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AchievinG efficiencieS ThROUGh PRAcTiceS & PRODUcTS
FeatureS PROfeSSiOnAL DeveLOPMenT SeRieS
certiﬁcation Matters, Part iv: Fluid Power Basics
Hydraulic systems are different animals. They require special care and feeding. ©iStockphoto.com/parrus
Ray Thibault, Contributing Editor
SPECIAL REPORT 13
Should We Be Concerned?
You need to get real when it comes to your components. Anything less is too risky. That’s especially true with your bearing purchases.
Bob Williamson, Maintenance Technology Magazine
DeLiveRinG The GOODS 18
The Anatomy Of A centralized Lubrication System: Oil/Air Mist Systems
From Our Perspective
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Here’s some of the devices, carts and lubricant-management systems that have shown up on our editors’ radar screens.
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Achieving EffiCIencies THROUGH PRACTICES & PRODUCTS
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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 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 2011. 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.
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FROM OUR PERSPECTIVE
Ken Bannister, Contributing Editor
Talking To The Shoe
couple of weeks ago, I embarked on my monthly pilgrimage to the local big-boxstore alley. The reason: to be voluntarily seduced into surrendering my wallet in exchange for all manner of items I didn’t know I needed. To ensure maximum efficiency, each store is checked out diligently in a pre-determined route so that I don’t miss any new item(s). First stop: the automotive and tools section. Second stop: the gadget and computer section. Third stop: the book section. (Get my drift?) Finally, if I have to pick up anything on the “official shopping list,” so be it! Looking around, I see I’m not the only lost soul taking a similar ritualistic approach to buying “stuff.” On this most recent occasion, I was excited to see a new addition to the tools section in the form of a digital flexible inspection camera probe for the paltry sum of $125. That’s almost a third of what I paid for mine last year! Most maintainers are old enough to remember the 1960s and ‘70s program Get Smart. In it, Don Adams played the idiot spymaster Maxwell Smart, who relied on a plethora of futuristic gadgets to stay ahead of his enemies— who can forget the shoe phone? Adams went on to provide the voice for a similar cartoon character known as “Inspector Gadget” in the ‘80s and ‘90s. Again, gadgets were the name of the game. We are a society that grew up with the promise of living with futuristic neat gadgets designed to make our lives easier. The dreamers, designers and engineers since the 1960s have worked hard to realize most of those television fantasies and so much more, as evidenced by spacecraft, smart appliances, digital cameras, smart phones, music devices and wireless connectivity, to name a few! This trend has also been strong in the maintenance arena, where we now find cool gadgets, devices and gizmos that were virtually unaffordable 20 years ago, but can now be purchased on any regular operating budget— for every maintainer, in some cases!
LUBRICATION MANAGEMENT & TECHNOLOGY
I purchased my digital inspection camera to enhance my hobby of restoring old cars and motorcycles, and use it to perform non-intrusive internal inspections of gearboxes to check gearteeth condition and, through the spark-plug hole, to inspect piston and bore condition. I now classify it as an invaluable tool that sits alongside my smartphone with Internet access and builtin digital still and movie camera for recording before and after events of concern; my electronic infrared thermometer (now available for between $50 and $75); and my handheld infrared thermographic camera system for checking bearing temperatures, heat exchange and oil-cooler input/output temperatures.
These days, every maintenance department can afford to ‘Get Smart.’ Amazingly, that last technology cost upwards of $100,000 two decades ago—today, outfitted with many more features than the original models, it can be had for less than $1000! The list goes on and on, including computerization and advanced diagnostics that can give us sophisticated oil-analysis capability for less than $20 per sample. I bet you can add several examples of your own. Technology is ever-moving and omnipresent. At prices like those noted here, every maintenance department can afford to “Get Smart” and arm its lubrication department with some “Inspector Gadget” state-of-the-art diagnostic equipment for what amounts to—in most cases—less than the cost of a single bearing failure. It might even inspire us to best practice. Go ahead and “talk to the shoe, 99!” Good Luck! LMT firstname.lastname@example.org
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Certification Matters: Part IV
Fluid Power Basics Hydraulic systems are different animals. Ray Thibault CLS, OMA I, OMA II, MLT, MLT II, MLA II, MLA III Contributing Editor
They require special care and feeding.
his article continues our ongoing series on the important components of lubrication certification examinations administered by the Society of Tribologists and Lubrication Engineers (STLE) and the International Council for Machinery Lubrication (ICML). Please refer to pgs. 10-14, LMT January/February 2011, for more information on STLE and ICML certifications.
n High power-to-size ratio n Ability to achieve high variable speeds and forces n Forces can be transmitted over long distances n Allows large loads to be moved by small forces n Instantly reversible n High level of flexibility and simplicity n High level of accuracy and control n Reliable and maintainable Pascalâ€™s Law (as illustrated in Fig. 1) is the basic principle that governs hydraulics. Pascalâ€™s Law notes that the pressure applied to a confined fluid is transmitted equally and undiminished in all directions throughout the confined vessel. For example, in Fig. 1, if 10 lbs. of force is applied on a 1-in2 piston face, the pressure 8 | LUBRICATION MANAGEMENT & TECHNOLOGY
Hydraulics is defined as the transmittance of force from one point to another using the fluid as the transmitter. The advantages of hydraulics are:
PROFESSIONAL DEVELOPMENT SERIES
Fig. 1. Pascal’s Law is the basic principle governing hydraulics.
exerted by the fluid is 10 psi in all directions at right angles to the surface of the confined vessel. Since force equals pressure times area, the 10-lb. force applied can generate a 100-lb. force on the bottom of the container. Looking at a simple hydraulic system Figure 2 depicts a simple hydraulic system. Fluid stored in a reservoir flows through the system with the aid of a pump. A valve controls the flow in the Fig. 2 system. To prevent the type of system over-pressurization that can lead to safety issues and equipment damage, a pressure-relief valve is installed. It’s designed to open at a preset pressure and divert the fluid back to the reservoir. The pressurized fluid moves through the system and comes in contact with the linear actuator—which can be a piston in a cylinder or a hydraulic motor. The pressure of the fluid in contact with the face of the piston creates the force that moves the load. For example, in Fig. 2, a fluid pressure of 1000 psi in contact with a 5-in2 piston face can move a 5000-lb. load. The direction of high-pressure fluid flow is controlled by directional control valves—which are among the most critical components in a hydraulic system. As shown in Fig. 2, pressurized fluid can come in contact with each face of the piston to move the load in either direction. (There are many types of directional control valves; they’ll be discussed later.) Most hydraulic systems incorporate the following components: n A reservoir usually sized two to three times the pump fluid flow n Fluid conductors (i.e., piping, tubing, hoses and fittings) to transport fluid through the system n Hydraulic fluid n A pump n A filtration system to keep the fluid clean for the tight clearances in the directional control valves n A pressure-relief valve n Directional control valves to control direction of highpressure fluid flow in the actuator (some can also control amount of flow) n Flow-control valves to control actuator speed by controlling fluid flow SEPTEMBER/OCTOBER 2011
Fig. 2. A simple hydraulic system
Pumps The heart of the hydraulic system is the pump. There is a popular misconception that pumps provide pressure. Pumps, however, provide flow—the resistance to that flow generates the pressure. Hydraulic-system pumps are generally positive displacement (PD) types: n Fixed displacement ◆ Gear ◆ Vane ◆ Piston n Axial • Bent axis • Inline n Radial n Variable displacement ◆ Axial n Bent axis n Inline ◆ Vane The gear type—which operates at low pressures—is the simplest and one of the most common pumps in hydraulic systems. Compact, economical and low-maintenance, gear pumps have a high tolerance for particulate contamination. www.LMTinfo.com | 9
PROFESSIONAL DEVELOPMENT SERIES
n Flow-control Fig. 3. Vane pumps operate at a maximum pressure of 3000 psi. Tight clearances, however, make these popular hydraulic system pumps susceptible to particulate contamination.
