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SEPTEMBER/OCTOBER 2013 • VOL 14, NO. 5 • www.LMTinfo.com

Contents FEATURES

ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS

©marek_usz—Fotolia.com ©Felix Pergande—Fotolia.com

REAL-WORLD CASE HISTORIES 8 A Good Case For Improved Oil Filtration Its filtration-improvement program is helping specialty-metals producer ATI Wah Chang realize significant savings. Ray Thibault, Contributing Editor

MAINTENANCE LOG 16

Methods For Monitoring Bearing Performance Augmenting your human senses with advanced technologies is truly a PdM best practice. Consider all of your options. Galen Burdeshaw, Baldor Electric Co.

THE FUNDAMENTALS

DEPARTMENTS

20

6

From Our Perspective

27

Problem Solvers

29

Info Highway

30

Supplier Index

30

Classified

Do We Know What We’re Talking About? This author called for a compilation of common maintenance terminology in an easy-to-use, “evergreen” reference. It’s a done deal! Paul D. Tomlingson, Paul D. Tomlingson Associates, Inc.

ICML CERTIFICATION SERIES 24

Industrial Lubrication Fundamentals: What’s In A Lubricant? (Synthetic Base Oils) These man-made products are designed to work in the types of harsh conditions where animal/vegetable and mineral-based products typically can’t. Ken Bannister, Contributing Editor

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RICK CARTER Executive Editor rcarter@atpnetwork.com

KENNETH E. BANNISTER RAY THIBAULT, CLS, OMA I & II Contributing Editors

RANDY BUTTSTADT

Director of Creative Services rbuttstadt@atpnetwork.com

GREG PIETRAS

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Editorial/Production Assistant gpietras@atpnetwork.com

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Editor-In-Chief jalexander@atpnetwork.com

LUBRICATION MANAGEMENT & TECHNOLOGY

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 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: 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.

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FROM OUR PERSPECTIVE

Ken Bannister, Contributing Editor

Going Forward By Understanding The Past

I

confess: I am again held captive by a new obsession! With no other older living relatives, it’s my octogenarian parents or, to be more specific, my octogenarian parents’ memories. Baby boomer me is now the self-appointed family genealogist. As the future caretaker of our family history, I find that visits to my parents have taken on greater meaning as I attempt to tap into their wealth of recollections. The nice thing about talking with seasoned information caretakers is that they love to share their thoughts with you—including countless enlightening and perhaps long-forgotten “back in the day” factual nuggets. In my quest to capture our family history, I’ve employed the services of a number of online genealogy sites to help corroborate my parents’ memories through government censuses and military records dating back hundreds of years. These sites have also helped me delve further into the past, and to capture and report on my findings using powerful and sophisticated database engines. For example, to my amazement, I recently discovered that I have family ties to reportedly wealthy early settlers in Virginia (something that I certainly want to learn more about). One of the genealogy sites I’ve consulted is findmypast.com. It recommends using a contextual “three W” foundational approach of asking Who, Where and When in collecting family-history information and mining search-engine databases. Not surprisingly, this is markedly similar to how best-practice organizations develop maintenance reliability profiles for their assets. When building a reliability profile, it’s crucial to confer with the asset-history caretaker. At this point, most people tend to direct their questions to the maintenance planner—if there is one. While that’s not a bad strategy, if the asset in question predates the planner, the most resourceful information caretaker would likely be the operator or a maintainer who has worked with and parented

6|

LUBRICATION MANAGEMENT & TECHNOLOGY

the machine for many years. In fact, the simple act of striking up conversations with these types of individuals about a specific asset (and being prepared to actually listen to what they tell you) can often elicit the most insightful information about the equipment’s behavior under all conditions of use and abuse.

Think of the ‘three W’ technique as a best practice in building accurate asset reliability profiles. Still, plenty can be gleaned by using the “three W” foundational approach to ask information caretakers about previous asset failures: “What” is about any incidents in the past, and in “what” context or circumstances they occurred. “When” refers to the time frames of such occurrences. “Why” seeks to determine a relevant root cause of failure. The same “three W” questions should then be used to data-mine your workorder history archives—those in your old filedaway paper documents, as well as computerized maintenance management databases. The straightforward “three W” technique can help you tap into all available history sources at your plant and deliver the most accurate assetreliability profile from which to learn and build a suitable, proactive maintenance strategy. In turn, this approach will help you ensure asset reliability and optimized life-cycle management. But that’s not the entire story. In the process, you’ll also have fun learning how things were maintained and managed in the past—and coming to understand how that past can help you change the present and future for the better. Good luck! LMT kbannister@engtechindustries.com

SEPTEMBER/OCTOBER 2013


BOOSTING YOUR BOTTOM LINE

Forget Guesswork: Tracking Boosts Reliability

I

mproving your plant’s reliability is a gift that keeps on giving. In implementing effective motor management practices, you make your job as a maintenance professional easier by improving operating and production performance, lowering maintenance costs and reducing equipment downtime. The first step toward greater reliability is to conduct a plant-wide motor survey that records basic, but crucial, data about your motor fleet. It’s worth the time Although conducting a motor survey and implementing a tracking program may seem daunting, remember that it’s not necessary to survey every motor in the facility. If your site has many motors, it could make sense to start with equipment running the most critical applications, units with the longest run-times or highest failure rates, or simply the oldest ones. Maintaining a log of motor repairs through a tracking program can help flag opportunities to repair or replace motors before failure, during scheduled downtime. Some facilities have reported that it’s not unusual for a motor to be repaired and then installed in a different application in another part of the plant. Tracking programs record the unit’s history to help predict reliability or prevent misapplication. Your local motor-service expert can help you with a motor inventory. Free help is available There are also a number of motor tracking resources available that will not only make your life easier, but are free to download. One of the best-known tools is MotorMaster+ 4.0*, created by Washington State University through a grant from the U.S. Department of Energy (USDOE). This software is a comprehensive program that enables you to create a detailed motor database. You can use the database to make data-driven decisions for long-term savings. It also contains important manufacturer information for more than 20,000 motors.

| MAINTENANCE TECHNOLOGY 32 SEPTEMBER/OCTOBER 2013

What’s next? A motor survey and tracking program are the first steps in developing a motor management plan. Simply put, you can only manage a motor fleet if you know what’s in it and monitor changes over time. That’s where Motor Decisions MatterSM (MDM) can help.

Implementing a tracking program isn’t as daunting as it might seem. The MDM Motor Planning Kit, available as a free download at www.motorsmatter.org, explains the fundamentals of motor management and helps you get started. The MDM 1·2·3 Approach software tool includes a motor inventory sheet that runs simple calculations and provides motor reports and tags, using sample data from customer plants and facilities. Additionally, MDM has a comprehensive case-study library with numerous examples of how customers saved money and energy by implementing motor management strategies, beginning with a motor inventory. Start tracking today, and enjoy the long-term benefits of increased reliability. LMT * MotorMaster+ 4.0 is available at https://www1. eere.energy.gov/manufacturing/tech_assistance/ software_motormaster_intl.html For more info, enter 01 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.

|7 OCTOBER 2007 www.LMTinfo.com


REAL-WORLD CASE STUDIES

A Good Case For Improved Oil Filtration Learn how a well-designed filtration-improvement program is helping specialty-metals producer ATI Wah Chang realize significant savings through enhanced equipment reliability.

