDs can also improve operational processes and reduce motor maintenance costs. Second, to help assess the economics of this investment, you’ll need to estimate how much energy can be saved—and what the payback period will be. The Bonneville Power Administration (BPA) developed an ASD Calculator to help you estimate the installed cost of an adjustable speed drive, including materials and labor, energy savings and simple payback for installations on fans and pumps. Users have the option of selecting from specific fan and pump types or providing measured power (kW) entries for application types not included in the calculator. Developed for the Department of Energy (DOE), the BPA ASD Calculator is an excellent tool. With these resources, you’ll be in a better, more informed position to talk with an expert such as a utility account rep, motor distributor or your local service center about installing a drive. LMT For more info, enter 04 at www.LMTfreeinfo.com
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 email@example.com or (617) 589-3949.
|9 www.LMTinfo.com OCTOBER 2007
WHAT WORKS FOR OTHERS...
Building on Real-World Success
This year, we explore lubrication trends, techniques and benefits using the scale of proven success.
ver the past eight years, I’ve written articles on lubrication principles, best lubrication practices, oil analysis, the importance of cleanliness to equipment reliability and how to develop a world-class lubrication program. This year, I’ll cover many of these topics, but from a real-world standpoint. Here’s a summary of what you’ll see: Ray Thibault CLS, OMA I, OMA II, MLT, MLT II, MLA II, MLA III Contributing Editor
10 | LUBRICATION MANAGEMENT & TECHNOLOGY
...CAN WORK FOR YOU
PART I: Developing a World-Class Lubrication Program A large chemical plant in the Southwest that lacked an organized lubrication program experienced many failures due to poor lubrication practices. A decision was made to hire an outside company to investigate the company’s practices and implement a world-class lubrication program. A lubrication engineer with program experience at a major oil refinery was placed in the plant full-time to evaluate and develop the new program. This was five years ago. Since then, major reliability gains have resulted from dramatic improvements in the lubrication program. In this and any world-class program, at least some of the following criteria must be met:
involving various synthetic types will be investigated to demonstrate real-world cost benefits. Major benefits for synthetics are shown here in Fig. 1.
■ Right attitude ■ Lubricant champion ■ Updated lube survey
Energy Savings Wear
■ Proper scheduling & record keeping
Fig. 1. The major benefits of synthetics
■ Consolidation ■ Hiring of competent personnel
While the justification for synthetics typically has been associated with energy savings, as the following points make clear, that’s just part of their appeal:
■ Temperature Extremes. . . Because synthetics contain no
■ Use of correct lubricants ■ Minimizing lubricant contamination
wax, many can be used in very low-temperature conditions. Because of their purity and molecular structure, many are also stable at very high temperatures, and will often greatly exceed the high-temperature stability of mineral oils.
■ Utilizing an oil-analysis program for condition
monitoring ■ Continuous updating and improvement of the
lubricant program Each of these criteria will be examined before and after the chemical company’s world-class program was implemented. Also covered will be the results achieved with the new program and future improvements to be implemented. PART II: Using Synthetics for Energy Savings and More Properly used, synthetic lubricants can result in significant benefits that far outweigh their cost. Several case histories
■ Wear. . . Synthetics’ uniform molecular structures result
in higher film strengths and enhanced lubricity, causing less metal-to-metal contact between lubricated surfaces, which leads to less wear. ■ Energy Savings. . . Synthetics’ uniform molecular struc-
tures also reduce internal fluid friction between metal surfaces, lowering energy requirements. This is particularly evident with gears where a high level of sliding between the metal surfaces occurs. The common synthetics we will investigate are detailed in Table I (page 12).
www.LMTinfo.com | 11
WHAT WORKS FOR OTHERS...
PART III: Oil Analysis Improves Mine-Equipment Reliability Oil analysis is one of the most power-ful tools you can use for achieving condition-monitoring objectives and enhancing equipment reliability. For example, a comprehensive oil-analysis program implemented at a major mine in the western U.S. generated substantial cost savings and reliability improvements. A case history on this mine will discuss the program from development through implementation, and the benefits it produced, based on the careful documentation of its 40,000 annual samples.
Table I. The Most Common Synthetics Synthetic Type Applications Polyalphaoleﬁ ns Synthetic Type Applications Most versatile, with many applications Low-temperature bearings Polyalphalefins Most versatile, with many applications Enclosed gear boxes, non-ﬂooded rotary Low-temperature bearing screw compressors and high-temperature Enclosed gear boxes, ooded rotary screw bearingsnon-fl in fans, blowers, pumps and compressors and high-temperature bearings in fans, motors. blowers, pumpsOil andmist motors. Oil mist Automotive Automotive Diesters Reciprocating compressors, highDiesters Reciprocating compressors, high-temperature temperature bearings and oil mist bearings and oil mist Polyol Esters High-temperature aero-derivative gas turbines Polyol Esters High-temperature aero-derivative gas turbines Rotary screw air compressors Rotary screw air compressors Fire-resistant and biodegradable hydraulic Fire-resistant and bio-degradable hydraulic fluids ﬂuids Polyalkylene Glycols Hydrocarbon-flooded screw compressors Polyalkylene Glycols Hydrocarbon-ﬂ ooded screw compressors Enclosed gear boxes Enclosed gear boxes Rotary screw airRotary compressors screw air compressors
The objectives of this program were to. . .
