LubeOil OilContamination ContaminationSolutions Solutions Lube FluidContamination ContaminationUnder UnderControl Control Fluid Fluid contamination is the leading cause Fluid contamination is the leading cause of of component failure and system breakdown. component failure and system breakdown. Hy-Pro’s rated filter elements Hy-Pro’s DFEDFE rated filter elements andand fluidfluid conditioning equipment extend component conditioning equipment extend component andand useful fluid by removing particulate water useful fluid life life by removing particulate andand water contamination from your fluid. contamination from your fluid. Keep fluids in bulk storage clean & dry Keep fluids in bulk storage clean & dry withwith dedicated off-line skids particulate dedicated off-line skids for for particulate andand water removal. water removal. New oiltypically is typically dirty New oil is tootoo dirty for for lubelube andand hydraulic systems. Use Hy-Pro equipment hydraulic systems. Use Hy-Pro equipment to to transfer condition fluids to critical systems. transfer andand condition fluids to critical systems.
Maintain Control Over Fluid Contamination Maintain Control Over Fluid Contamination VUD Vacuum Dehydrator VUD Vacuum Dehydrator Removes Water Removes Water & Particulate & Particulate
Drum Top Filter Tote Drum Filter Tote & forTop Fluid Transfer for Side Fluid Loop Transfer & Filtration Side Loop Filtration
DFE Rated DFE Rated Upgrades Filter Element Filter Element Upgrades With Water Removal Capacity With Water Removal Capacity
COT Coalescer COTRemoves Coalescer Water Removes Water & Particulate & Particulate
Fluid Contamination Under Control with… Fluid Contamination Under Control with… and Solutions Innovative Filtration Products, Support, Innovative Filtration Products, Support, and Solutions Make Hy-Pro a part of your lube team and arm yourself with tools and Make Hy-Proexpertise a part oftoyour lube team and arm yourself with tools industry maximize reliability from your hydraulic & and lube industry expertise to maximize reliability from your hydraulic & lube assets. Hy-Pro will help you develop and implement strategies to assets. Hy-Pro help you develop and implement to useful achieve and will maintain target fluid cleanliness levelsstrategies and extend achieve and maintain target fluid cleanliness levels and extend useful fluid life. fluid life.
www.hyprofiltration.com
www.hyprofiltration.com Made in U.S.A., ISO 9001 Certified Made in U.S.A., ISO +1.317.849.3535 9001 Certified Fishers, Indiana U.S.A. For more info, enter 61 at www.LMTfreeinfo.com Fishers, Indiana U.S.A. +1.317.849.3535
For more info, enter 61 at www.LMTfreeinfo.com
MAY/JUNE 2010 • VOL 11, NO. 3 • www.LMTinfo.com
Contents
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
© STUDIO VII-FOTOLIA.COM; © SLAVED-FOTOLIA.COM © ANOSHKIN-FOTOLIA.COM; © DOGUKAN YILDIZ-FOTOLIA.COM
FEATURES CONDITION MONITORING 6
The Case Of The Crucial Spare
Armed with an arsenal of powerful predictive maintenance tools, the investigators at a nuclear power plant took all the right steps to eliminate a problem with a critical cooling-water pump before it could impede the progress and vastly increase the cost of a planned shutdown.
Ray Thibault, CLS, OMA I & II, Contributing Editor
A CLEAN PUNCH 14
Lubricant Storage & Handling Tips For World-Class Contamination Control
Contamination never quits, nor should you when it comes to fighting this destroyer of lubricants and the equipment and systems to which they’re applied. Revisiting and, perhaps, rethinking how your site stores and handles its new lubricants is a great way to strengthen your punch. Jarrod Potteiger, Des-Case Corporation
MARTS 2010 RECAP 16
Another Success All The Way Around Check out who was there and what you may have missed!