Ray Thibault CLS, OMA I, OMA II, MLT, MLT II, MLA II, MLA III Contributing Editor

A

TI Wah Chang, a division of Allegheny Steel, produces reactive and refractory specialty metals used in a variety of unique high-performance applications for engineered products and material solutions. The operation was the first to process zirconium and produce a number of other specialty metals such as hafnium, titanium, niobium, tantalum and vanadium. It is a highly innovative company in a highly specialized field.

8 | LUBRICATION MANAGEMENT & TECHNOLOGY

SEPTEMBER/OCTOBER 2013


REAL-WORLD CASE STUDIES

In 2011, faced with significant vacuum pump failures attributed mainly to contaminated oil, ATI Wah Chang’s maintenance department embarked on a proactive lubrication program to enhance fluid cleanliness through improved filtration. This program was spearheaded by Dale Jones, who has extensive lubrication experience and currently holds six lubrication certifications. Jones worked with his lubricant marketer Moreland Oil and, through Moreland, with Hy-Pro Filtration, in an effort to develop a filtration improvement program. The result was a dramatic improvement in fluid cleanliness that significantly enhanced bottom-line savings for the company. This case history focuses mainly on improvements made to vacuum-pump reliability and the operation’s Z-Mill rolling oil. They have led to enhanced product quality, dramatic equipment life-cycle extensions and increased productivity. A quick review of basic filtration principles It’s been shown that approximately 70% of premature equipment failures are caused by particulate contamination, and over two-thirds of equipment wear is from abrasive particles. Since 70% of premature failures are caused by contamination, it stands to reason that controlling particulate contamination through better exclusion and filtration would provide a high return on investment. Although the basic principles of fluid cleanliness have been discussed in previous articles in this and other series in LMT, let’s review some of them here: Fluid cleanliness is measured primarily with the use of laser particle counters. Particles are measured in many size ranges but are expressed in a simplified system ISO 4406. This system expresses cleanliness in three size ranges: > 4µm(c), > 6µm(c) and > 14µm(c). Table I is used to arrive at the ISO 4406 Cleanliness Code. Notice that for each increase in range number, the number of particles doubles. This method is a convenient shorthand way of assessing fluid cleanliness without worrying about the actual number of particles. As an example, assume you measure 1042 particles/ml > 4µ. 412 particles/ml > 6µ and 152 particles/ml > 14µ. Referring to Table 1, the range number for particles > 4µ is expressed as 17. The number of particles > 6µ is 462/ml,

Table I. ISO 4406 Chart

Number of particles per ml

Range Number

More Than

Up To & Including

24

80000

160000

23

40000

80000

22

20000

40000

21

10000

20000

20

5000

10000

19

2500

5000

18

1300

2500

17

640

1300

16

320

640

15

160

320

14

80

160

13

40

80

12

20

40

11

10

20

10

5

10

9

2.5

5

8

1.3

2.5

7

0.64

1.3

6

0.32

0.64

which translates to a range number of 16. Finally, the number of particles > 14 µ is 152/ml, which is expressed as a range number of 14. Putting this three-number code together results in expressing the above fluid cleanliness as 17/16/14. Remember, the first number is always greater than the second, which is greater than the third.

Some companies still don’t believe that fluid cleanliness affects equipment reliability. The company featured in this article has discovered otherwise. SEPTEMBER/OCTOBER 2013

www.LMTinfo.com | 9


REAL-WORLD CASE STUDIES

filter manufacturer designates the filter as no longer operable and needs to be changed. The filtration efficiency of the test filter is expressed as the filtration ratio here:

Filtration Ratio (Beta Ratio) βx

Number of particles upstream of filter greater than µ[c] Number of particles downstream of filter greater than µ[c]

For example, a filter with a Beta Ratio of β6 = 200 indicates that for every 200 particles greater than six microns in size entering the test filter, one will pass though. Therefore, 199 will be captured. The efficiency of the filter is calculated as β - 1/β x 100. The efficiency of a filter with a Beta Ratio of 200 is 99.5%. The standard today for calling a filter absolute is a minimum Beta Ratio of 200, and some filter companies express their filters with a Beta Ratio of 1000, which eventually will be the standard for absolute filters.

Fig. 1. A Stokes 412 vacuum pump

Filter performance should be based on the absolute filter rating, which is determined in a laboratory with the Multi-Pass Filter Performance Test. Dirt in milligrams per liter is introduced in a test fluid at a constant rate. The fluid is circulated at a constant or variable rate through a test filter. The test concludes when the terminal pressure drop of the filter is reached. This is the point when the

Vacuum pump improvements At ATI Wah Chang, a large number of Stokes 412 vacuum pumps (similar to the one shown in Fig. 1) are utilized to create a non-oxygen atmosphere by producing a highvacuum environment in a vast network of furnaces during a chemical reactive process. The pumps operate in a highly hostile environment requiring frequent oil changes. The volume of oil consumed is so great that an oil reclamation unit has been established to recondition the oil. Bath lubrication of the pumps with an R&O ISO VG 150 lubricant is used in this process. Major pump failures occur due to wear of the piston slide plate; as the tolerances between the piston and slide plate increase, the integrity of the piston’s sealing surface is jeopardized, resulting in loss of vacuumproducing efficiency.

Fig. 2. The reclaimed oil process Reclaimed/New Fluid

Vacuum Pumps Collected Fluid Settling Tank Reclaimer

Filtration Course

Vacuum Dehydration

10 | LUBRICATION MANAGEMENT & TECHNOLOGY

Clay Filtration

Filtration Fine

Clean Fluid SEPTEMBER/OCTOBER 2013


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REAL-WORLD CASE STUDIES

It was established that the major cause of wear was from abrasive particles that accumulated in the oil during the process. The cost to rebuild each pump is $22,500 (calculated on the basis of 225 man hours at $100/hr). Before the change in the company’s filtration program, an average of 24 pump rebuilds—costing a total of $540,000—had to be done each year. The reclaimed oil process is illustrated in Fig. 2. The used oil is collected and sent to the oil reclamation unit for reconditioning. The initial step is to use a settling tank to remove the free water and heavy solids. The next step is to use course filtration through a β25 = 200 filter. The oil is then heated to 160 F and passed through a vacuum dehydrator to remove much of the remaining emulsified water. After the oil is vacuum-dehydrated, it’s sent through clay filtration to remove the acidic contaminants generated during the process. The final step—and one of the most crucial—is fine filtration. The major change in the process was to upgrade filtration in that final stage: The original filtration was a β3 = 75 and was upgraded to a β2.5 = 1000 filtration system from Hy-Pro. Figure 3 illustrates the results from the improved filtration.