■ Develop a sampling strategy ■ Select the appropriate oil-analysis tests, based on
equipment type ■ Improve asset reliability ■ Select and allocate personnel for the program, along ■ Identify and eliminate repetitive problems ■ Reduce unscheduled maintenance
with a program coordinator ■ Work closely with the oil-analysis laboratory to improve
program and meet objectives ■ Maximize use of lubricants in service ■ Train personnel to use internal and external resources ■ Reduce maintenance and lubrication costs ■ Track and document cost benefits ■ Achieve fault-free component life extension ■ Practice continuous improvement by adapting to ■ Utilize proactive maintenance, flanked by
predictive maintenance technology ■ Achieve condition-based maintenance
The following steps were identified to properly implement the program. . . ■ Select an oil-analysis laboratory to help achieve
objectives ■ Develop criteria for equipment to be sampled;
prepare an equipment list 12 | LUBRICATION MANAGEMENT & TECHNOLOGY
changing conditions and requirements PART IV: Improved Oil Cleanliness Boosts Pump Reliability A growing number of companies recognize the importance of oil cleanliness to equipment reliability. An estimated 70% of equipment failures in circulated fluid systems are caused by particulate contamination. Abrasive wear, caused by clearance-size particles between metal surfaces, accounts for more than 66% of total wear. Therefore, controlling particulate contamination through exclusion and filtration will result in enhanced equipment reliability. Table II illustrates the benefits of clean oil on the life of rolling element bearings. JANUARY/FEBRUARY 2013
...CAN WORK FOR YOU
Table II. The Benefits of Clean Oil on the Life of Rolling Element Bearings (Source: Eaton Corp.)
Current ISO Code
Target ISO Code 2x Life
Target ISO Code 3x Life
Target ISO Code 4x Life
Target ISO Code 5x Life
28/26/23 27/25/22 26/24/21 25/23/20 25/22/19 23/21/18 22/20/17 21/19/16 20/18/15 19/17/14 18/16/13 17/15/12 16/14/11 15/13/10
25/22/19 23/21/18 22/20/17 21/19/16 20/18/15 19/17/14 18/16/13 17/15/12 16/14/11 15/13/10 14/12/9 13/11/8 13/11/8 13/11/8
22/20/17 21/19/16 20/18/15 19/17/14 18/16/13 17/15/12 16/14/11 15/13/10 14/12/9 13/11/8 -
20/18/15 19/17/14 19/17/14 17/15/12 16/14/11 15/13/10 15/13/10 13/11/8 -
19/17/14 18/16/13 17/15/12 16/14/11 15/13/10 14/12/9 13/11/8 -
How to read Table II… Fluid cleanliness is designated by a three-number code per ISO 4406. This code is expressed as all particles ≥ 4µ[c], ≥ 6µ[c], and ≥ 14µ[c]. The numbers are obtained from the chart in Table III (page 14): For example, consider a fluid where the particles per milliliter of fluid were measured as follows:
Dramatically extends equipment life!
≥ 4µ[c] 7500 particles ≥ 6µ[c] 850 particles ≥ 14µ[c] 95 particles In the above example, fluid cleanliness is expressed as 20/17/14, which comes by first determining the range number that expresses the number of particles per milliliter. In this case, 7500 particles were found at the range number of 20 where the range is 5000 to 10,000 particles. Note that for every increase in range number, the number of particles can double. Thus, even a moderate increase in range number can result in a large introduction of particles. JANUARY/FEBRUARY 2013
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WHAT WORKS FOR OTHERS...
Table III. ISO 4406 Chart
Range Number 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6
Number of particles per ml More Than Up To and Including 80000 160000 40000 80000 20000 40000 10000 20000 5000 10000 2500 5000 1300 2500 640 1300 320 640 160 320 80 160 40 80 20 40 10 20 5 10 2.5 5 1.3 2.5 0.64 1.3 0.32 0.64
As can be seen by referring back to Table II, improving the cleanliness of lubricating rolling element bearings can result in a dramatic increase in rolling element life. For example, starting with a 22/20/17 fluid and cleaning it to a 16/14/11 fluid can result in a tripling of the rolling-element bearing life. These tables are available for many types of equipment components. In Part IV, we’ll meet a specialty metals producer in the Northwest that was lubricating vacuum pumps with 23/20/14 oil and experiencing high failure rates. After realizing that cleaning the oil could reduce failures, the producer enlisted the help of a filter manufacturer to create a filtration program that improved oil cleanliness to 18/17/15. This resulted in a 70% reduction in pump failures and more than $350,000 per year in pump-rebuild savings. This case history will discuss the steps taken to improve fluid cleanliness and the economic impact on the operation, as well as future steps that will further optimize pump reliability. PART V: The Benefits of Training and Certification Lubricator training is not only a crucial element of any effort to improve job performance, it can—and should— lead to professional certification for lubrication proficiency. Two major organizations provide competency testing that 14 | LUBRICATION MANAGEMENT & TECHNOLOGY
Some of the best ways to make the case for sound lubrication programs are success stories about others. There are many of them. can lead to certifications: the International Council for Machinery Lubrication (ICML) and the Society of Tribologists and Lubrication Engineers (STLE). Following are the certifications they offer: ■ ICML—Machinery Lubrication Technician Levels I and
II; Machinery Lubrication Analyst Levels I, II, & III; and Laboratory Lubricant Analyst levels I and II ■ STLE—Certified Lubrication Specialist; Oil-Monitoring
Analyst Levels I and II; and Certified Metalworking Specialist Certification is a hallmark of two major groups of users… The first group includes the lubrication technicians and engineers in manufacturing plants. Certifications most popular with these professionals are Machinery Lubrication Technician Level I and Certified Lubrication Specialist. Certification is also important to lubricant sales and marketing personnel. Becoming STLE-certified gives this group an edge over the competition because lubricant purchasers want to deal with technically competent sales engineers. A recent industry salary survey, for example, revealed that salespeople who were Certified Lubrication Specialists averaged $20,000 per year more than uncertified salespeople. They also had greater management opportunities. Part V of this series will focus on several lubrication professionals and the benefits they reaped after obtaining certification. Coming up Look for the first installment of this series, “Building A WorldClass Lubrication Program,” in the March/April issue. 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) 250-0279. Email: email@example.com. For more info, enter 01 at www.LMTfreeinfo.com JANUARY/FEBRUARY 2013
BIG MONEY TALKS XX UM UM William C. “Bill” Livoti
Power Generation 2013
012 was quite a year for change in the power industry. What can we expect in 2013? The keynote speakers at Power-Gen advised the attendees to expect changes, but what will they look like? Here’s a brief run-down: ■ Industry executives (decision-makers) expect an
increase in combined-cycle natural-gas power generation. Capacity factors for these plants will also increase. ■ Coal-fired power generation is expected to decrease
from a high of 52% to around 35% by the year 2030. ■ Nuclear power will retain 21% of the generating
capacity in the US with a couple of new plants under construction after a 30-year hiatus. In spite of the negative press, nuclear power continues to develop new technology. There is quite a bit of interest in small modular reactor (SMR) technology, for which benefits include faster licensing and lower cost. ■ Renewable energy is expected to provide 24% of
power generation worldwide by 2035. It appears wind-generation tax credits have been extended for another year. This extension will cover all wind projects that begin construction in 2013. Had the tax credits been extended earlier in 2012, wind generation could have seen 8 Gigawatts of new construction in 2013. Unfortunately, the delay in extending the credits means only 8000 to 8500 MW will reach the construction stage this year. ■ Solar photovoltaic is growing in leaps and bounds
as the cost per KWH continues to drop. Photovoltaic will also play a major role in distributed generation as increasing numbers of homeowners and businesses install the technology. ■ Geothermal, biomass and tidal and wave tech-
nology will also play a role. How large that role may be remains to be seen, as a majority of funding is being focused on solar and wind development.