◆ Butterfly ◆ Diaphragm ◆ Globe ◆ Need n Pressure-control ◆ Pressure-relief is normally set 10-15% above normal system pressure.
The vane (illustrated in Fig. 3) and axial piston (Fig. 4) pump types are also commonly used in hydraulic systems. Vane pumps can be either fixed or variable displacement (wherein fluid flow can be adjusted by adjusting the cam ring). These pumps are quiet and operate at a maximum pressure of 3000 psi. Based on their low cost and compact size, they’re among the most popular pumps for hydraulic systems. Tight clearances, though, make these units susceptible to particulate contamination. Because of the contact between the vanes and cam ring during boundary lubrication, an anti-wear hydraulic fluid is required. There are two basic designs for axial piston pumps: inline and bent axis. Figure 4 is the inline type—compact and economical, but also susceptible to fluid particulate contamination. Pressures for inline axial piston pumps are between 3000 and 6000 psi. The bent axis axial piston pump is both fixed and variable displacement. The most efficient of all hydraulic-system pump types, these high-pressure units also operate between 3000-6000 psi. The highest-pressure hydraulic-system pump is the radial piston—a fixeddisplacement design. These units can achieve pressures up to 9000 psi. According to Eaton, the major failure modes for hydraulic system pumps are:
◆ Unloading allows flow from a larger pump to be diverted to the reservoir when smaller volume pump is providing flow to the system. ◆ Sequence keeps actuator from moving before another moves. ◆ Counterbalance maintains control of loads subject to move by gravity. ◆ Pressure-reducing regulates pressure in branch circuit while maintaining higher pressure in remainder of circuit. ◆ Brake regulates flow when hydraulic motor is stopped.
n Contamination (80%) n Aeration & Cavitation (10-12%) n Over Pressurization (5-6%), and n Other (2-5%). Fluid cleanliness of hydraulic fluids is critical to good performance both for pumps and valves. Valves There are three major control valves associated with hydraulic systems: flow, pressure-control and directional. The various types include: 10 | LUBRICATION MANAGEMENT & TECHNOLOGY
Fig. 4. This inline axial piston pump operates between 3000 and 6000 psi. These compact, economical units, though, are also susceptible to fluid particulate. SEPTEMBER/OCTOBER 2011
PROFESSIONAL DEVELOPMENT SERIES
& Machine Base Flatness
Fig. 5. Servo valves provide the most precise control of any valve type.
n Directional-control valves ◆ Check valves permit flow in one direction.
◆ Solenoid (bang bang) valves permit flow in two directions and are activated by an electrical control magnet. ◆ Proportional valves allow movement in an infinite number of positions through the use of a solenoid. ◆ Servo valves (Fig. 5) allow movement in an infinite number of positions where an electrical sensor provides control. Servo valves, which also control flow, have the tightest clearances at 1-4 microns. This design provides the most precise control of any valve type. Oil cleanliness is critical in maintaining good operation of these components. (A minimum fluid cleanliness of 16/13/11 is required with servo valves, depending on pressure.) Hydraulic fluids The major functions of a hydraulic fluid are power transmission, followed by lubrication of the pump. Other secondary functions include sealing, cooling and contaminant removal. Hydraulic fluids are classified into the following types: n Mineral oils n Fire-resistant ◆ Water-based n High water-based fluids typically are 95% water and 5% oil. n Invert emulsions are typically 60% oil and 40% water. n Water glycol fluids are typically 40-50% water. ◆ Synthetic n Phosphate esters are used as aviation and turbine hydraulic fluids. n Polyol esters are used in many different industrial applications. n Polyalkylene glycols ◆ Biodegradable fluids n Vegetable oils n Polyol esters SEPTEMBER/OCTOBER 2011
h WatcOS E D I V ine Onl
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The major properties desired in a hydraulic fluid are: n The ability to meet or exceed OEM specifications n Minimum Viscosity Index (VI) of 95 n Good thermal and oxidative stability n Good anti-wear protection for pumps n Good water separability n Low foaming n Good air release n Rust and corrosion protection n Compatibility with seals n High filterability n Good shear stability Given the fact that viscosity is the most important property of a lubricant, selection of the correct viscosity is key for proper pump operation in a hydraulic system. Typical viscosities for industrial applications are ISO 32, 46 and 68. The pump OEM will recommend the viscosity required. The viscosity has a minimum and maximum operating range
based on operating temperature. Optimum temperature to run a hydraulic system is 110-140 F. The maximum viscosity allowed for pump startup also must be considered. As an example, Eaton has published the requirements in Table I for gear, vane and axial pumps in industrial applications: Table I. Eaton Industrial Pump Viscosity Requirements Pump Type
Min./Max. Optimum Viscosity, cSt Viscosity, cSt
Maximum Viscosity at startup, cSt
Troubleshooting hydraulic systems Table II lists basic troubleshooting tips for keeping a hydraulic system running optimally. Any problems should be identified as early as possible and corrected before permanent damage or safety issues are encountered. Table II. Troubleshooting Hydraulic Systems
Unsatisfactory oil condition
Debris in oil Oil is cloudy/white indicating air or water Dark color and burnt smell indicating oxidation Cavitation Aeration Dirty oil Servo/proportional valve varnishing Damaged or worn components Defective fluid conductors, piping, tubing, hoses or ﬁttings
Pump noise Erratic system control Oil leakage
Conclusion The basic information presented here can be useful in pursuing lubrication certification through STLE and ICML. Bear in mind, though, it’s just that—very basic. For those considering certification, deeper knowledge of fluid power is required to pass an STLE or ICML exam. Coming up Part V of this series (in the November/December issue) will address pneumatic systems and compressor lubrication. LMT Ray Thibault is based in Cypress (Houston), TX. An STLECertified Lubrication Specialist and Oil Monitoring Analyst, he conducts extensive training for operations around the world. Telephone: (281) 257-1526; email: email@example.com. For more info, enter 66 at www.LMTfreeinfo.com
12 | LUBRICATION MANAGEMENT & TECHNOLOGY
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SPECIAL REPORT This article is based on the author’s September 2011 “Uptime” column in MAINTENANCE TECHNOLOGY.