piece during the rolling process, the oil produces an elastohydrodynamic lubricating film between the work rolls and the product. Because an elastohydrodynamic lubricating film is very thin (estimated at less than 1 micron), virtually all of the dirt that is suspended in the oil is larger than the lubricating film separating the work rolls and the product. The dirt in the oil makes contact with the work piece and work rolls, having a significant effect on the surface quality of the product and the longevity of the rolling mechanism. The original filtration system was evaluated by draining, cleaning and filling the reservoir with new oil and installing new original filters. After several months of normal operation, a baseline fluid cleanliness was established. A study was then conducted with the following steps: ■ Research new filter options ■ Test and evaluate options ■ Determine if an improvement opportunity exists ■ Initiate the improvement and monitor the results

Base Line Performance Level 23/20/14 Cleanliness 24 rebuilds/yr at cost of $540,000

Upgraded Performance Level 18/17/15 Cleanliness 7 pump rebuilds/yr at cost of $157,500

Fig. 3. Examples of vacuum pump oil before and after implementation of filtration upgrades in the final phase of the site’s oil-reclamation process

The total savings from the upgrade is $382,500/year, with a minimal increase in filter cost. The most recent information from the plant notes a further drop in the need for pump rebuilds—down to five or six per year. Z-Mill rolling process improvements ATI Wah Chang’s rolling mill produces very thin metal sheets—to under 0.001 inches thick. The rolling mechanism is enclosed and flooded with 60 cSt oil during the process. Due to the extreme amount of force applied to the work 12 | LUBRICATION MANAGEMENT & TECHNOLOGY

The original filtration system utilized a β3 = 75 filter, producing an average ISO cleanliness code of 23/20/12. The filtration system was modified using a custom-built Hy-Pro filter, with a specification of β2.5 = 1000. The ISO cleanliness of the fluid improved to an average of 13/10/4. After two months of operation with the improved system, the department engineer identified a 15% product yield increase due to surface-quality improvements. The resulting yield increase was valued at $100,000/year. Additional savings were realized in roller-bearing cost. Historically, bearings were replaced every six months at an average cost of $70,000. Referring to Table II on bearing-life extension, it can be concluded that over a fivefold bearing life extension may be realized with the increased cleanliness. The following cost-savings estimate relates to bearing life extension and a conservative threefold life-cycle increase was used for the sake of generating credible estimates. The estimated savings was $93,333/year. After nearly three years of operation since the improvement, only one bearing has failed. The actual results are a realized sixfold increase in bearing life. Actual savings from this activity are in excess of $200,000 annually. It is interesting to note that the increase in filter cost is just $1700/year. Put another way: an annual investment of $1700 for the purchase of high-quality filtration has a return of over $200,000—without the plant having to turn out any extra product. SEPTEMBER/OCTOBER 2013


REAL-WORLD CASE STUDIES

Table II. Rolling Element Bearing Life Extension Target Target ISO Code ISO Code Current 2X Life 3X Life ISO Code

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 14/12/9

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 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 -

ISO Code 4X Life

Target ISO Code 5X Life

20/18/15 19/17/14 18/16/13 17/15/12 16/14/11 15/13/10 14/12/9 13/11/8 -

19/17/14 18/16/13 17/15/12 16/14/11 15/13/10 14/12/9 13/11/8 -

The savings that ATI Wah Chang has realized are substantial. Based on continuing improvement efforts, it should be able to capture even more.

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REAL-WORLD CASE STUDIES

LARGE GEARBOX

SMALL GEARBOX

Fig. 4. The plant’s Cold Roll Mill

Fig. 5. Fluid evaluation of Cold Roll Mill’s large and small gearboxes

Coupled with the oil filtration improvements associated with its vacuum pumps, ATI Wah Chang’s fluid-cleanliness improvement in its Z-Mill operations means the company has captured approximately $600,000/yr in savings—from just two assets.

and discovered a typical shipment had a fluid cleanliness of 18/16/13—which he interpreted as not clean enough.) As shown in Fig. 6, the new pre-cleaning process involved a tote fitted with an off-line filtration system to polish new hydraulic fluid before it was used in the plant’s equipment. Using a β5 = 1000 filter helped achieve a cleanliness code of 15/13/10.

Other filtration improvement projects Cold Roll Mill gearboxes. . . The large and small gearboxes in the plant’s Cold Roll Mill (Fig. 4) were also investigated. Both gearboxes showed normal to low wear on the oil analysis reports, with emission spectroscopy results of 34 and 16 ppm of iron, respectively. As shown in Fig. 5, evaluation through an in-house 0.8µm micro patch revealed a significant number of large metallic particles in the fluid of the relatively new large gearbox. Particles >5 microns cannot be seen with emission spectroscopy, rendering them undetectable by the lab analysis. The large gearbox is lubricated with ISO EP 220 oil. After the contamination was discovered, Dale Jones brought in a 4-gal.-per-minute filter cart fitted with a 36” tall Hy-Pro filter element (β5= 1000) to handle the high-viscosity fluid. The unfiltered fluid had a cleanliness rating of 23/23/18. After 24 hours of filtration, it had a cleanliness rating of 17/14/11. The condition was corrected before any problems occurred and this gearbox has been operating flawlessly for three years. This is a clear example of the value of proactive maintenance.

Conclusion ATI Wah Chang’s well-designed, proactive lubrication program and approach to improved filtration has significantly reduced particulate contamination in the plant’s fluids: Savings of over $574,000/year have been documented. This is a result of properly structured efforts by Dale Jones, coupled with a strong cooperation between ATI Wah Chang, Moreland Oil and Hy-Pro Filtration. The plant is well on the way to establishing a world-class lubrication program by identifying the importance of fluidconditioning and implementing successful strategies and techniques to achieve world-class status, including: ■ Use of a portable oil diagnostic system (PODS) with both

online and bottle-sampling capabilities for on-site condition-monitoring and rapid analysis. ■ Filtration of new hydraulic fluids to meet a cleanliness

level of 15/13/11. ■ Testing, evaluation and improvement of existing systems.

Hydraulic fluids. . . Because of the vast number of hydraulic systems in the ATI Wah Chang plant, a proactive approach to hydraulic fluid cleanliness has also been implemented. To accomplish this, Dale Jones established a program for pre-cleaning new bulk hydraulic fluids. (He had tested new AW 46 hydraulic fluid 14 | LUBRICATION MANAGEMENT & TECHNOLOGY

■ Failure prevention through the use of various condition-

monitoring tools. ■ Continuous improvement efforts aimed at enhancing

equipment reliability. SEPTEMBER/OCTOBER 2013


REAL-WORLD CASE STUDIES

Based on my experience, I believe this facility will continue to identify opportunities for lubrication-program improvements, and thus be able to generate numerous additional cost savings. LMT Acknowledgement This article would not have been possible without the information provided by Dale Jones of ATI Wah Chang: He is a true lubrication professional. He and his peers are doing a remarkable job of improving equipment reliability and providing their company with noteworthy savings that go directly to the bottom line. I also want to thank ATI Wah Chang for allowing me to share the results of a well-designed program and the benefits they have realized from utilizing clean oil in their processes. There are still companies across industry that don’t believe oil cleanliness has an effect on equipment reliability. I trust this article will help change their perception.