The long view of coal What’s to become of our coal-fired power plants? The technology has an uphill battle to fight in dealing with special interest groups, EPA (Clean Air and Clean Water Act) and fly ash issues. Few utilities are willing to take the risk of investing billions in new coal-fired generation without clear, defined regulations from our government. A number of large utilities have targeted older coal plants for decommissioning over the next few years, which will result in reduced capacity. However, due to the downturn in our economy and successful implementation of state, local and federal energyefficiency programs, power demand has decreased, minimizing the impact of reduced generation.
While coal technology has an uphill battle to fight with special interest groups, the EPA and fly ash issues, it should remain a power-gen staple for the foreseeable future, just with a smaller piece of the pie. The changing landscape In a nutshell, we will see more combined-cycle natural-gas-fired power plants with a mix of wind and solar. Coal will remain a staple for the foreseeable future, albeit with a smaller piece of the pie. Is this a good mix? I’m not so sure; remember the 1990s and the big push for natural gas? At least we have alternatives. UM Bill Livoti is Power-Generation Business Development Manager for WEG Electric Corp. and Electric Machinery Co., Inc. For more info, enter 261 at www.MT-freeinfo.com
VOLUME 82 / NO. 12
UTILITIES MANAGER | 15 19
UM EFFICIENCY SHOWCASE
Packing Solution Reduces Flush Rates
hesterton’s SuperSet has been specifically designed to increase packing and equipment service life while dramatically reducing flush rates. It combines the sealing capabilities of the company’s Mechanical Packing products (including enhanced performance, sealibility, leak prevention, chemical compatibility, strength, toughness and thermal characteristics) with the patented design of the EnviroSeal SpiralTrac™ Version P Environmental Controller for Packed Stuffing Boxes. The SpiralTrac Version P enhances the utilization of the flow and centrifugal effects around the shaft by performing like a centrifugal separator. The built-in tangential lantern ring and helical grooving system impart motion to the flush, and the resulting centrifugal force throws the particulates in the fluid to the outside of the bushing. The SpiralTrac grooving system then hydrodynamically pumps the solids to the bottom of the stuffing box and back into the pump casing. A.W. Chesterton Co. Woburn, MA
For more info, enter 262 at www.MT-freeinfo.com
AODD Accessories Boost Pump Efficiency
arren Rupp’s SANDPIPER brand has launched a new, improved line of Air Filter/Regulators and Lubricators for air-operated double-diaphragm (AODD) pumps. Features include a liquidfilled pressure gauge, as well as accessories such as lockout valves and mounting bracket kits. These point-of-use Air Filter/Regulators have been specifically developed to reduce maintenance and lower operating costs. The addition of a Filter/Regulator will help prevent dirty, wet and contaminated compressed air from decreasing the performance of an AODD unit, and SANDPIPER recommends the use of these items with all of their pumps. Although the company’s AODD pumping equipment is designed to operate without lubrication, in applications with poor-quality air supplies or where nitrogen runs the pump, lubrication of the compressed air is required. For these situations, SANPIPER offers a full-line of Lubricators that easily connect to its Filter/Regulators. Warren Rupp, Inc. A Unit of IDEX Corp. Mansfield, OH
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Next-Generation, Eco-Friendly PAGs
ubriplate®’s PGO & PGO-FGL Series products are 100% polyalkylene glycol (PAG) fluids for gearboxes, bearings and chains operating in the most demanding conditions. They provide outstanding thermal stability, excellent extreme-pressure and anti-wear performance, protection against micropitting and exceed 13 stages of the FZG test. With their extremely low coefficient of friction, fluids in this series have been shown to reduce worm-gear energy use up to 7%. Free of zinc and other additives that could be undesirable in environmentally sensitive areas, they offer long service life and work well over extended fluid-change intervals, which conserves resources and helps ease waste-oil disposal problems. They’re available by the gallon, as well as in 5-gal. pails and 55-gal. drums. Lubriplate® Lubricants Newark, NJ 16 | UTILITIES MANAGER
For more info, enter 264 at www.MT-freeinfo.com VOLUME 8 / NO. 1
Synthetic Improves Equipment Efficiency
oyal Purple’s SYNFILM® GT is recommended for use in gas and steam turbines, blowers and vacuum pumps, bearings, gears, air tools, etc. It should be considered instead of SYNFILM® in applications where oil reservoir temperatures exceed 200 F, improved low-temperature fluidity is desired or when a viscosity grade is unavailable. Formulated with a superior blend of synthetic base oils plus Royal Purple’s proprietary SYNERLEC® additive technology that’s been proven to make equipment run smoother, cooler, quieter, longer and more efficiently, Synfilm GT rapidly and completely separates from water and has a very low-temperature fluidity. According to the company, the product offers excellent protection against rust and corrosion and is extremely oxidation-stable, which leads to long oil life and extended oil-drain intervals. It typically replaces conventional, low-film-strength R & O (rust and oxidation inhibited) oils that rely solely on their viscosity to protect equipment against wear. Royal Purple Porter, TX
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Analyze Power And Quantify Energy Losses