Should We Be Concerned? Get real when it comes to components. Anything less is too risky. Bob Williamson, Contributing Editor, Maintenance Technology Magazine “We’re buying spare parts from a new supplier who has offered us an amazing discount. They appear to be genuine machine parts, but we’re not sure how that’s possible at these prices. Should we be concerned?” “Our new equipment has shown increasing failure rates of basic parts: roller chains, bearings and seals. We have not changed our maintenance practices one bit. But the failures have increased. Should we be concerned?” Absolutely, positively, without a doubt, 100% YES! You should be very concerned…and for good reason! Today’s global economy coupled with a lingering/growing/ lingering recession and the hunger for money has led to an explosion of scams and counterfeit, fake, pirated, bogus and sub-standard industrial parts. Manufacturers, trade associations, governmental units and law-enforcement agencies have been taking steps to stem the frightening flow of these products into the global and U.S. supply chains. In March 2008, Boeing engineers presented a technical paper entitled “The Counterfeit Parts & Materials Challenge” that stated: “Nearly anything can be counterfeited. Parts such as bolts, nuts, rivets and fluid fittings are all components that can easily be replicated and sold. But the list doesn’t end there. Electronic components, such as capacitors, resistors and integrated circuits, as well as materials like titanium and composite chemicals, are also commonly counterfeited… Counterfeit parts are usually half or less of the street price for genuine goods.” SEPTEMBER/OCTOBER 2011
Analysts have estimated that counterfeiting costs U.S. companies over $250 billion annually ($600 billion worldwide). Over 750,000 jobs may be lost because of the fake, bogus, counterfeit and smuggled products entering our marketplace. And the problem is projected to grow even larger. U.S. government takes action Counterfeit parts certainly cost American jobs—and could even cost American lives. For example: ■ The U. S. Department of Commerce has estimated that our automobile industry could employ 210,000 new workers if the influx of counterfeit products could be eliminated. ■ In a January 2010 report, the Commerce Department’s Bureau of Industry and Security, Office of Technology Evaluation noted that troubling amounts of counterfeit electronics have already gotten into the U.S. Department of Defense (DOD) supply chain. In June 2011, the National Intellectual Property Rights Coordination Center launched “Operation Chain Reaction,” a comprehensive initiative targeting counterfeit items entering the supply chains of DOD and other U.S. government agencies. “Counterfeit and pirated goods present a triple threat to America,” observed John Morton, the director of U.S. Immigration & Customs Enforcement (ICE). “They rob Americans of jobs and their innovative ideas; fuel organized crime; and create www.LMTinfo.com | 13
a serious public safety risk. Counterfeiting has evolved to such a great extent that intellectual property thieves will sell just about anything that will make them a buck, with no regard for integrity of the federal supply chain or the safety of our war fighters. Anytime you purchase a knock-off or pirated product, it’s a virtual certainty the quality and reliability will be inferior to the genuine article.” (See Sidebar). China strikes again In case you didn’t know it, there’s a very healthy global underground market for industrial bearings, seals, roller chains, electronics parts, computer hardware and other assorted equipment parts. One of the most distressing problems is associated with bearings. These mission-critical items are an enormous business in China—netting nearly $4.3 billion in sales. Bearings are an essential component in almost any machine or appliance with moving parts. More and more consumer products, ranging from washing machines to cooling fans and from automobiles to motorcycles, are being manufactured in China. The explosive rise in sales of low-cost cars in China is creating a huge opportunity in bearings for both the OEM and the automotive after-market. All in all, the demand for bearings produced by local Chinese suppliers has skyrocketed. Although no specific type of bearing has been targeted by counterfeiters, according to Derwyn Roberts, the general manager of SKF’s Automotive Division in China, the automotive after-market is one area of growing concern: The bearings typically used in many automotive applications tend to be small. They require less technical capability to produce and therefore are among the easiest to copy. And
while problems with counterfeits are not unheard of in the OEM market, the big rise in recent years of so-called “backstreet” after-market sales operations have helped the fakes to flourish. The increasing wave of fake after-market bearings in China has created a major headache for legitimate and respected international bearing makers who say that it’s often quite difficult to distinguish the fakes from the real thing. Counterfeiters are becoming real good at reproducing the original markings and packaging—in some instances they’re getting almost too good. How it works Illegal bearing manufacturers employ devious techniques to fool end-users and OEMs. Some of these include: ■ New low-quality bearings are re-labeled with false brand markings and put into imitation packaging that appears identical to the real thing. ■ Bearings are remanufactured and then sold with no indication that they have been remanufactured. ■ Old bearings are cleaned, polished and supplied without the buyer being informed of how old they are. ■ Genuine bearings are removed from their packaging and replaced with look-alike fakes. The originals are then sold new in plastic bags. Counterfeiters will make unmarked bearings by the thousands in a variety of popular sizes and then laser etch part numbers in the bearings that look just like
ANSI Speaks To The Counterfeiting Crisis To read more about those quality and reliability issues ICE Director Morton was referring to, you may want to check in with the American National Standards Institute (www.ANSI.org). The organization has published a free 29-page report: “Best Practices in the Fight against Global Counterfeiting: An Action Guide to Strengthen Cooperation and Collaboration across Industry Sectors and among Global Supply Chains.” This comprehensive document is the product of a 2010 ANSI conference and workshops on anti-counterfeiting. It includes insights from industry representatives and professionals from trade organizations and associations, academia, consumer groups, law enforcement and government agencies. For more info, enter 04 at www.LMTfreeinfo.com
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OEM part numbers—sometimes even better. While the fake bearings may look exactly like the OEM’s in many ways, their service life will be very short. That’s because their tolerances, metallurgy, heat-treating and quality is NOT right. Buyers beware! Premature bearing failures don’t just damage equipment and processes, they can cause injury or death. Bearing manufacturers unite in the fight World Bearing Association (WBA)… To raise awareness about counterfeiting, the WBA, formed in 2006, has launched a campaign to spread the word about potential safety hazards arising from counterfeit bearings. Consumers can learn more about the counterfeiting of bearings and what is being done to combat it at www.stopfakebearings.com. American Bearing Manufacturers Association (ABMA)… In July 2011, ABMA presented a Webinar series on counterfeiting and the impact of fake bearings on the global supply chain as part of an educational outreach with the American Gear Manufacturers Association (AGMA). This outreach is part of efforts by ABMA to ensure the bearing supply chain is aware of issues and activity around counterfeit bearings, leading to successful partnerships and enhanced enforcement. The Timken Company… In a November 2010 news release on behalf of the WBA, Timken noted that in the previous two decades counterfeiting in general had grown by 10,000% globally. “While there has been much reporting about consumers being taken advantage of by counterfeits in music, film, home electronics and designer clothing, a far greater risk lies in industrial counterfeiting of items such as tires, seals and bearings. All these products are safety-critical and fake versions pose a real threat.” NSK Ltd… A December 2010 press release quoted NSK’s president and CEO Norio Otsuka: “Bearings support our daily life, although we cannot see them. If counterfeit bearings find their way into our customers’ products, it will not only afflict the product reliability, but it may also damage the safety of our customers’ products. In order to keep our commitment to our customers all over the world to guarantee their safety and security, NSK participates actively in the WBA campaign to stop product counterfeiting.”