Fig. 6. A pre-cleaning process for hydraulic fluids involves a tote fitted with an off-line filtration system to polish new fluids prior to introducing them into the plant’s equipment.

Long-time Contributing Editor Ray Thibault is based in Cypress (Houston), TX. An STLE-Certified Lubrication Specialist and Oil Monitoring Analyst, he conducts extensive training for operations around the world. Telephone: (281) 250-0279. Email: rlthibault@msn.com. For more info, enter 02 at www.LMTfreeinfo.com

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www.LMTinfo.com | 15


MAINTENANCE LOG

Consider the alternatives...

Methods For Monitoring Bearing Performance A range of traditional and advanced options are available to help you monitor your bearings. Don’t disregard any of them. Leveraging instrumentation to augment our human senses is very much a predictive maintenance best practice.

T

ARTSTUDIO PROŠFotolia.com

he health of your bearings is critical to the health of your equipment and processes. With proper performance monitoring, imminent failures can be identified and corrected. Conversely, without a sound monitoring program in place and subsequent corrective actions not being taken when needed, a single bearing failure can result in full machine shutdown and countless hours of lost production.

Galen Burdeshaw Baldor Electric Co.

16 | LUBRICATION MANAGEMENT & TEChNOLOGy

SEPTEMBER/OCTOBER 2013


MAINTENANCE LOG

Bearing monitoring is guided by three main human senses: sight, sound and touch. Basic monitoring has typically been conducted through elemental observations. Fortunately, there are a number of highly sensitive tools that can amplify these observations—making them more noticeable and recordable. They also include basic logic to assist with warning identification. Keep these technologies in mind as you seek to augment your bearing sense(s): #1. Visual monitoring: Looking Monitoring bearings visually through classical methods includes observing lubricant condition, corrosion and deterioration. Mounted bearings that are lubricated properly will purge grease from their seals. The condition of the grease upon purging can indicate improper relubrication intervals and/or contamination. Dark, cakey or milky grease are visual signs that relubrication intervals and procedures may be improved. Evidence of corrosion is a valuable monitoring tool as well. High levels of corrosion can degrade material strength and performance. Deterioration of the surface, seals or obvious physical dimensional characteristics should also warrant further investigation. These observations are often signals of wear, heat and other abnormal performance prior to total bearing failure. Sight-gauge bearings and thermal imaging guns are among the readily available monitoring tools that leverage visual observations. Bearings that are lubricated by oil rather than grease are often fitted with sight gauges to indicate the presence and quantity of oil available to the bearing. These types of gauges aren’t just practical—they’re inexpensive. #2. Audible monitoring: Listening Traditionally, audible monitoring is one of the most common methods of machinery monitoring. That’s because odd noises are obvious indicators of improper operation, even to the untrained user. This type of monitoring is conducted quickly—through an operator’s daily routines. After all, if a machine bearing doesn’t sound well, it usually isn’t. There can be two problems with a bystander’s audible observations: (1) Such observations usually identify the later stages of bearing failure, when planning downtime for bearing replacement is impractical; and (2) audible feedback of a single bearing can be masked by the overall noise of its environment. This is where instruments such as stethoscopes (with amplification) and decibel-level meters are advantageous. Both are available with a wide range of features, including quantified readings and recording capabilities that allow users to trend bearing performance. These SEPTEMBER/OCTOBER 2013

tools are also more useful at identifying improper operation at a less-threatening stage of failure. Bearings should run quietly and smoothly—anything different likely will reflect a flaw in or problem with the bearing itself. Noises such as grinding or banging should be investigated quickly. These noises may indicate complete bearing failure and continued use may lead to catastrophic failure and/or damage to neighboring equipment. Bearing noises like light clicking and squealing may indicate looseness, faults or skidding, and should be inspected for cause and remedy. Audible evaluation is not as sensitive as other monitoring techniques. It’s really more of a method of identifying failure than identifying poor performance. One more thing to keep in mind: Audible monitoring in the early stages of failure is more noticeable at higher operating speeds than lower speeds. #3. Physical monitoring: Touching Monitoring bearings by touch—and then trending the observations against historical performance—is by far the most useful and accurate means for assessing bearing condition and predicting failure. The touch method can be used to monitor temperature, vibration and lubrication parameters. Temperature. . . Operating temperature is the most practical and beneficial monitoring method for bearings because expensive tools are not required. It’s also appropriate to all types of applications (i.e., slow to high speeds and light to heavy loads). For example, the average threshold of pain for humans is approximately 130 F. Thus, if it’s difficult to maintain handto-bearing contact for several seconds, the temperature probably exceeds 130 F. (A related method, wherein water droplets that are placed on a bearing housing quickly boil, will indicate that bearing temperature has exceeded 212 F.) Monitoring bearing temperatures is crucial: As these components fail, they get hotter. Trending their temperatures over time will help identify the early stages of failure. The most common tools for doing this include thermocouples and resistance temperature detectors (RTDs)—both of which can be permanently mounted to locations on the bearing housing for continuous real-time monitoring. Temperature switches that can be utilized for warning and/or shutdown at dangerous operating temperatures are also available. Many bearing manufacturers offer permanently mounted sensors that are pre-installed in bearing housings (in areas that accurately reflect the true bearing temperature, not just the housing-skin temperature). www.LMTinfo.com | 17


MAINTENANCE LOG

You may also consider vibration-measurement instruments to not only identify stages of bearing failure, but to also identify overall machine performance and problems. Sensors mounted to the bearing may include permanently mounted or portable magnetic-base accelerometers, displacement probes or velocity pickups. Sensor selection is dependent upon the bearing speed, sensitivity requirements and the application. Although vibration feedback is highly desirable, proper training is important due to the complexity in data collection and interpretation. Lubrication. . . Simple tests can also be conducted on purged grease to detect hard-particle contaminants. After re-lubrication, the technician should rub some freshly purged grease between his/her fingertips. Gritty grease may indicate a need for more frequent lubrication—or wear from a failing bearing. LMT Galen Burdeshaw is Baldor’s Customer Order Engineering Manager for DODGE Bearings and PT Components. For more info, enter 03 at www.LMTfreeinfo.com

Many bearing manufacturers offer various permanently mounted sensors pre-installed on bearings that provide online, real-time monitoring of temperature and speed.