ccording to Fluke, its 430 Series II Three-Phase Power Quality and Energy Analyzers not only offer exceptional power-quality analysis capabilities, they introduce, for the first time, the ability to monetarily quantify energy losses. The models in the Series II (the 434, 435 and 437) help locate, predict, prevent and troubleshoot powerquality problems in three-phase and single-phase power-distribution systems. Incorporating what the company calls revolutionary functions, they can help a facility reduce electrical-power consumption and improve the performance and lifespan of its electro-mechanical equipment. Capabilities include: ◆ Frontline troubleshooting: Quickly diagnose problems on-screen. ◆ Energy loss management: Measure and quantify causes of energy losses to enable simple ROI, calculation of harmonics and unbalance mitigation. ◆ Power inverter efficiency: Simultaneously measure AC input and DC out-put for power electronics systems. ◆ Dynamic load testing: Capture instantaneous values to see the effect of load switch on generators and UPS systems. ◆ Capture fast RMS data: Show halfcycle and waveforms to characterize electrical system dynamics. ◆ Predictive maintenance: Detect and prevent power-quality issues before they cause downtime. ◆ Quality of service compliance: Validate incoming power quality at the service entrance. ◆ Long-term analysis: Uncover hard-to-find or intermittent issues. ◆ Load studies: Verify electrical system capacity before adding loads. Fluke Corp. Everette, WA For more info, enter 266 at www.MT-freeinfo.com VOLUME 8 / NO. 1
UTILITIES MANAGER | 17
ICML CERTIFICATION SERIES
Domain of Knowledge Element #1
Industrial Lubrication Fundamentals: Certiﬁcation matters. The more certiﬁed lube professionals there are, the stronger the ‘voice’ of lubrication will be throughout industry.
Ken Bannister Contributing Editor
he topic of lubrication can be easily divided into two specific areas, 1) the science and chemistry of lubricating materials, and 2) the practical application of lubrication knowledge and materials to effectively reduce the friction, wear and energy loss of moving parts. LMT’s mandate is to inform its readers, from those who are highly experienced to those who are less so, not just about what’s new in the world of lubrication, but about the basic concepts and principles that guide GLP (Good Lubrication Practices). These fundamentals—or “Elements”—are what make up the International Council of Machinery Lubrication (ICML) Domain of Knowledge. They’re also the focus of a new 12-part series that kicks off in this issue.
18 | LUBRICATION MANAGEMENT & TEChNOLOGy
ICML CERTIFICATION SERIES
Keep in mind that the articles in this series aren’t meant to replace requisite formal preparatory training. The goal is to introduce (or refresh readers on) the fundamental knowledge requirements for working in a best-practice lubrication environment, spur them to pursue a certification path (if they haven’t already) and give the lubrication community a stronger voice in the world of asset reliability. Friction is why we lubricate The word “tribology,” coined by Sir H. Peter Jost (see Sidebar below), comes from the Greek word tribos, meaning “to rub,” and is used to describe what happens when two hard surfaces move over one another. The resistive force causing this “rubbing” action is known as friction, and was first recognized by Sir Isaac Newton in his laws of motion as an external force to motion. Webster’s describes friction as “the force, which opposes the movement of one surface sliding or rolling over another with which it is in contact.” Simply put, friction is the resistive force that retards motion. And it’s not necessarily a bad force: We employ frictional forces when we want to intentionally
slow a body in motion (i.e., retarding the movement of a rotating machine or automobile by applying a rough and soft consumable braking material with a high coefficient of friction against a smooth, hard [less-consumable] surface). Friction becomes an undesirable force when it robs energy from an applied force used to intentionally move an object. Frictional forces have, in fact, been estimated to consume over one-third of the world’s energy. When ignored in such cases, friction causes heat, wear and, sometimes, catastrophic failure of the moving body. To understand friction we must recognize that there are two unchanging fundamental laws that govern it: n Friction varies directly with load. n Friction is independent of surface area.
Figure 1 depicts the forces at play on two bodies at rest. To begin to move Body “A” across Body “B,” we must first overcome its resistive frictional force. This resistive force is a result of the load N representing the weight of the body Continued on next page
A Brief History of Lubrication Certification In the mid-1960s, a groundbreaking study by the British government (under the charge of Sir H. Peter Jost) quantified the tangible effects of poor lubrication practices on the nation's gross national product. That study, now referred to as the Jost Report, introduced us to the word “tribology” (the science of lubrication, friction and wear). For the first time, lubrication was recognized for its role as a bone fide science in the area of asset reliability, and for its fiscal impact on industry when practiced poorly. Once awakened, sleeping giants take time to stir and get moving. Unfortunately, it wasn’t until the turn of the new millennium that a heightened awareness surrounding the field of lubrication began to emerge on a global scale. This has been emphasized through industry’s rapidly growing recognition of—and demand for—certified lubrication specialists in the practical application and lubricant diagnostic/analysis fields. Although there are no specific apprenticed trade designations for lubrication specialists, over the past two decades many of the world’s leading lubrication experts and proponents (including scientists, engineers, consultants, suppliers and practitioners) have worked to develop certification programs backed by a body and domain of knowledge.