UTILITIES MANAGER 19
DEPARTMENTS 5 23 24 28 29 32
From Our Perspective Motor Decisions Matter Green Edge Showcase Solution Spotlight Problem Solvers Supplier Index
■ Big Money Talks ■ Making Energy Audits Feasible
SUPPLY CHAIN LINKS 26
Sustainability And Your Facility: It’s All About Choices You’re not alone in this ongoing journey. Just ask your suppliers. M. Randi Young, LEED AP, Grainger
JUST HOW GOOD ARE YOU?
Applications For
The 2010 NORTH AMERICAN MAINTENANCE EXCELLENCE (NAME) AWARD Are Available Online
www.nameaward.com MAY/JUNE 2010
www.LMTinfo.com | 3
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
May/June 2010 • Volume 11, No. 3 ARTHUR L. RICE President/CEO arice@atpnetwork.com
BILL KIESEL Executive Vice President/Publisher bkiesel@atpnetwork.com
JANE ALEXANDER Editor-In-Chief jalexander@atpnetwork.com
RICK CARTER Executive Editor rcarter@atpnetwork.com
KENNETH E. BANNISTER RAY THIBAULT, CLS, OMA I & II RAYMOND L. ATKINS Contributing Editors
RANDY BUTTSTADT
Director of Creative Services rbuttstadt@atpnetwork.com
GREG PIETRAS
Editorial/Production Assistant gpietras@atpnetwork.com
ELLEN SANDKAM
Direct Mail esandkam@atplists.com
EDWARD KANE
Reprint Manager 800-382-0808, ext. 131 ekane@fostereprints.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
For more info, enter 62 at www.LMTfreeinfo.com
Achieving Efficiencies Through Practices & Products Apply for a free, one-year subscription at
www.LMTinfo.com 4|
LUBRICATION MANAGEMENT & TECHNOLOGY
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 2010. 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.
MAY/JUNE 2010
FROM OUR PERSPECTIVE
Ken Bannister, Contributing Editor
‘I Six It’
I
grew up in the shadow of The Beatles, in the industrial port city of Liverpool, England. Dad was a fleet-truck mechanic for a frozenfood company; Mom was a seamstress. While both were skilled workers, due to our modest post-WWII means, the only family transportation was a motorcycle and sidecar— a British motorcycle that Dad regularly needed my “help” to “fix.” Always up for a challenge, I would dive in, shouting, “I six it! I six it!” I must have shown real promise. On my third birthday, I received my first toolbox. It was an honest-to-goodness toolkit with a small wood saw—sharp metal teeth included—a hammer, rule, screwdriver and wrenches, all packed neatly in a wooden chest (no plastic for kids back then). Armed with these tools, I embarked on a relentless campaign to re-engineer everything I could put my hands on. Nothing was spared, including a leg of the family’s heirloom dining room table that I sawed halfway off! Despite such setbacks, my parents continued to be supportive, supplying items for me to dismantle, then helping me reassemble them, patiently providing answers to my constant “Why?” “Why?” “Why?” At the early age of three, my destiny was sealed: I was, and remain, an incorrigible tinkerer, fascinated by the design and inner workings of all things man-made. At the recent MARTS 2010 event in Chicago, Keynote speaker John Ratzenberger (famous for his work in the Cheers and John Ratzenberger’s Made in America television series and all Pixar films to date) introduced us to the work of his “Nuts, Bolts & Thingamajigs Foundation” (NBT). Through humor-laden personal testimony, this self-confessed, inveterate tinkerer evoked powerful memories in quite a few of us in that room full of skilled maintenance pros. Who among us wasn’t thinking back to a time when someone first encouraged us to find our inner “tinkerer,” something that helped define both our careers and our self-esteem?
MAY/JUNE 2010
Ratzenberger’s NBT organization works to introduce young people to the joys of working with their hands through sponsored summer industrial camps, and provides scholarships for those pursuing technical degrees at trade schools and colleges. A skilled carpenter turned actor, he has long recognized what much of North America seems afraid to accept—that our one-time manufacturing might, supported by the greatest skilled workforce in the world, is rapidly disappearing. With an average skilled-worker age of 56, and no national backup plan to replace these critical “assets” once they retire, we’re facing one of our greatest challenges ever. An early, widespread addiction to television, along with a pervasive video-gamer numbness and the closing of school “shop” programs, have led to an almost nonexistent pool of up-and-coming tinkerers to fill the critical skilled-trade positions of tomorrow.