SKF Group… To further help customers avoid being duped, SKF offers a six-page tip sheet on how to detect fake bearings. It’s entitled “Where are your bearings coming from – Get the facts about the growing problem of counterfeiting.” Let’s end this ugly story Think about it: The making, selling, transporting and distribution of trademarked counterfeit goods is punishable under U.S. law with fines as high as $15 million and up to 20 years imprisonment. Counterfeit parts can cause severe injury and death. They can lead to job loss, legitimate profit loss, tax losses, increased lawsuits and ever-higher product-liability insurance rates. Just as disgusting is the fact that they’re frequently produced under dirty, substandard conditions that pose great health and safety risks for the workers—which can include children. Proceeds from this type of counterfeiting can often be traced to drugs and arms trafficking, violent crime and smuggling operations. So, you tell me: Should we be concerned? Without any doubt, YES! As maintenance and reliability professionals, it’s our job to help stop the flow of counterfeit parts! Be vigilant. Carefully inspect suspicious components and packaging. Report any unusual findings to your suppliers. And don’t be afraid to just say “NO,” to anything that you know or sense to be or to involve fake parts, no matter how attractive the price may seem. LMT RobertMW2@cs.com For more info, enter 02 at www.LMTfreeinfo.com
References National Intellectual Property Rights Coordination Center: www.IPRCenter.gov ANSI: www.ansi.org World Bearing Association (WBA): www.stopfakebearings.com American Bearing Manufacturers Association: http://www.americanbearings.org WBA free Website banners: http://www.stopfakebearings.com/#/banners Anti-Counterfeiting Training: www.americanbearings.org SKF: www.skf.com/files/891104.pdf Timken: www.timken.com (“Launches Awareness Campaign Against Product Counterfeiting”) NSK: http://www.nsk.com/company/presslounge/news/2010/ press101208.html www.LMTinfo.com | 15
BOOSTING YOUR BOTTOM LINE
Your Just Desserts: A Piece Of The Savings Pie
ccording to the U.S. Department of Energy (USDOE), industry consumes 20% of our country’s electricity—at over $30 billion a year. Within this national bottom line, USDOE estimates $3 billion could be saved annually through improvements to motor-driven systems. Have you taken steps to capture a piece of these savings from your systems? Here are some suggestions for carving out a big slice of the pie: If you haven’t already done so, start with the basics. Identify opportunities to replace older, lowefficiency motors with higher-efficiency replacements, such as NEMA Premium® or greater. When considering these upgrades, remember that while a specific motor is now (or always has been) driving a particular process in your plant, it might not be the best size for the application (and could be consuming more energy than necessary). Ensuring the right size motor, in addition to selecting the most appropriate nameplate efficiency, is an important first “cut.” Just as there is more than one ingredient in your motor-systems pie, savings can be found through more than just improvements to motors within the system. There often are opportunities to capture large savings by ensuring that you have all of the right equipment to achieve your application objectives and that all the equipment works together efficiently. For example, as discussed in previous installments of this column, some applications— i.e., those that don’t need to operate constantly at full speed or those powering centrifugal equipment like pumps and fans—can obtain significant savings through a retrofit with an adjustable speed drive (ASD), also known as a variable frequency drive (VFD) or variable speed drive (VSD). Sweet! Engineers at Boeing’s Renton manufacturing facility realized energy savings by first focusing on their motors and then expanding to consider the full motor-driven system. Their first step was to create an extensive motor inventory of
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LUBRICATION MANAGEMENT MAINTENANCE TECHNOLOGY & TECHNOLOGY
all active and spare motors. The next step was to consider the objectives that each system was designed to achieve. For example, the facility had recently reduced its airflow requirements, which led to the operation of many unneeded—and inefficient—fans. As a result of its motor inventory and system assessment, the Renton facility was able to identify opportunities for motor upgrades, ASD retrofits and decommissioning of systems that were no longer necessary, all of which led to an especially sweet slice of savings: 136,984 kWh or $16,578 annually. More information to support assessing and finding efficiency in motor-driven systems is available on the Motor Decisions MatterSM (MDM) Website at www.motorsmatter.org. Among other things, you’ll find the MDM Motor Planning Kit that outlines simple steps in developing an effective motor management program. The VFD section of the Helpful Resources page includes details on identifying the conditions when these drives are appropriate. A visit to the MDM Website is a great way to get started on serving up your just desserts: That’s a sizeable helping of available motor-systems energy savings! LMT 1. USDOE, 2008. (http://www1.eere.energy.gov/ industry/bestpractices/pdfs/motor.pdf) 2. Northwest Energy Efficiency Alliance, 2004. (http://www.motorsmatter.org/case_studies/ boeing.pdf) For more info, enter 67 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 firstname.lastname@example.org or (617) 589-3949.
SEPTEMBER/OCTOBER 2011 OCTOBER 2007
BIG MONEY TALKS XX UM William C. Livoti
A Matter Of Survival
iven the surge in demand for electricity and a projected increase in global population (9 billion by 2030), the importance of available energy can’t be underestimated. In the United States, our nation’s economic growth and prosperity depend on plentiful, reliable and affordable electricity. For almost a century, coal has been our primary source of electric power—providing over half of U.S. electricity demand. Today, the power industry is being challenged by federal- and state-mandated environmental and energy regulations that will change the industry forever. Environmental concerns about the effects of burning fossil fuels have ignited a worldwide pursuit of renewable energy sources. At the same time, events in Japan have soured interest in nuclear power, leading to projected delays or cancellations of planned construction. The result of all this? We have effectively eliminated two primary sources of base load power (coal and nuclear)—sources that are responsible for approximately 75% of electric power generation in our country. Emerging technology for cleaner electricity production will play a vital role in our economic growth. How and when this technology is implemented— and at what cost—will determine the future of our existing base load fleet. But, what’s to become of our economic growth in the meantime? With the focus on renewable energy and the negative press surrounding fossil fuels and nuclear, the power industry has few options to meet the growing demand for power. One of those options (maybe the best one of all) has been staring us in the face for a long time: Efficiency is the future of power generation. Begging the question I’ve often asked, “What has the U.S. power industry done to improve power-plant efficiency? Answer: For the last 75 years, it’s done little to nothing. Coal plants are still operating in the 33% range. New ultra-super critical units may be approaching 45%, but we can’t seem to get past the permitting
VOLUME VOLUME 62 // NO. NO. 32
stage to build them. The short-term solution is “combined cycle.” Still fossil-fuel in nature, the upside of combined cycle technology is that it’s more efficient than coal (assuming the unit is operating at design point, since reducing loading or going to duct fire has a negative impact on the plant heat rate). Unfortunately, combined-cycle still doesn’t address the projected increase in power demand. TVA and Duke have both announced plans to decommission a number of aging coal plants (the main reason being the cost associated with meeting new EPA legislation). These operators can’t justify the cost of bringing their aging units into compliance. Other utilities are being forced to take similar action. A better way While we’re losing base-load generation due to an aging fleet and with no clear direction from the federal government (think energy plan), federal legislation is forcing utilities to build combinedcycle plants. This will most likely push natural gas prices up (remember the ‘90s?), the cost of which will be passed on to the consumer. It seems to me that the most cost-effective solution is to drive more out of our existing plants— not by pushing equipment beyond its design capacity, but by improving efficiency. There are several benefits to this approach, including the fact that with efficiency comes reliability. If a plant’s equipment is operating at optimum efficiency, reliability will be optimized, heat rates will improve, parasitic load will be reduced and net megawatt output will increase. And we get it all for a lot less money and grief than what’s involved with building a new plant. I’ll explore this topic in detail in an article entitled “The Future of Power: Survival of the Efficient,” in October’s Maintenance Technology. LMT Bill Livoti is sr. principal engineer, Power Generation and Fluid Handling, at Baldor Electric Co., a business of ABB. Email: email@example.com..
UTILITIES UTILITIES MANAGER MANAGER || 17 23
DELIVERING THE GOODS
The Anatomy Of A Centralized Lubrication System
Oil/Air Mist Systems An environmentally friendly descendant of the original oil mist systems, oil/air mist technology is one of the most efficient automated lubrication delivery systems available today, and one of the least expensive.
In Line Air Heater
Vortex Generator Baffle
Mist Out Filter
Oil Pickup Tube Oil Heater
Oil Reservoir Mist Generation Unit
Ken Bannister Contributing Editor
il mist systems have come a long way since their introduction to the European textile industry over 70 years ago. Initially designed to resolve high-speed spindle bearing failures that would not respond to conventional oil and grease lubrication tactics, oil mist first found favor in the North American market in the 1960/70s with the oil and gas industry, which adopted these systems to successfully lubricate large pump- and motor-bearing assemblies.