Portable thermal imaging tools offer a quick and efficient means of monitoring bearing performance. These devices use infrared (IR) thermography to visually identify variations in temperature—the most common being the infrared thermometer. Although portable thermal imaging tools typically can’t measure temperatures over a broad area, they’re inexpensive and easy to use. Vibration. . . Vibration analysis is the most information-rich method available for bearing analysis—and touch is a good way to distinguish between smooth and rough operation. As safety permits, feel the bearing housing during operation. Rough operation, jostling or grinding may indicate a bearing problem. Utilizing a portable temperature-measuring tool, like a thermal imaging gun, will help you accurately monitor bearing temperature. As a bearing fails, its temperature will continually increase. Trending temperature over time will help identify a bearing in the early stages of failure.

18 | LUBRICATION MANAGEMENT & technology

SEPTEMBER/OCTOBER 2013


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CUSTOM REPRINTS Use reprints to maximize your marketing initiatives and strengthen your brand’s value. Reprints are a simple way to put information directly into the hands of your target audience. Having been featured in a well-respected publication adds the credibility of a third-party endorsement to your message.

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www.LMTinfo.com | 19


Editor’s Note: This article is based on one that first ran in the June 2013 issue of Maintenance Technology

Do We Know What We’re Talking About? Is there a need to define and compile common maintenance terminology into an easy-to-use reference? This author says yes, and we’ve delivered. Paul D. Tomlingson Paul D. Tomlingson Associates, Inc.

D

id you know that even some veterans of the maintenance wars have trouble distinguishing a “rebuild” from an “overhaul”? Many struggle with the question of whether or not “overhaul” falls into the category of preventive maintenance. Still others wonder if “PM” means planned maintenance, predictive maintenance, preventive maintenance or periodic maintenance—and may be confused further with the acronym “PdM.” And how many in our field think that “CMMS” means a magical solution that’s somehow exclusive to managing maintenance? If we in maintenance are this confused, what must our customers in operations think? Consider, too, the managers of some plants who, according to word on the street, might still be characterizing our activities as “seat of the pants.” Moreover, how about those folks in the warehouse and purchasing whose services we count on: What must they be thinking? (One warehouse manager accurately observed that while inventory control universally defines a “reorder point,” maintenance “speaks with several tongues.”) Do we need to sort out our terminology and advise all parties with whom we deal? I vote “yes.” While it’s been a desired goal for some time (one that many of us have discussed off and on for years), with so many new, inexperienced workers entering our field, the need to formally define terms used in our vernacular is becoming ever more critical. How, though, to begin? 20 | LUBRICATION MANAGEMENT & TEChNOLOGy

A good starting point is what you see here: a list of some of “our” terminology definitions—a glossary of sorts— that allows for review, revision, addition to and combination into other lists. The end result can be a truly “evergreen” document, something that Maintenance Technology magazine is hosting on its Website, www.mt-online.com. To get the ball rolling, this abridged (due to print-page limitations) alphabetical listing was offered. There are certainly more definitions—many more—with which those in the maintenance community should be familiar. For an expanded version, as well as instructions on how you and other maintenance professionals can augment this fundamental knowledge base, go to www.mt-online.com/ glossary. Please feel free to visit, use and contribute to this knowledge base regularly. SEPTEMBER/OCTOBER 2013


A SPECIAL SUPPLEMENT TO LUBRUCATION MANAGEMENT & TECHNOLOGY

A adjustments — Minor tune-up actions requiring hand tools, no parts and less than a half hour of time. autonomous maintenance — Performance of maintenance-related activities such as cleaning, adjustment, lubrication, minor repairs or simple machine calibration by equipment operators. (a cornerstone of total productive maintenance [TPM]). B backlog — The total number of estimated man-hours, by craft, required to perform all identified, but incomplete, planned and scheduled work. benchmarking — The systematic process of searching for best practices, innova­tive ideas and highly effective procedures that lead to superior performance. C capitalized — Funding for work that expands the plant operating capacity; gains economic advantage; replaces worn, damaged or obsolete equipment; satisfies a safety requirement; or meets a basic need. cost center — A department or area in which equipment operates or in which functions are carried out. D decision-making information — Details necessary to control day-to-day maintenance and determine current and long-term cost and performance trends for management decisions. deferred maintenance — Maintenance that can be postponed to some future date without further deterioration of equipment. downtime — Period during which equipment cannot be operated to perform its intended function. E engineering work order (EWO) — A control document authorizing use of the maintenance workforce or a contractor for engineering project work such as construction. equipment life cycle — Encompasses selection, purchasing, commissioning, testing, operating, maintaining, overhauling, modifying and replacing equipment. equipment management strategy — A fully coordinated, mutually supporting effort of every plant department and individual to achieve maximum reliability and productive capacity of critical equipment throughout its entire life cycle. F failure analysis — The study of equipment failure data and related field experiences to determine the source of chronic, repetitive equipment problems and the determination of actions to reduce or eliminate them. failure modes and effects analysis (FMEA) — Procedure that studies failure causes and ranks their risk, then applies the best technology to reduce occurrences while improving detection capabilities. SEPTEMBER/OCTOBER 2013

I ISO 9000 — A set of quality-assurance standards that can be applied to any organization regardless of size or type. Used to develop a common approach to obtaining quality service or product. L level of service — The degree of maintenance performed to meet desired levels of equipment performance. A high level ensures little chance of failure, whereas a low level meets minimum requirements, risking breakdowns on less-critical equipment. life-cycle costing — The cost incurred during the life-span of equipment to keep it in optimum operating condition. M maintenance work order (MWO) — Formal document for controlling planned and scheduled work. maintenance work request (MWR) — Informal document for requesting unscheduled or emergency work. Also called a job ticket or job request. major repairs — Extensive, non-routine, scheduled work requiring the deliberate shutdown of equipment, the use of a repair crew (possibly covering several elapsed shifts), significant materials, rigging and, if needed, lifting equipment. mean time before failure (MTBF) — Average time between replacements of a specific component on a designated type of equipment. Also referred to as the life span of a component. Extended MTBF indicates successful actions in extending component life span such as more planned work. minor repairs — Repairs usually performed by one person using hand tools, few parts and usually completed in less than two hours. N nondestructive testing (NDT) — The use of technologies to detect cracks, flaws or porosity in components, structures, frames or components. Techniques include magnetic-particle, liquid-dye-penetrant, ultrasonic, eddycurrent and radiographic testing. See also predictive maintenance (PdM). O on-condition status — Following discovery of a potential failure, equipment is left in operation on condition that it can continue to perform its intended function. Equipment condition is monitored carefully during this period to preclude sudden deterioration to a functional failure. overhaul — Process during which a piece of equipment must be removed from service and subjected to inspection, teardown and repair of the total unit to restore it to effective operating condition in accordance with current design specifications. See also rebuild. www.LMTinfo.com | 21