Today, there are three lubrication certifying bodies: STLE (Society of Tribologists and Lubrication Engineers); ICML (International Council of Machinery Lubrication); and ISO (International Organization for Standardization). Originally designed for engineers, the STLE Certified Lubrication Specialist (CLS) program has been in place since 1993. ICML has developed two certifications for “hands-on” lubrication practitioners: the MLT (Machine Lubrication Technician) and MLA (Machine Lubrication Analyst) designations. A relative newcomer, ISO’s lubrication certification program has chosen to adopt the ICML model and, in fact, has collaborated with the ICML to use its body of knowledge. Participants who attend the requisite preparatory formal training associated with ICML certification are also eligible to take corresponding ISO exams (upon payment of the appropriate examination fees). Of these three programs, ICML’s (currently offered in nine languages) has issued the most certifications around the world. For information on the ICML program, please visit: www.lubecouncil.org. For more info, enter 02 at www.LMTfreeinfo.com
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ICML CERTIFICATION SERIES
Applied Frictional Force
Normal Force (Weight) Fig. 1 Forces on bodies at rest (Source: Engtech Industries, Inc.)
multiplied by the coefficient of friction. For example, if the upper body represented a full steamer trunk resting on a concrete floor, using the formula F = uN we can calculate the initial (static) resistive force we need to overcome to start the trunk moving across the floor. Thus, if we assume the loaded trunk weighs 100 lbs., and the coefficient of friction of wood on dry concrete is 0.65, the applied force required to start the trunk moving would be 0.65 x 100 = 65 lbs. Once the trunk has begun to move, the static friction barrier has been broken and the force required keeping the trunk moving reduces somewhat as long as the body remains moving. The frictional force has changed from a static frictional load to a kinetic frictional load The Coefficient Of Friction (COF) (which is different for every material and fluid) is represented by the Greek letter mu (u). COF values range from almost 0 to well over 1, and the lower the value, the lower the resistance and retardation effect. Therefore whenever we want to produce work from moving parts, lower COF values are preferred because they require less energy expenditure to achieve movement—or work (i.e the motor requires less amperage draw, or the engine requires less fuel to achieve the desired work performance). Obviously, we would expend enormous amounts of energy to move things around if we were only to allow surface-tosurface contact on all moving parts. To reduce these forces and overcome the large static and kinetic forces we must introduce a fluid film to separate the two moving parts. The fluid film is referred to as the lubricant. The principle of reducing friction while supporting a moving sliding load is 20 | LUBRICATION MANAGEMENT & technology
referred to as lubrication. Lubricants or fluid films are not themselves “frictionless,” as they rely on an action known as “shearing,” depicted in Fig. 2, whereby fluid friction occurs between the molecular shear planes of the lubricant as they move across one another when the load moves. The following exercise demonstrates this point: First sweep your hand back and forth quickly on the surface of a table. Then place your hand atop a deck of cards on the table and move it back and forth. Compared to your hand's movement on the table, sweeping it back and forth over the deck of cards will be relatively effortless. That’s because the movement generates little or no heat as the cards “shear under the load” (slip over one another). Fluid friction is a similar phenomenon, in that it increases as viscosity becomes thicker or as a lubricant becomes dirty. Although a small amount of energy is required to overcome fluid friction, it’s negligible compared with having no fluid film present. When mechanical moving parts are present, the amount of lubrication required depends on the state of friction that manifests itself in three specific ways: n Sliding friction n Rolling friction n Combination friction (sliding and rolling)
Sliding friction is common where any plain surfaces move over one another (like in plain bearings where a journal moves within a sleeve). Sliding friction arrangements require the most lubricant, as the friction is evident over a larger surface contact area. JANUARY/FEBRUARY 2013
ICML CERTIFICATION SERIES
Coming up The next issue will cover ICML's Body (Domain) of Knowledge Element #2: “The Functions of a Lubricant.” LMT
MOVEMENT OF FORCE
Fig. 2. Magniﬁed cross-section of two bodies in motion separated by a ﬂuid ﬁlm (Source: Lubrication for Industry, by Ken Bannister, Industrial Press)
Rolling friction is found in all rolling element bearings that at one time were described as “frictionless” bearings. The contact surface is considerably smaller than in sliding friction bearings, and thereby requires much smaller amounts of lubrication to achieve a protective full-fluid film. Combination friction, on the other hand, is unique to meshing gears. This is due to the changing gear-tooth profile that requires the teeth to slide on one another until the opposing pitch surfaces meet and rolling friction takes over as they disengage. Certain types of gears, such as hypoid gears and worm gears, are capable of producing much higher degrees of sliding friction. Whenever moving parts are present, friction will be present— ever present, that is. Understanding friction helps us develop effective lubrication practices that, in turn, help us tame the harmful effects of friction and increase the life cycles of our equipment components. JANUARY/FEBRUARY 2013
Ken Bannister holds certiﬁcations as both a maintenance professional and a lubrication management professional. A Principal with ENGTECH Industries, Inc., he’s the author of the Machinery’s Handbook “Lubrication” chapters, as well as the best-selling Lubrication for Industry textbook recognized as part of the ICML and ISO Domain of Knowledge. Bannister also teaches numerous formal preparation courses for the ICML MLT/MLA program and ISO LCAT certiﬁcations. For information, including details on his ICML Pro Course at MARTS 2013 and the opportunity to take the ICML exam, telephone: (519) 469-9173; or email: firstname.lastname@example.org.
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
email@example.com •Forwww.cannoninstrument.com For more info, moreenter info, 71 enter at www.LMTfreeinfo.com 31 at www.LMTfreeinfo.com
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SUPPLY CHAIN LINKS Editor's note: This story originally appeared in the Sept. 2012 issue of Maintenance Technology.