As oil mist became more mainstream and moved into the large manufacturing industries, however, its open-vent system design—combined with the ability for operators and maintainers to easily adjust the air-flow pressure at will— often created oily workplaces. An increased awareness of environmental safety eventually resulted in a ban on both well-designed and poorly designed oil mist systems in many plants. That’s not the case these days. Things have really changed: With the introduction of micro-process control, vortex-style mist generation and closed-loop system design, coupled with airborne-mist18 | LUBRICATION MANAGEMENT & TECHNOLOGY
detection systems, one of the most effective lube-system designs has experienced a dramatic resurrection. How the System Works In the original oil mist system design, a pressure-controlled, filtered compressed air supply is passed through a venturi. Oil is then siphoned from a reservoir by the quickened airflow directly following the venturi and is directed at a baffle plate, causing the oil to atomize into very fine droplets known as “dry mist.” Anything less than a ratio of 1-part-oil to 200,000-partsair ratio (approximately 1.5 microns or 0.00006” diameter) SEPTEMBER/OCTOBER 2011
falls back to the reservoir as heavy oil particles. Mist is then piped into a 2” diameter scheduled pipe header at between 5-40” water pressure, creating a velocity of up to 24 ft/sec. As it approaches the bearing point, the mist is passed through a series of mist-metering fittings that allow an engineered amount of oil to enter the bearings. Depending on the fitting type used, the “dry mist” or partially reclassified mist then “envelops” and “wets” the entire bearing surface area with a thin lubricant film while imparting a partial positive pressure within the bearing housing that works to prevent contamination influx. In the original design, the mist was allowed to vent to atmosphere. New system designs (now characterized as oil/air mist types) employ sloped lines to carry reclassified oil within the lines directly back to the reservoir, and more important, reflect a closed-loop design with drain legs and components designed to capture coalescent waste and eliminate open venting. An improved vortex air-chamber design to replace the old venturi design has led to more efficient mist generation that can now carry over distances of 600 feet— three times that of the original systems. This translates into the ability to lubricate substantially more points from a single mist-generation unit. The coalesced-oil-return improvements have turned a once total-loss system design into a much more effective partial-recovery system using less lubricant. Pros & Cons Improved system design, micro-process control and access control to the mist generator have made oil/air mist systems virtually tamper-resistant—and provided the ability to generate mist with finite control based on ambient conditions. With hermetic bearing contact seals to eliminate stray mist, this has resulted in an environmentally sound system and the elimination of any stigma associated with the old mist delivery systems. Oil/air mist is not to be confused with air/oil mist (which we’ll discuss in January/February). Oil/air mist is well-suited for lubricating both slow-moving and highspeed rotating equipment. Because a very small amount of lubricant is being introduced over the entire bearing surface on a continual basis—lubricating and cooling the bearing— oil/air mist is one of the most efficient automated delivery systems available, and one of the least expensive. Coming Up In the November/December issue, we’ll be looking at Single-Point Lubricator systems. LMT For more information regarding automated lube systems, check out Ken Bannister’s best-selling book Lubrication For Industry, published by Industrial Press. Telephone him directly at: (519) 469-9173; or email: firstname.lastname@example.org. For more info, enter 03 at www.LMTfreeinfo.com SEPTEMBER/OCTOBER 2011
For more info, enter 65 at www.LMTfreeinfo.com For more info, enter 68 at www.LMTfreeinfo.com
www.LMTinfo.com | 19
Lube Transfer Solutions FlowGuard™ LT Series Lubricant Management System
IFH 3060 Mobile Lubrication Cart
es-Case’s FlowGuard LT Series Lubricant Management System (LT-LMS) incorporates multiple technologies in a single unit to keep lubricants clean before they enter your equipment. Sturdy, stackable and customizable storage pods free up valuable floor space, while features like quick-disconnects and desiccant breather filters help keep fluids clean and dry. High-density polyethylene and steel tanks are available in a range of sizes with a variety of hose-end connections. Each container features a dedicated pump and motor and allows for the management of a number of lubricant types.
FH Group’s 3060 Mobile Lubrication Cart can hold six separate products, each in 15-gal. polyethylene containers that feature molded-in gallon markers, 5” flip-lid fill caps, permanent suction tubes and outlet fittings. The cart has a 3/4” reversible air-operated diaphragm pumping system with filter-regulator-lubricator, air shut-off valve and a 10’ product dispensing hose with an on/off control handle. The unit’s base functions as a large drip pan, helping to eliminate spills. Other features include a tight turning radius and storage space for oil cans, rags, grease guns and more.
Des-Case Corp. Goodlettsville, TN
IFH Group Rock Falls, IL
For more info, enter 30 at www.LMTfreeinfo.com
30080 Vacuum-Powered Oil Cart
age Oil’s 30080 Cart, part of its Vac Streamline Shop Series, is suited to both shop and factory environments. The unit’s small size means it can fit in almost any space and ease fluid changes. It works via the same vacuum and pressure process as the company’s larger systems. Intended for fluid recovery only, the 30080 has a 30-gal. usedoil tank and an integrated off-load hose. Other features include a filter stinger and a 3/4” x 15’ hose with manual hose wrap. Sage Oil Vac, Inc. Amarillo, TX For more info, enter 32 at www.LMTfreeinfo.com
20 | LUBRICATION MANAGEMENT & TECHNOLOGY
For more info, enter 31 at www.LMTfreeinfo.com
Three Speed Bulk Transfer Cart (patent pending)
iquidynamics’ Three Speed Bulk Transfer Cart incorporates a gearbox that allows the pump to be used with a range of viscosities up to 3150 cps. By simply shifting gears, a user can pump “thin” fluids like 100% antifreeze or hydraulic oil at 40 GPM, mediumviscosity fluids like 10W30 motor oil at 20 GPM, or “thick” fluids like 120 wt gear oil at 10 GPM. Constructed of heavy-gauge 1” powder-coated steel tubing, the cart features a 2 ½-gal. drip catch tank with convenient drain valve for dealing with drippage. Liquidynamics Wichita, KS For more info, enter 33 at www.LMTfreeinfo.com SEPTEMBER/OCTOBER 2011
OIL MISER™ FILLorDRAIN™
Model 5265 Portable Oil Dispensing System
he OIL MISER FILLorDRAIN from JLM Systems standardizes fluid-handling procedures by closing the loop on airborne contamination from drum to reservoir or vice versa. Available in tank- and drum-mounted versions, its cast aluminum body has two separate internal cavities, one an oil passage, the other an air passage. A 5-micron replaceable air filter prevents unfiltered air from entering the reservoir or drum when internal fluid levels change. As shown in the accompanying photo, the product is offered with an external port that allows oil sampling under operating conditions.
ational-Spencer says its Model 5265 Portable Oil Dispensing System is ideal for synthetic oil or for when mobility is needed to dispense bulk oils. The 17-gal. wheel-mounted tank is equipped with a level gauge and a loading funnel with an anti-splash rim. A 3:1 ratio pump delivers 3.7 gallons per minute. The unit also features an air regulator with a gauge, filter and an automatic water drain. Its 3” front and 6” rear wheels with ball bearings make for smooth and easy rolling.
JLM Systems Limited Richmond, BC, Canada
National-Spencer, Inc. Wichita, KS
For more info, enter 34 at www.LMTfreeinfo.com
For more info, enter 35 at www.LMTfreeinfo.com
For more info, enter 69 at www.LMTfreeinfo.com
www.LMTinfo.com | 21
IT TAKES ONE TO KNOW ONE... There’s more than just bragging rights at stake...