P periodic maintenance — Maintenance actions carried out at regular intervals. Intervals may be fixed (e.g., every six months) or variable (e.g., every 4500 operating hours). P–F curve — A down parabolic shaped curve denoting the deterioration of equipment condition from the discovery of a potential failure (P) to a functional failure (F). P–F interval — The elapsed time between the discovery of a potential failure (P) until a functional failure (F) occurs, if no corrective action is taken. planning — Determination of resources needed and the development of anticipated actions necessary to perform a scheduled major job. predictive maintenance (PdM) — Techniques to predict wear rate, determine state of deterioration, monitor condition or predict failure. preventive maintenance (PM) — Performance of services to avoid premature equipment failure and extend equipment life, specifically, equipment inspection testing, and condition monitoring to ensure the early detection of equipment deficiencies and lubrication, cleaning, adjusting, calibration and minor component replacements to extend equipment life. proactive maintenance — The application of investigative and corrective technologies to reduce failures, improve equipment performance and extend equip­ment life. The following analytical tools are associated with proactive maintenance: root cause failure analysis, failure modes and effects analysis and risk-based inspections. Also, the intensive application of positive, aggressive maintenance steps to actively defeat potential failures. Q quality standard — A standardized procedure for accomplishing a major maintenance task in the best way. quantity standard — The resources required to meet the prescribed quality standard. R rebuild — The repair of a component to restore it to serviceable condition in accordance with current design specifications. See also overhaul. reliability engineering — Actions taken through the use of information, field experience and engineering techniques to design or redesign equipment in order to reduce or eliminate faults that imperil equipment reliability. reliability centered maintenance (RCM) — A strategy for achieving max­imum equipment reliability and extended life at the least cost. Implementation identifies specific equipment functions in their exact operating context. Then, equipment performance standards are identified For more info, enter 73 at www.MT-freeinfo.com for each function and failures are defined when performance standards are not met. Based on the consequences 22 | LUBRICATION MANAGEMENT & technology

of failures, a maintenance program featuring conditionmonitoring techniques is applied to identify potential failures (equipment is starting to fail) accurately and quickly to preclude its deterioration to functional failure (equipment no longer operates) levels. Thus, equipment life is extended and the consequences of functional failures are reduced or avoided. See also P–F curve, P–F interval, on-condition status. reliability engineering — Actions taken through use of information, field experience and engineering techniques to design or redesign equipment to reduce or eliminate faults that imperil equipment reliability. repetitive maintenance — Maintenance jobs with a known labor and material content that occur at a regular interval. risk priority number (RPN) — In a failure modes and effects analysis, an RPN is assigned to the failures related to the equipment being studied to establish the priority of corrective actions. RPN = severity × occurrence × detection capability. See also failure modes and effects analysis. root cause failure analysis (RCFA) — Actions to discover why a failure happened and determine corrective actions to eliminate the failure or reduce its impact. S scheduling ­— Determination of the best time to perform a planned maintenance job to appreciate operational needs for equipment or facilities and the best use of maintenance resources. standard — A goal or ideal target to be met. Quality standards prescribe the end product. Quantity standards prescribe the amount of resources required to carry out specific work under normal conditions. standing work order — A reference number used to identify a routine, repetitive action. stock issue card — The authorized accounting document for making stock material withdrawals or returns. strategy — A global, corporate or plantwide plan to secure a major objective, such as the successful implementation of total productive maintenance. T time card — Authorized accounting document for reporting the use of labor data. total productive maintenance (TPM) — Productive maintenance carried out by all employees through small-group activities (e.g., quipment maintenance performed on a plantwide basis). U utilization — Percentage of time that a maintenance crew is available to perform productive work during a scheduled working period or shift. SEPTEMBER/OCTOBER 2013


A SPECIAL SUPPLEMENT TO LUBRICATION MANAGEMENT & TECHNOLOGY

V verbal orders — A means of assigning emergency work when reaction time doesn’t permit preparation of a workorder document. W work-order system — A communications system by which maintenance work is requested or identified, classified, planned, scheduled, assigned and controlled. Help build this base of knowledge See an expanded version of this beginning maintenance glossary at www.mt-online.com/glossary. There, you’ll also find instructions on how to contribute more definitions and/or add to existing ones. Please do. LMT

This compilation of common maintenance terminology is now available at www.mt-online.com/glossary. You are invited to visit, use and contribute to it regularly.

Paul D. Tomlingson is the Principal of Paul D. Tomlingson Associates, Inc., based in Denver, CO. 82+-years-young, he’s been working as a worldwide maintenance consultant for almost 45 years. Email: pdtmtc@msn.com. For more info, enter 04 at www.LMTfreeinfo.com

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

SEPTEMBER/OCTOBER 2013

www.LMTinfo.com | 23


ICML CERTIFICATION SERIES

Domain of Knowledge Element #5

Industrial Lubrication Fundamentals:

WHAT'S IN A LUBRICANT?

(SYNTHETIC BASE OILS) These man-made products are designed to work in the types of harsh conditions where animal/vegetable and mineral-based products typically can't. Ken Bannister Contributing Editor

I

n Element #4, we reviewed animal/vegetable and mineral base oils and their specific characteristics. Completing the trio of base stocks available to today's lubricant blenders is a synthesized, man-made option commonly known as synthetic base oil. These "synthetics" are designed to perform in the harshest of climatic conditions (where their animal/vegetable and mineral-base-oil siblings are unsuited).

24 | LUBRICATION MANAGEMENT & TECHNOLOGY

SEPTEMBER/OCTOBER 2013


ICML CERTIFICATION SERIES

Most of today’s industrial oils use either a mineral or synthetic base oil. These base oils are categorized into five groups according to their refining or manufacturing process. Groups I, II and III represent conventional mineral-based lubricants, while groups IV and V are reserved for manmade synthetic base oils. (Refer to Table I.)

■ Group IV base oils are reserved for Polyalphaolephin

■ Group I reflects what is known as “conventional” base

Specifics of synthetics Synthetic lubricants owe their inception to the early jet engine: They were developed to cope with the extreme temperatures encountered when operating a jet aircraft. Using a polymerization process similar to that used in the plastic manufacturing industry, synthetic base oils are designed with specific and consistent molecular structures that result in highly stable base oils with a very high Viscosity Index (VI) rating. Synthetic lubricants offer many advantages over mineral-based oils, the largest being the ability to operate reliably in both extremes of heat and cold at temperature ranges much wider than mineral oils. In addition to increased VI levels and improved thermal stability, synthetics also demonstrate improved oxidation stability (major reduction of sludge and acid buildup) and lower volatility, resulting in extended lubricant life and reduced oil consumption. The disadvantages of synthetics are primarily associated with their cost—which, depending on the type, can range from as little as three times the cost of a mineral base oil to exponentially more. Certain synthetics can also cause seal swelling, and many are not compatible with any other base oil type. Manufactured from chemically modified petroleum constituents or from a number of chemical bases and compounds, there are five common types of synthetic base oils. Their characteristics and costs compared to mineralbased products are summed up in Table II:

oils. They're made from solvent refined crude stock and have a Viscosity Index between 80 and 120. Their sulfur content is above 0.03%, and their saturated hydrocarbon levels are less than 90%. ■ Group II base oils are refined using a hydro-processing

method known as “hydrotreating” that adds hydrogen to the base oil at temperatures above 600 F. This is done using a catalyst and applying moderate pressure over 500 psi to convert the base stock and reduce its sulfur content to less than 0.03% and increase its hydrocarbon saturation to levels of 90% and above. ■ Group III base oils are known as “bright stock.” They're

primarily manufactured through a severe hydro-processing conversion method known as “hydrocracking" that employs a catalyst at a temperature above 650 F combined with pressures exceeding 1000 psi to take out undesirable elements like sulfur and nitrogen and replace them with hydrogen. The result is a more stable base oil with a Viscosity Index above 120 and a low pour point. In addition, remaining wax compounds are often removed to reduce the pour point further. Due to this more complex refining process, Group III base oils perform in a similar manner to Group IV pure synthetic base oils—and in most countries around the world, including North America, are allowed to be classified as a synthetic lubricant (even though they are hydrocarbon-based).

(PAO) synthetically manufactured base oils made up of very small synthesized hydrocarbon molecules. ■ Group V base oils represent all other synthetic base oil

configurations.

Table I. Base Oil Groups

Group

VI

% Saturates

% Sulphur

Description

I

80-120

<90

>0.03

Solvent processed

II

80-120

>90

<0.03

Hydro processed

III

>120

>90

<0.03

Severe Hydro processed

IV

>140

-

-

PAO - Polyaphaolephin Synthetic

V

>150

-

-

All other base oils not in I-IV and all other synthetics

SEPTEMBER/OCTOBER 2013

www.LMTinfo.com | 25


ICML CERTIFICATION SERIES

Table II. Synthetic Base Oil Comparison*

Synthetic

Class

Pour Point

High Temp

VI

Cost vs. Mineral

Polyalphaolefin (PAO)

IV

-90 F

550 F

>140

4-5x

Polyalkaleneglycol (PAG)

V

-60 F

500 F

>150

4-8x

Di-Basic Acid Ester (Di-Ester)

V

-80 F

525 F

>150

4-8x

Polyol-Ester

V

-95 F

600 F

>160

10-15x

Silicone

V

-95 F+

600 F

>250

30-100x

Approximate Guideline Values, Always Check Manufacturers Specification

■ Poly-alpha-olefin (PAO) is often described as a man-made mineral oil formulated by synthesis of ethylene gas molecules into a polymerized uniform structure similar to pure paraffin. With a pour point down to -90 F, a VI above 140 and good seal and mineral-oil compatibility, PAOs are widely used in automotive crankcase oils, industrial gear oils, compressor oils and turbine oils. Their negatives include poor additive solubility and biodegradability. ■ Poly-alkylene-glycol (PAG) is an organic-chemical fluid with excellent lubricity (friction-reducing capabilities) and an inherent ability to volatilize (clean burn) any decomposed or oxidized products at high temperatures, thus leaving no sludge, acid buildup or damaging particles should oxidation take place. Polymers of alkylene oxides, PAGs are used primarily for industrial compressor oils, hydraulic oils (water glycol-type) and severe-duty gear oils. With a pour point of -60 F and a VI greater than 150, they have excellent biodegradability, but fall short in terms of mineral-oil and PAO compatibility. ■ Di-basic acid ester (Di-Ester) originally saw use at the end of World War II for jet-engine lubrication (thanks to their high-shear VI stability of 150 and above). Formulated from a reaction between alcohol and acid-laden oxygen, it can suffer from poor hydrolytic stability (reacts to water presence) and poor seal compatibility. Today, Di-Ester is commonly used in high-temperature compressor oils. ■Polyol-Ester replaced Di-Ester as the preferred jet-aviation lubricant because of its increased thermal stability. With a low pour point of -95 F and a VI of 160, it is the preferred lubricant for gas turbines and two-cycle oil applications and is also used as a refrigerant oil. This type of synthetic is expensive (at up to 15 times the cost of mineral oil) and, like its Di-Ester cousin, suffers from poor hydrolytic stability, seal compatibility and corrosion stability. 26 | LUBRICATION MANAGEMENT & TECHNOLOGY

■ Silicone, one of the most expensive lubricants on the market, has a very high flash point and VI of over 250. These characteristics make silicone well suited for hightemperature applications—despite its poor lubricity. Typical applications are brake fluids and fire-resistant hydraulic oils. More recent additions to the marketplace are semi-synthetic base oils blended with mineral base-oil products. These blends generally contain up to 20% pure synthetic product and are less expensive than pure synthetic oils. Because of the lack of standardization with them, their engineered value continues to be debated. Changing base oil characteristics All commercial oils are a unique proprietary blend of base oil and additives. Oil-company chemists and engineers choose the best base oil for the product’s intended purpose and use it as a canvas on which they color with additives to change and expand the base oil’s characteristics, delivering a new set of attributes for the finished product. In the next installment of this "ICML Domain of Knowledge" series (Element #6), we will investigate more base-oil characteristics and how typical additives affect them. Look for it in the November/December issue. LMT

Ken Bannister is a certified Maintenance and Lubrication Management Consultant with ENGTECH Industries, Inc., and author of the Machinery’s Handbook lubrication chapters, and the Lubrication for Industry text recognized as part of the ICML and ISO Domain of Knowledge. He teaches numerous preparatory training courses for ICML MLT/MLA and ISO LCAT certifications. Telephone: (519) 469-9173; or email: kbannister@engtechindustries.com. For more info, enter 05 at www.LMTfreeinfo.com

SEPTEMBER/OCTOBER 2013


PROBLEM SOLVERS

Oil-Free Chain Cuts Downtime And Maintenance Costs

U

.S. Tsubaki’s Lambda® Chain delivers strong, reliable, clean operation without the need for additional lubrication. Suitable applications include packaging, food processing and others that need to be lube-free, or where manual lubrication is difficult or unfeasible. Since no lubrication is required, downtime and maintenance costs are reduced. According to the company, additional features and benefits include: ◆ Oil-impregnated bushings that minimize chain elongation. ◆ The ability to perform in temperatures up to 302 F. ◆ Smooth roller engagement that reduces sprocket wear and replacement costs. Lambda Chain is available in both drive and conveyor (with attachments) styles, with the same maximum allowable loads as U.S. Tsubaki’s standard chains. U.S. Tsubaki Power Transmission LLC Wheeling, IL For more info, enter 30 at www.LMTfreeinfo.com

Anti-Seize Food-Grade Lubricant

C

hesterton’s 785FG is a high-performance antiseize acceptable for use in the food and beverage industries. The lubricant is NSF-registered H1 for incidental food contact and does not contain PTFE or heavy metals. It was specifically developed to provide highpressure thread lubrication for the assembly and disassembly of stainless steel and other common bolting metals used in the food industry. 785FG is available in 200 gm tubes, 500 gm brush-top cans or large bulk packaging. A.W. Chesterton Woburn, MA