Turning Out 30 Years Of Innovation And Success A lot goes into being on the cutting edge of something. Hereâ€™s how a leading machine-tool manufacturer got there and stays there. Jane Alexander Editor
ince its founding in 1983, Haas Automation, Inc., has grown into one of the largest machine-tool builders in the world, producing industry-leading products at consistently affordable prices. As it celebrates its 30th anniversary, this Oxnard, CA-based corporation's commitment to innovation and proactive equipment maintenance remain essential core values. To learn more about the company's recent accomplishments and the keys to its ongoing success, we caught up with Haas veteran, Thomas Velasquez, Manager, Rotary Products Engineering.
22 | LUBRICATION MANAGEMENT & TECHNOLOGY
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QUESTION: Haas Automation recently celebrated a major milestone with production of the 125,000th Haas CNC machine tool. Can you tell us more about that? Velasquez: It certainly was a big milestone. Since 1988, when we introduced the industryâ€™s first American-built vertical machining center (VMC) priced less than $50,000, our Haas VF-1 (like the unit shown in Fig. 1) has been the industry standard for affordable CNC technology. The 125,000th Haas CNC machine tool was a 2012 VF-1 vertical machining center (like the one shown in Fig. 2). This product is a perfect representation for how we have continued to enhance the performance of our machines over the years. Its many advanced features include the ability to operate at speeds as high as 8100 rpm standard, brushless servos on all axes, 1000-ipm rapids and a 20-tool ATC. So, that milestone was a great way for us to reflect on our history, legacy of innovation and commitment to delivering the best machines to our customers.
Fig. 1. The first Haas VF-1, still considered an industry standard for affordable CNC technology
Fig. 2. A Haas 2012 VF-1 vertical machining center
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SUPPLY CHAIN LINKS
QUESTION: Why do you think Haas Automation products remain so popular with customers? Velasquez: We cater to many industries, like aerospace, automotive, mining, appliances, electronics and, especially, the “Mom & Pop” shop. In the process, we’ve always focused on delivering innovative products that help our customers address the challenges they face on a daily basis. We never lose sight of the fact that, at the end of the day, our success stems from the performance of our machines. Frankly, our customers don’t have time to deal with maintenance issues and have their equipment be down, so we develop our products to be as durable and reliable as possible. We focus on manufacturing four major product lines: vertical machining centers (VMCs), horizontal machining centers (HMCs), CNC lathes and rotary tables, as well as a number of large five-axis and specialty machines. We make them easy to operate and maintain. We also ensure that our equipment has more standard features, high-tech innovations and rock-solid engineering than the many other CNC machines in the world. Moreover, the support we provide customers through our network of Haas Factory Outlets (HFOs) is another major advantage. Today we have more than 170 HFOs across more than 50 countries. Each one combines the convenience and security of a local dealer with the strengths of an international organization. Every HFO has complete showroom facilities, factorytrained service personnel, extensive spare-parts inventories and fully stocked service vehicles to provide the industry’s best service and support. Each HFO employee is dedicated to helping our customers succeed. This local approach is the best way to provide our customers with superior sales, service and applications assistance. QUESTION: How is the company the same since its founding three decades ago? Velasquez: The company’s approach to developing products and serving customers has remained exactly the same. Haas machine tools and rotary products are built to the specifications that (company founder) Gene Haas has set forth to ensure exceptional accuracy and durability. We produce all critical components for our machinery in-house, using dedicated state-of-the-art CNC machine tools—of which more than 70% are Haas machines. And, before leaving the plant, the typical Haas CNC machine is subjected to more than 300 quality-control tests. 24 | LUBRICATION MANAGEMENT & TECHNOLOGY
We always try to find new ways to do things better. To that end, we never overlook anything or dismiss something as “too minor.” We constantly challenge ourselves to keep improving—and we're constantly asking questions of ourselves. For example, can we find a new part to make our machines go faster and be more efficient? What kind of lubricants do we need to make our equipment as durable as possible? How can we make the operation of our machines even easier for our customers? We never stop asking questions and never stop looking for new and potentially better solutions. QUESTION: You mentioned lubricant selection. You have played a key role in the decision to factory-fill equipment with synthetic lubricants and to put them in the equipment used at the company’s production facilities. Can you tell us why? Velasquez: In the age-old equipment maintenance debate over conventional oils vs. synthetic oils, we are big proponents of synthetics. Today, we fill synthetic lubricants in much of the equipment that we sell and the equipment we use in our facilities. The move toward synthetics started nearly 18 years ago when, working with Gene Haas and other members of the engineering team, we sought to enhance the performance of our rotaries. We now factory-fill our rotaries, gearboxes and spindles, as well as some of our tool-changer gearboxes, with Mobil SHC™ 600 oils. Since we made the switch, we’ve seen gearbox life increase two-to-three times based on backlash measurements. We also use Mobil SHC synthetic greases (Mobilith SHC™ 007) in our linear guides and ball-screw grease systems, and we’ve recently switched to Mobil SHC 500 synthetic hydraulic oils for our hydraulic power units and rotary hydraulic brakes. For our customers, the performance that synthetics offer, as compared to conventional oils, can help deliver financial and operational benefits, like improved equipment performance and durability and longer oil drain intervals. The longer oil drain intervals you can obtain through the use of synthetics translates into less time that personnel need to spend on oil change-outs and less exposure to equipment, both of which are definite safety benefits. In addition, from an environmental-care perspective, using certain synthetics, like Mobil SHC 600, can help reduce oil consumption and minimize oil disposal costs. JANUARY/FEBRUARY 2013
SUPPLY CHAIN LINKS
Haas Automation builds roughly 60 CNC machines per day. All of its machines are manufactured in the company's 1-million-square-foot facility in Oxnard, California. QUESTION: As the company approaches its 30th anniversary, what do you think the future holds for Haas Automation? Velasquez: From a manufacturing standpoint, the trend toward faster, leaner and more efficient equipment will increase. I can also see that more equipment in the future will incorporate advanced diagnostic electronics like on-board maintenance alerts.