Presented By Applied Technology Publications
As the Grand Prize Winner, you could win an expense-paid trip to MARTS 2012 and more, including special prizes from the Innovators of Inpro/Seal, Royal Purple and Scalewatcher! More About Our Monthly Winner For August... Tom Frail, a Level III Thermographer with Con Edison of New York, has been performing infrared inspections for over 20 years. A monthly winner in the category of innovative processes and procedures, he also worked with a third-party resource. A member of Con Edison’s Power Quality Group, Tom has become the “go-to guy” regarding infrared (IR). Unlike other utilities, his company has many departments/groups that perform IR inspections, each reporting in different ways. Furthermore, there’s typically been no sharing of information among these groups. Tom knew there had to be a better way. It was at an IR-INFO conference that he saw the solution for creating a Web-based IR reporting system. He realized that Logos Computer Solutions’ InspecTrend software tool could bring together the disparate departments in Con Edison that use infrared technology. All reports would look the same, and there would be a single database for inspections. This would allow benchmarking and baseline trending, as well establishing of alarm-limit thresholds should inspected equipment show signs of change. Data could be easily and instantly shared across the company. As a result of Tom’s continuous lobbying, Con Edison’s R&D Group recognized the beneﬁts that the utility could reap using the Logos product, and the purchase go-ahead was recently given. The next step for Tom and the Power Quality Group is to develop an Infrared Web page, much like their Power Quality page on Con Edison’s intranet. Congratulations to Tom and everyone involved in this project!
Don’t Procrastinate... Innovate! Important Update...
Unfortunately, new entries didn’t arrive in time for us to announce a September winner. This contest runs through December 31, 2011. Don’t wait until the last minute to enter. The sooner you do, the better your chance of being named one of 3 remaining monthly winners. All entries have a shot at the Grand Prize and three Category* Awards. Enter now. For complete details and submission forms, go to www.ReliabilityInnovator.com *Categories include innovative devices, gizmos and gadgets; innovative processes and procedures; and innovative use of outside resources.
LUBRICATION MANAGEMENT & TECHNOLOGY
The Innovators Of
Are Proud To Sponsor The Maintenance & Reliability Innovator Of The Year Award
Inpro/Seal Rock Island, IL www.inpro-seal.com Inventor of the original Bearing Isolator, Inpro/Seal has been delivering innovative sealing solutions and superior customer service for more than 30 years. Now part of Waukesha Bearings and Dover Corp., Inpro/Seal is stronger and more innovative than ever and continues to invest in technology and product development. This brand built its reputation on the outstanding performance of the original Bearing Isolator, which increases the reliability of rotating equipment and provides cost savings by improving mean-time-betweenrepair (MTBR). Plus, Inpro/Seal offers same- or next-day shipments, even on new designs. But Bearing Isolators were just the start. In response to customer needs, Inpro/Seal now offers the Air Mizer® for sealing a variety of product-handling equipment; the Current Diverter Ring™ (CDR®), which protects motor bearings and coupled equipment by diverting damaging electrical currents to ground; and the Motor Grounding Seal (MGS®) that combines CDR technology with the complete protection of a Bearing Isolator to safeguard bearings from electrical currents and contamination.
The innovators of INPRO/SEAL will provide individual iPads and cases to the Grand Prize winner and 3 Innovation Category winners. *Categories include innovative devices, gizmos and gadgets; innovative processes and procedures; and innovative use of outside resources. For more info, enter 70 at www.LMTfreeinfo.com
...AN INNOVATOR, THAT IS! The Innovators Of
The Innovators Of
Are Proud To Sponsor The Maintenance & Reliability Innovator Of The Year Award
Are Proud To Sponsor The Maintenance & Reliability Innovator Of The Year Award
Royal Purple Porter, TX www.royal-purple-industrial.com
Scalewatcher North America, Inc. Oxford, PA www.scalewatcher.com
Lubricant performance can vary greatly between competing mineral-based and synthetic products. According to the innovators of Royal Purple, since quality differences can signiﬁcantly impact the cost of operating and maintaining equipment, your lube purchases can’t be effectively managed as a commodity: Lubricant excellence is paramount. The company notes that beneﬁts attainable across a broad population of rotating equipment from upgrading to Royal Purple lubricants include, among other things, energy savings greater than 3%, and a reduction in the need for equipment repair by at least 30%. Although Royal Purple products may cost more per gallon, an operation’s annual cost for lubricants changes little, due to greatly extended drain intervals and the elimination of oil changes associated with equipment repairs. Initiatives to reduce maintenance and improve equipment reliability often are time- and people-intensive. Royal Purple offers substantial improvements and savings simply through replacement of a product you already buy and use. It doesn’t get any easier than this.
Scalewatcher™ is a no-maintenance environmentally friendly descaler that does not change water composition. Scales and stains disappear gradually and completely, without further action required, guaranteed. The Scalewatcher products work by way of magnetic and electric ﬁelds and a continuously changing frequency. The process forces dissolved minerals such as calcium and magnesium to crystallize before mineral ions (the cause of hard scale) can settle on surfaces. This stops or reduces new buildup of hard scale, and because the water is better able to dissolve minerals, existing hard-scale layers are softened and eventually disappear. The Scalewatcher technology has been used by more than 250,000 satisﬁed customers worldwide. These products prevent corrosion in pipework; prevent settlement of zebra mussels in plants using sea or river water for cooling; reduce bacterial counts in cooling systems; reduce water and energy bills; extend the life of water-using equipment (especially boilers); can be installed without plant shutdown; are maintenance-free; and last 20+ years.
The innovators of ROYAL PURPLE will provide individual cases of Royal Purple products to the Grand Prize winner and 3 Innovation Category winners.
The innovators of SCALEWATCHER will provide individual water treatment units to the Grand Prize winner and 3 Innovation Category winners.
*Categories include innovative devices, gizmos and gadgets; innovative processes and procedures; and innovative use of outside resources.
*Categories include innovative devices, gizmos and gadgets; innovative processes and procedures; and innovative use of outside resources.
For more info, enter 71 at www.LMTfreeinfo.com
For more info, enter 72 at www.LMTfreeinfo.com
www.LMTinfo.com | 23
SOLUTION SPOTLIGHT Catch impending failure in hi-def…
Improved Low-RPM Rolling Element Bearing Analysis See what you might be missing long before ‘too late.’
Inner raceway damage on low-RPM bearings can take a process down.