For more info, enter 31 at www.LMTfreeinfo.com SEPTEMBER?OCTOBER 2013

Lubrication App For Motor Bearings

A

MRRI’s LubeCoach EM app for the iPhone and iPad can help address precise lubrication requirements for the 85 most common electric motor bearings. Through a series of drop-down menus detailing bearing data, service factors and oil properties, the application calculates and transmits the data and results via email. Deliverables include relubrication frequency and amount (grams or ounces) and verification of the selected lubricant’s fitness for use. Advanced Machine Reliability Resources, Inc. Franklin, TN For more info, enter 32 at www.LMTfreeinfo.com www.LMTinfo.com | 27


PROBLEM SOLVERS

CE-Compliant Coolant Cleaner

I

ndependent laboratory tests now certify that EXAIR’s Chip Trapper™ meets the standards required to attain the CE mark. Chip Trapper offers a fast, easy way to clean large coolant sumps, removing solids such as chips, swarf and shavings. The debrisfilled coolant or liquid is vacuumed into an included 55-gallon drum, trapping solids in a reusable filter bag. With a turn of the flow valve, clean liquid pumps back out. Exair Corp. Cincinnati, OH

Multipurpose NSF H1 Greases

T

he ALLPLEX FMG Series of greases from Klüber offers multi-purpose, NSF H1 registered products for the food processing, beverage and pharmaceutical industries. A special additive package provides anti-wear and extreme pressure protection from corrosion. Equipment in wash-down environments benefit from the aluminum complex thickener system, which adds water resistance and a broad temperature range. ALLPLEX is available in multiple standard packaging options from drums to cartridges, and can be used as a single-point lubricator. Klüber Lubrication Londonderry, NH

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

For more info, enter 34 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 info@engtechindustries.com For more info, enter 70 at www.LMTfreeinfo.com

28 | LUBRICATION MANAGEMENT & TECHNOLOGY

SEPTEMBER/OCTOBER 2013


PROBLEM SOLVERS

Extreme-Temperature Bearings

S

KF’s extreme-temperature bearings feature a graphite cage that lubricates the bearing at up to 350 C without the need for relubrication. According to the company, this allows operators in the metal industry to cut maintenance costs and boost reliability by replacing conventional grease-lubricated bearings. The extremetemperature bearing is included in the SKF BeyondZero portfolio, which contains products that offer enhanced environmental performance characteristics. SKF Lansdale, PA

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SEPTEMBER?OCTOBER 2013

G

raco’s Dyna-Star line of reciprocating pumps helps meet lubrication needs of heavy-duty equipment in mining, construction, fleet maintenance and other applications. The 24 VDC electric lubrication pump supplies grease to injectorbased, series progressive and dual-line metering systems. The Dyna-Star HP (High Pressure) model is capable of 5,000 psi (344 bar) with a maximum output of 18 cubic inches per minute, while the Dyna-Star HF (High Flow) model is capable of 3,400 psi (241 bar) with a maximum output of 25 cubic inches per minute. Graco, Inc. Minneapolis, MN

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

ATP List Services

Lube Pumps For Heavy-Duty Equipment

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INFORMATION HIGHWAY

U.S. Tsubaki is a leading manufacturer and supplier of Roller Chains, Engineering Class Chains, Power Transmission Products and KabelSchlepp Cable & Hose Carrier Systems. The Tsubaki name is synonymous with excellence in quality, dependability and customer service and support. An intense focus on research and development, along with continuously modernized production facilities and highly trained engineers allows Tsubaki to provide you with the right solutions for all of your application needs. For more info, enter 72 at www.LMTfreeinfo.com www.kabelschlepp.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. For more info, enter 73 at www.LMTfreeinfo.com www.airsentry.com

For rate information on advertising in the Information Highway Section Contact your Sales Rep or JERRY PRESTON at: Phone: (480) 396-9585 / E-mail: jpreston@atpnetwork.com For more info, enter 31 at www.LMTfreeinfo.com www.LMTinfo.com | 29


Index ADVERTISER

SEPTEMBER/OCTOBER 2013 Volume 14, No. 5 •

WEBSITE

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.....................................65,73 .. 11,29 ATP Lists.........................................................www.atplists.com .......................................71 ............ 29 Engtech Industries Inc...................................www.engtechindustries.com .....................70 ............ 28 Fluid Defense .................................................www.oilsafe.com/provenchoice.................61 ..........IFC Foster Printing Services.................................www.fosterprinting.com ............................68 ............ 19 Innovator of the Year.....................................www.reliabilityinnovator.com ...................74 ............ 31 Miller-Stephenson Chemical Co. .................www.miller-stephenson.com.....................62 .............. 4 NSK Corporation ..........................................www.nskamericas.com ..............................66 ............ 13 Royal Purple ...................................................www.royalpurpleindustrial.com ...............75 ...........BC SMRP..............................................................www.smrp.org/annualconference .............69 ............ 23 Strategic Work Systems, Inc. .........................www.swspitcrew.com .................................63 .............. 4 U.S. Tsubaki Power Transmission, LLC .......www.longlifelambda.com ..........................64 .............. 5 U.S. Tsubaki Power Transmission, LLC .......www.kabelschlepp.com..............................72 ............ 29 UVLM, Inc. ....................................................www.uvlm.com...........................................67 ............ 15

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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

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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.

IA, IL, IN, MI, MN, NE, ND, SD, WI 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

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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 6746 E. Tyndall Circle Mesa, AZ 85215 480-396-9585 JERRY PRESTON jpreston@atpnetwork.com

REPRINTS ARE IDEAL FOR:

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LUBRICATION MANAGEMENT AND TECHNOLOGY

PMS 370 C

SEPTEMBER/OCTOBER 2013


Calling All Innovators! Don’t just leave it to ‘the other guy’ to show off his/her innovation. You Could Be Our Next Grand-Prize Winner! Enter Now.

Categories: Innovative Devices, Gizmos & Gadgets Innovative Processes & Procedures Innovative Use of Third-Party Resources Honoring the essence of innovation in maintenance and reliability, entries will be judged on the following elements:

Practicality. . . Can it be adopted across industry? Can it be easily replicated, manufactured or sold?

Simplicity. . . Is the ROI less than 3 months? Is the idea intuitive and easily understood?

Presented By

Applied Technology Publications

Deadline for Entries is Midnight, December 31, 2013. Our Grand-Prize Winner & Runners-Up Will Be Announced Early 2014.

Details & Entry Forms Available At www.reliabilityinnovator.com

Impact. . . Reliability Ergonomics (operator, maintainer) Safety Energy reduction Environmental Maintainability (reduces maintenance)

Sponsored By The Innovators At

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LMT Sept/Oct 2013