That said, we think the competition will evolve and become even more global than it is today. In addition, our customers will be challenged to find new ways to improve productivity and minimize their environmental impact. But as we have over the past 30 years, we remain very confident that Haas Automation will continue to thrive and be seen as an industry leader for high-quality machine tools at affordable prices. LMT For more info, enter 03 at www.LMTfreeinfo.com
For more info, enter 68 at www.LMTfreeinfo.com JANUARY/FEBRUARY 2013
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Lube System Overcomes A Variety Of Challenges
echno-Sommer’s Sharpshooter system addresses a number of lube challenges, including, among others, hard-to-reach lubrication points and the unacceptability of mist lubrication. Working off standard shop air at up to 90 psi, it can place a drop of lubricant at up to 1m away with pinpoint accuracy. A pressurized tank generates internal pressures up to 750 psi. When a pulse is generated, a fixed drop size is dispensed. Up to eight dispensing nozzles ranging in size from 5mm3 to 100mm3 can be attached to one tank.
Next-Generation, Extended-Life Contamination Control Products
Techno-Sommer New Hyde Park, NY For more info, enter 31 at www.LMTfreeinfo.com
ir Sentry® is a leading developer of contamination control products that keep particulate matter and excess moisture from the headspace inside vessels like gearboxes that hold lubricants, greases, hydraulic fluids and fuels. This extends the life of critical machinery and equipment, and significantly reduces lifecycle costs. The company’s innovative products have been the gold standard in contamination control since 1997. Its line includes nine series of desiccant breathers, anodized color-coded closed system adapter kits that prevent cross-contamination, manifold adapters and pressure-vacuum-indicating gauges. Air Sentry has recently introduced a revolutionary new line of desiccant breathers called Guardian™. These “next-generation” contamination control products are the first breathers constructed of Tritan™. This patented material provides the most chemical-, temperature- and impact-resistant casing on the market. Guardian also is the first desiccant breather to incorporate an isolation check valve that protects the adsorbent from exhaust air and volatile splashing fluids. This lengthens the desiccant’s service life and reduces replacement frequency. Learn more about how Guardian increases fluid life, improves lubrication and lowers maintenance costs by visiting www.airsentry.com/air-sentry-breathers/guardian.htm.
Air Sentry® A Division of Whitmore Rockwall, TX
For more info, enter 30 at www.LMTfreeinfo.com
26 | LUBRICATION MANAGEMENT & TECHNOLOGY
NSF H1-Registered Spray Lubricant
lüberpaste UH1 96-402 from Klüber Lubrication is a light-colored, high-temperature paste available as a spray. Designed for assembly purposes and the lubrication of screws at temperatures between 392 and 2192 F, it’s registered as NSF H1, making it suitable for food-processing and pharmaceutical use. The product adheres to metals and is water-resistant. Klüber Lubrication North America L.P. Londonderry, NH For more info, enter 32 at www.LMTfreeinfo.com JANUARY/FEBRUARY 2013
Multi-Point Lubrication Delivery System
il-Rite’s Hydracision multi-point lubrication system can distribute to as few as 12 or up to hundreds of separate points. It combines efficient hydraulic movement of fluid with the precision of positive displacement injection. The reservoir housing contains a gear pump motor which pressurizes the outlet for uniform fluid distribution. A PLC with programmable display allows selection of lube cycles, while a lowlevel switch prevents operation when oil supply is depleted. Oil-Rite Corp. Manitowoc, WI For more info, enter 34 at www.LMTfreeinfo.com
Compact And Easy-To-Clean CNC Oil Skimmer
banaki’s Mighty Mini® SST is intended for the removal of unwanted oil in coolants and parts washers. Capabilities include removal rates of up to two gallons of medium-weight oil per hour, depending on belt selection. An improved wiper blade system fits securely in the trough and allows for cleaning on both sides of the belt. Its lightweight and small footprint allow it to fit underneath most CNC machines. Abanaki Corp. Cleveland, OH For more info, enter 33 at www.LMTfreeinfo.com JANUARY/FEBRUARY 2013
“Visual systems, when applied to equipment, can reduce training time by 60 to 70% and eliminate errors.” —Robert Williamson, lean equipment specialist
Our Visual Supplies Can Improve Your Equipment’s Performance! Colored gauge marking labels Problem and Opportunity Tags in English or Spanish Red Move Tags Colored paint pens Colored grease fitting caps and lube point labels Vibration analysis pickup discs and labels Proven Tips for Equipment Troubleshooting handbook Lean Machines instructional book for applying visuals Temperature indicating strips and more
Visual systems supplies that deliver results...fast! To view and order from our complete line of Visual Systems Products, go to...
www.swspitcrew.com To order by phone or fax, call (864)862-0446 Strategic Work Systems, Inc. PO Box 70 Columbus, NC 28722
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Bio-Based Oil With No VOCs
Air-Operated Piston Pumps
aster Chemical’s TRIM® OV 2200 is a biobased straight oil free of volatile organic compounds. Developed to machine difficult alloys and stainless steel, the chlorine-free oil contains no sulfurized EP additives and protects aluminum and copper alloys. It also has improved oxidation inhibition compared with other vegetable oils, according to the company. Master Chemical Corp. Perrysburg, OH
RO Fluid Products’ AFX™ line of air-operated piston pumps and systems features air motors in five sizes from 4.25” to 12”. Each includes ARO’s Progressive Exhaust™, True Link Valve™ and integrated regulator technology used on 2-ball, 4-ball and chop-check pumps. The pumps are well suited for transfer of shear-sensitive, viscous, corrosive and abrasive fluids in a range of applications.