Time signal from a 10 RPM bearing showing “inner raceway” failure (4 months pre-warning)
SPM®HD Overall Trend Graph before and after bearing replacement
olling element bearings (also known as anti-friction bearings) are found throughout industry. Due to their construction, metal fatigue eventually causes every one of these bearings to deteriorate and fail, taking critical equipment and processes down with them. For many decades, companies have used vibration analysis to monitor equipment condition. While a successful Condition Monitoring program can aspire to predict and therefore prevent all “unplanned” failures, in light of their very low energy content, low-RPM applications (i.e., under 50 RPM) have traditionally been some of the most difficult to monitor. An answer to this dilemma has been the “Shock Pulse Method.” Developed and patented in 1969, this technique has been widely used to successfully monitor rolling element bearing condition ever since. And, just as technology has advanced, so has the Shock Pulse Method. Most recently, SPM Instrument has released SPM®HD (SPM High Definition). Particularly well suited for low-RPM
LUBRICATION MANAGEMENT & TECHNOLOGY
applications, this new technology can be utilized on rolling element bearings throughout the range of 1-20,000 RPM. According to SPM, with damage indications and pre-warning times up to 16 months in advance of failures, the product is providing neverbefore-seen detail in the time signal and FFT. In many cases, low-RPM bearings are typically very large—or of a specialty type where replacement bearings can be many months out from delivery. In those cases, long pre-warning times are especially important. Improvements to the Shock Pulse Transducer, advanced algorithms to filter out irrelevant signals and advanced sampling times, including better data acquisition, provide sharp time signals and crisp, detailed spectrums. SPM®HD is currently available from SPM Instrument in the Intellinova line of continuous monitoring products. LMT SPM Instrument, Inc. Eugene, OR For more info, enter 36 at www.LMTfreeinfo.com SEPTEMBER/OCTOBER 2011
Flame-Resistant, Highly Visible Work Clothing
niFirst has added a reflective striping option to its Armorex FR® flame-resistant work shirts, pants and coveralls to create a line of combined Flame Resistant/Enhanced Visibility safety uniforms. This new offering features 3M Scotchlite™ reflective striping that completely encircles elbow and knee areas, with shirts and coveralls also incorporating striping across back and waist areas. These uniforms can be either rented or purchased. UniFirst Corp. Wilmington, MA
Tough Penetrating Grease
robe Delayed Viscosity Penetrating Grease from Frederickseal combines natural and synthetic lubricating agents with a highmolecular-weight polymer in a transparent, high-pressure product with superior adhesive strength. The company notes that Probe stays in place without being thrown off, squeezed out or washed off when subjected to high pressures, vibrations, repeated impact or water spray. It operates in temperatures from -30 F to over 530 F. Frederickseal, Inc. Manchester, NH For more info, enter 39 at www.LMTfreeinfo.com
KRYTOX® FLUORINATED LUBRICANTS
For more info, enter 37 at www.LMTfreeinfo.com
Revamped Line Of Extreme Service Greases
hell Lubricants has launched an improved range of Shell Gadus greases designed to meet the challenges of large, fast equipment operating in some of the most extreme conditions imaginable, including mining, steel-production, power-gen and marine applications, among others. The revamped lineup makes it simpler for customers to compare product benefits and performance while taking into account variables such as compatible thickeners, base oil viscosity, NLGI grade and other special performance characteristics. Shell Lubricants Houston, TX For more info, enter 38 at www.LMTfreeinfo.com SEPTEMBER/OCTOBER 2011
Krytox® Fluorinated Greases and Oils are: Chemically Inert. Insoluble in common solvents. Thermally stable. Temperature range (-103°F to 800°F). Nonflammable. Nontoxic. Oxygen Compatible – safe for oxygen service. Low Vapor Pressure. Low Outgassing. No Migration – no silicones or hydrocarbons. Krytox® offers Extreme Pressure, Anticorrosion and Antiwear properties. Milspec, Aerospace and Food Grades (H1 and H2) available! Useful in Vacuum Systems. For technical information, call 203.743.4447 / 800.992.2424 (8 AM – 4 PM ET)
Miller-Stephenson Chemical Company, Inc. California – Illinois – Connecticut – Canada Email: email@example.com
www.miller-stephenson.com For more info, enter 73 at www.LMTfreeinfo.com www.LMTinfo.com | 25
Lightweight, Digitally Controlled, Mechanical Torque Multipliers
Environmentally Friendly Pre-Lubricated Coupling
dvanced Torque Products’ digitally controlled, mechanical torque multipliers have ranges from 600 to 40,000 ft./lbs., with accuracy to ±1%, even over extreme temperature fluctuations. These lightweight, all-mechanical multipliers need no external power and present a small, ergonomic footprint. According to the manufacturer, a host of drive adapters and mounting fixtures accommodate existing tooling for nearly any application.
Advanced Torque Products, LLC Berlin, CT For more info, enter 40 at www.LMTfreeinfo.com
he Baldor•Dodge pre-lubricated GRID-LIGN coupling is a lubed-for-life design that’s interchangeable with existing grids, hubs and covers. Easy to install and maintenancefree, it eliminates downtime associated with improper lubrication. The environmentally friendly product features high-performance synthetic oil impregnated in a polymer shell encapsulating the grid element. Acting as an oil reservoir, the polymer helps to prevent the introduction of any contaminants during installation and does away with the mess associated with greasing a traditional grid design.
Baldor Electric Co. A member of the ABB Group Fort Smith, AR For more info, enter 41 at www.LMTfreeinfo.com
ASTM-Compliant Grease Sampling Kits
n June, ASTM issued Method D7718 - 11 entitled “Standard Practice for Obtaining In-Service Samples of Lubricating Grease.” In it, a method is outlined for obtaining trendable samples from motor-operated valves, gearboxes and more. With the Grease Thief sampling kits from MRG labs, users can develop sampling procedures consistent with the guidance in the practice, and ensure trendable analysis. Grease Thief samplers can be used with Kittiwake’s ANALEXfdMplus ferrous debris analyzer for rapid wear-level determination, while the Grease Thief Analyzer can give insight into wear, consistency, contamination and oxidation condition. MRG, LLC York, PA
For more info, enter 74 at www.LMTfreeinfo.com
26 | LUBRICATION MANAGEMENT & TECHNOLOGY
For more info, enter 42 at www.LMTfreeinfo.com SEPTEMBER/OCTOBER 2011
Synthetic Machining Coolants
System For Complete, Uniform Lubrication Of Critical Areas
AG’s CYCLO COOL® 900 and 5000 series additive-free, low-foam synthetic coolants are specially formulated for machining titanium, Inconel, beryllium copper, hardened and stainless steels and other superalloys. MAG notes these products can replace semi-synthetics and soluble oils to deliver savings through lower initial cost, longer tool life, increased stock removal rates, long sump life and freedom from biocides/fungicides/pH adjusters. Both products are clear during use, allowing excellent cutting-zone visibility.
praying Systems says its AutoJet Electrostatic Lube System can provide complete, uniform lubrication of critical areas and is also well suited for oil-coating applications and other lube tasks calling for singlepoint delivery. Capable of accommodating up to four electrostatic nozzles with an injector pump for each, the system eliminates oil mist concerns in the work environment, minimizes cleanup and reduces potential for product contamination. It can also help reduce oil consumption.
MAG Erlanger, KY
Spraying Systems Co. Wheaton, IL
For more info, enter 45 at www.LMTfreeinfo.com For more info, enter 43 at www.LMTfreeinfo.com
Contain And Clean Up Spills
raphic Products has released its first catalog of spill-containment and cleanup products. According to the manufacturer, this 10-page SpillArrest catalog fully complements the company’s line of safefacility signs, labels and printers that help keep workplaces cleaner, safer and more productive. Items include those for spill removal (pads, rugs and mats, pillows, loose sorbents); isolation (berms, booms, containment pools, pallets, workstations, socks); oil, universal and HazMat spill kits; and diverters/drain guards. Items are colorcoded to help users identify appropriate products for various spills. Graphic Products Portland, OR For more enter at www.LMTfreeinfo.com For more info,info, enter 72 at44 www.LMTfreeinfo.com SEPTEMBER/OCTOBER 2011
Customized, Targeted Lists For Your Marketing Needs
ATP List Services Ellen Sandkam www.atplists.com 1300 S. Grove Ave., Suite 105, Barrington, IL 60010 847-382-8100 x110 / 800-223-3423 x110 firstname.lastname@example.org / email@example.com For more info, enter 75 at www.LMTfreeinfo.com www.LMTinfo.com | 27
High-Performance, Synthetic Industrial Gear-Oil Family
xxonMobil’s new Mobil SHC Gear Series is a line of high-performance, fully-synthetic industrial gear oils formulated to help general manufacturing and processing industries increase productivity and reduce costs by lowering energy consumption and extending oil drain intervals. Approved by Siemens for use in Flender gearboxes, these lube products, according to ExxonMobil, meet or exceed nearly every other major industry and OEM specification for industrial gearbox applications. The company notes that in statistically validated laboratory tests and field trials, these fluids exhibited energy savings of up to 3.6% compared with conventional oils.* *Energy efficiency relates solely to the fluid performance when compared with conventional reference oils of the same viscosity grade in gear applications. The technology used allows up to 3.6% efficiency compared with the reference when tested in a worm gearbox under controlled conditions. Efficiency improvements will vary based on operating conditions and application.
ExxonMobil Corp. Fairfax, VA
For more info about ExxonMobil, enter 46 at www.LMTfreeinfo.com
For more info about Flender/Siemens, enter 47 at www.LMTfreeinfo.com
7-Step Best Practice Lubrication Program Professional Self-Directed Implementation ToolKit
Tap into your Liquid Gold for less than $20 per day!* Whether you’re looking to increase asset utilization and maintainability, reduce contamination, downtime, energy consumption and/or your carbon footprint, or simply cut your maintenance and operating costs, you’re ready for a 7-Step Best Practice lubrication program! For more information on this “expert in a box” approach to successful lubrication programs, contact ENGTECH Industries at 519.469.9173 or email firstname.lastname@example.org * Amortized over one year
For more info, enter 76 at www.LMTfreeinfo.com
28 | LUBRICATION MANAGEMENT & TECHNOLOGY
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
1300 South Grove Avenue, Suite 105 Barrington, IL 60010 PH 847-382-8100 FX 847-304-8603
Machinery Health Personnel PM & PdM Field Service • Mgt • Sales • Hrly
Nationwide • Conﬁdential • All Fees Company Paid
For rate information on advertising in the Classified Section Contact your Sales Rep or JERRY PRESTON: Phone: (480) 396-9585 e-mail: email@example.com
� Disconnect Switch Rated � Simplifies NFPA 70E compliance www.meltric.com • 800.433.7642
Customized, Targeted Lists For Your Marketing Needs Ellen Sandkam www.atplists.com
847-382-8100 x110 / 800-223-3423 x110 firstname.lastname@example.org / email@example.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 firstname.lastname@example.org 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
SEPTEMBER/OCTOBER 2011 Volume 12, No. 5 •
ATP Lists ....................................................www.atplists.com ............................. 75................... 27 Baldor Electric Company.........................www.baldor.com .............................. 63..................... 5 Bel-Ray Company .....................................www.belray.com............................... 64..................... 7 Dropsa USA Inc ........................................www.dropsa.com ............................. 68................... 19 Engtech Industries Inc..............................www.engtechindustries.com........... 76................... 28 FosteReprints .............................................www.fosterprinting.com ................. 62..................... 4 JLM SYSTEMS LTD..................................www.oilmiser.com ........................... 66................... 12 LubeStarz ...................................................www.lmtinfo.com/lubestarz ........... 77................... 30 LUDECA, INC...........................................www.ludeca.com .............................. 65................... 11 Miller-Stephenson Chemical Co. ............www.miller-stephenson.com.......... 73................... 25 Royal Purple ..............................................www.royal-purple-industrial.com . 79..................BC Shell ............................................................www.shell.us/lubricants .................. 61..................... 2 SMRP .........................................................www.smrp.org/conference.............. 69................... 21 Strategic Work Systems, Inc. ....................www.swspitcrew.com ...................... 74................... 26 U.S. Tsubaki Power Transmission, LLC ..www.longlifelambda.com ............... 78................... 31
Access LMTfreeinfo.com and enter the circle number of the product in which you are interested, or you can search even deeper and link directly to the advertiser’s Website. Submissions Policy: Lubrication Management &Technology gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish, and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. MARCH/APRIL 2011 SEPTEMBER/OCTOBER 2011
SALES STAFF OH, KY, TN 135 N. Rocky River Road Berea, OH 44017 440-463-0907; Fax 440-891-1254 JOHN DAVIS firstname.lastname@example.org
TOLL FREE 877-386-1091
IL, IN, IA, MI, MN, NE, ND, SD, WI 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 847-382-8100 x108; Fax 847-304-8603 TOM MADDING email@example.com
AR, KS, LA, MO, NM, OK, TX 5930 Royal Lane, Suite E #201 Dallas, TX 75230 972-816-6745; Fax 972-767-4442 GERRY MAYER firstname.lastname@example.org 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
CLASSIFIED ADVERTISING 3605 N. Tuscany Mesa, AZ 85207 480-396-9585 JERRY PRESTON firstname.lastname@example.org
www.LMTinfo.com | 29
WE’RE BUILDING A TEAM...
e b u Meet Our L rz a t S
We love to learn about LMT readers, including what they do in the field of lubrication (and what they like about their jobs)! Here’s what our September/October Lube Star told us:
Steve Vaughan, MLT I Title: Maintenance Mechanic
Alcoa – Mt. Holly Goose Creek, SC Background: Steve Vaughan has been working
in the Alcoa – Mt. Holly operations for 28 years, including 24 in his current position as a maintenance/lubrication professional. He ranks his overall knowledge of industrial lubrication as “advanced,” and tells us that he received much of his lubrication-related education and training on the job and through live workshops and non-structured online opportunities (such as Webinars, company videos, etc.). Why He Became A Lubrication Professional: According to Steve, he viewed
professional development in the lubrication arena as an opportunity to focus on a part of a job that he had been doing for years. After all, as he points out, “There is a lot more to it [lubrication] than shooting grease and filtering oil.” What He Likes Most About His Work: Steve summed up the best part of his work
in one sentence: “I like the wealth of information on lubrication and figuring out the best way to apply that knowledge with resources available.”
e b u L tarz S
Congratulations to Steve for being selected to our Lube StarzCompany team! Info Contact Our congratulations (and thanks) also go out to Alcoa – Mt. Holly Info Here www.websitehere.com for helping us put a spotlight on Steve, as well as for helping grow the maintenance/lubrication profession. Our caps are off to all hardworking Lube Starz, who’ll receive their own baseball caps for making the team. Up for the game? Go to www.lmtinfo.com/lubestarz or www.lubestarz.com to tell us about yourself!
Follow the instructions for submitting your own application and photo and you might find your work-related profile in a future LMT issue. We look forward to hearing from you soon!
For more info, enter 77 at www.LMTfreeinfo.com
LUBRICATION MANAGEMENT & TECHNOLOGY
I N C RE ASE
D E C R E A SE
C H A IN
C O STS .
Step up to Tsubaki Lube-Free LAMBDA Roller Chain. ®
The limits of ordinary carbon chain will keep letting you down. It’s time to move it up a notch or two and lose the weak link. Advance to Tsubkai LAMBDA® lube-free roller chain and get long-term operation without additional lubrication and step up your operation.
To sign up for a
SPECIAL RISK FREE TRIAL go to:
Visit us at Pack Expo 2011 booth # 5278 © 2011 U.S. Tsubaki Power Transmission, LLC. All Rights Reserved.
For more info, enter 78 at www.LMTfreeinfo.com
W O R R Y- F R E E
“...we extended drain intervals from every 15 days to every three months AND reduced engine repairs and replacements.” Luis Garza Kingfisher Marine Most efforts to improve operating efficiency and lower maintenance costs are labor intensive and involve painful cultural changes. Numerous progressive companies have experienced significant cost savings simply by upgrading lubricants. You can learn how by reading the special report ‘Lowest Total Cost of Ownership’. This special report includes extensive case studies that document real-world savings through lubricant upgrades. Get your FREE copy of the ‘Lowest Total Cost of Ownership’ today by calling 866-447-5173 . . .
For more information on Royal Purple, visit royal-purple-industrial.com today. For more info, enter 79 at www.LMTfreeinfo.com