ARO Fluid Products An Ingersoll Rand Co. Brand Davidson, NC For more info, enter 35 at www.LMTfreeinfo.com
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ATP List Services Customized, Targeted Lists For Your Marketing Needs www.atplists.com Contact: Ellen Sandkam 847-382-8100 x110 800-223-3423 x110 firstname.lastname@example.org email@example.com 1300 S. Grove Ave., Suite 105, Barrington, IL 60010 For more info, enter 70 at www.LMTfreeinfo.com
Air Sentry® is a leading developer of contamination control products that keep particulate matter and excess moisture from the headspace inside gearboxes, drums, reservoirs, oil tanks, etc. that hold oils, greases, hydraulic fluids, and fuels. Air Sentry breathers and adapters ensure longer fluid life, better lubrication and lower maintenance costs.
The Maintenance & Reliability Technology Summit is the #1 learning venue and source of practical solutions for anyone concerned with the reliability, maintenance and the overall capacity assurance of critical equipment systems in a plant or facility. Mark your calendars! MARTS 2013 is taking place April 30-May 3, 2013 at the Hyatt Regency O’Hare in Rosemont, IL.
For more info, enter 71 at www.LMTfreeinfo.com www.airsentry.com
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For rate information on advertising in the Information Highway Section Contact your Sales Rep or JERRY PRESTON at: Phone: (480) 396-9585 / E-mail: firstname.lastname@example.org
28 | LUBRICATION MANAGEMENT & TECHNOLOGY
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Cost-Effective ‘Check-Engine-Light’ Technology For Monitoring Semi-Critical Equipment
KF’s new CMSS 200 Machine Condition Indicator is a low-cost, battery-powered, standalone monitoring solution for semi-critical machines with constant operating conditions that usually aren’t evaluated on a regular basis. Independent and self-sufficient, it periodically measures vibration and velocity, and monitors for problems relating to misalignment, imbalance, etc. It also measures enveloped acceleration to detect bearing degradation and keeps a running check on operating temperatures. Built-in intelligence evaluates data and helps avoid false alarms. Performing like a car’s check-engine light, the device indicates alarm status on three LEDs. Individual units can be stud-mounted or epoxied to the monitored equipment. SKF Lansdale, PA For more info, enter 37 at www.LMTfreeinfo.com
“Industrial Lubrication Fundamentals” 3-Day, On Site, Certification Preparation Training Program
With over 70% of all mechanical failures attributed to ineffective lubrication practices, you will want to have professionally trained and certified lubrication personnel working on your reliability efforts!
Unlock the Secrets that let you Tap your True Maintenance Potential and Maximize Asset Reliability! World Class organizations know that increased asset reliability, utilization and maintainability, reduced operating costs, downtime, contamination, energy consumption and carbon footprint all commence with a best practice lubrication program! Course design is based on ISO 18436-4 and the ICML body of knowledge and exceeds minimum training requirements to write the ICML, MLT1, MLA1 and ISO LCAT1 International lubrication certification exams. Exams can be arranged to take place at your site immediately following the training. For more information on this unique training program developed and delivered by internationally accredited lubrication and maintenance expert Ken Bannister, author of the best selling book Lubrication for Industry endorsed by ISO and the ICML as part of their certification Domain of Knowledge Content. Contact ENGTECH Industries Inc at 519.469.9173 or email email@example.com For more info, enter 73 at www.LMTfreeinfo.com
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JANUARY/FEBRUARY 2013 Volume 14, No. 1 •
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
CIRCLE # PAGE #
1300 South Grove Avenue, Suite 105 Barrington, IL 60010 PH 847-382-8100 FX 847-304-8603
Air Sentry .......................................................www.airsentry.com.....................................30,71 .. 26,28 ATP Lists.........................................................www.atplists.com .......................................70 ............ 28
Cannon Instrument Co.................................www.cannoninstrument.com ...................67 ............ 21
Engtech Industries Inc...................................www.engtechindustries.com .....................73 ............ 29
OH, KY, TN 135 N. Rocky River Road Berea, OH 44017 440-463-0907; Fax 440-891-1254 JOHN DAVIS firstname.lastname@example.org
MARTS ...........................................................www.martsconference.com .......................65,72 .... 7,28 Miller-Stephenson Chemical Co. .................www.miller-stephenson.com.....................66 ............ 13 NSK Corporation ..........................................www.nskamericas.com ..............................64 .............. 5 Royal Purple ...................................................www.royalpurpleindustrial.com ...............75 ............ 32 Strategic Work Systems, Inc. .........................www.swspitcrew.com .................................69 ............ 27
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 email@example.com
U.S. Tsubaki Power Transmission, LLC .......longlifelambda.com ...................................61 .............. 2 UVLM, Inc. ....................................................www.uvlm.com...........................................68 ............ 25
Access LMTfreeinfo.com and enter the circle number of the product in which you are interested, or you can search even deeper and link directly to the advertiser’s Website.
IA, MN, NE, ND, SD 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 847-382-8100 x116; Fax 847-304-8603 BILL KIESEL firstname.lastname@example.org
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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 email@example.com IL, IN, MI, WI 1173 S. Summit Street Barrington, IL 60010 847-382-8100 x108; Fax 847-304-8603 TOM MADDING firstname.lastname@example.org
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CUSTOM REPRINTS Use reprints to maximize your marketing initiatives and strengthen your brand’s value.
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 email@example.com
REPRINTS ARE IDEAL FOR:
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CLASSIFIED ADVERTISING 3605 N. Tuscany Mesa, AZ 85207 480-396-9585 JERRY PRESTON firstname.lastname@example.org
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LUBRICATION MANAGEMENT AND TECHNOLOGY
PMS 370 C
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Lubrication Management & Technology January/February 2013 magazine...Achieving Efficiencies Through Practices & Products