Consider helping sponsor, or getting your company to help sponsor, a new generation of tinkerers. John Ratzenberger has had enough—he’s out there trying to “six it.” Let’s help. Let’s encourage our own children and grandchildren and those of others to tinker. Help them see that learning a skill is not only for life, it’s an honorable pursuit. One way to do this is by sending a deserving youngster to a Nuts, Bolts & Thingamajigs Camp! Go to www.nutsandboltsfoundation.org ASAP. Consider helping sponsor, or getting your company to help sponsor, a new generation of tinkerers. Working together, we can help “six it!” We can help secure North America’s future, and make our industries great again! LMT kbannister@engtechindustries.com
www.LMTinfo.com | 5
CONDITION MONITORING
CSI: Critical Equipment
The Case Of The Crucial Spare
Armed with powerful predictive maintenance tools, investigators took the right steps to eliminate a problem with a critical cooling-water pump before it could impede the progress and up the cost of a planned shutdown. Ray Thibault, CLS, OMA I & II Contributing Editor
6 | LUBRICATION MANAGEMENT & TECHNOLOGY
MAY/JUNE 2010
CONDITION MONITORING
T
his case study details the use of oil analysis and other powerful condition-monitoring techniques in the identification and resolution of problems with critical equipment at a large nuclear power plant. The equipment in question was a centrifugal coolingwater pump used in the shutdown process before an outage. It goes without saying that in a nuclear plant, each piece of critical equipment must have a spare that is capable of functioning at 100%. In this case, two cooling-water pumps were both required to function at 100% during shutdown. These units were rotated during shutdown events, with one being the main pump and the other the spare.
Data results & evaluation: Both centrifugal pumps were normally sampled every six months for routine in-house oil analysis. Pump #2 (P2) was to serve as the main pump for an upcoming outage; Pump #1 (P1) was to serve as the spare. During routine evaluation, the spare pump (P1) showed a high lubricant viscosity of 58.2 cSt. Table I illustrates the results for a more complete evaluation comparing the results to the previous sampling period and the new oil reference. Table I. P1 Bearing Housing Oil Sample
New Oil Most Recent Test Reference Sample ISO Cleanliness Code 15/12 22/18 Viscosity, cST 32.0 58.2 Fe (ppm) 35.9 Cu (ppm) 88.9 Pb (ppm) 32.1 Sn (ppm) 4.8 Zn (ppm) 6.6 7.5
Previous Sample 20/16 28.7 3.5 1.2 9.2 0.1 1.1
Analytical ferrography was run on the oil sample and indicated large amounts of brass sliding wear and small ferrous-particle wear. Evaluation of the main pump (P2) indicated no major wear metals. With an oil viscosity of 33.2 cSt and an ISO Cleanliness Code of 19/16, this unit was deemed ready for use during the outage. The problem came about in properly preparing P1 as backup for the outage. The investigation found that the wrong oil had been added to the backup pump and a flush and change-out was scheduled. (The results of the oil analysis from the bearing housing are shown in Table II.) At that point, the pump was drained, flushed and run for 30 minutes. MAY/JUNE 2010
Table II. P1 Original Bearing Housing Oil Sample
Test Results ISO Cleanliness Code 25/22 Viscosity, cSt 40.8 Fe (ppm) 51.5 Cu (ppm) 226 Pb (ppm) 34.6 Zn (ppm) 21.4 Sn (ppm) 9.5 Based on the results in Table II, investigators concluded that the oil had been added without a flush, resulting in a higher viscosity than the added new oil, and that the wear particles in the bottom had been agitated—which, in turn, led to high wear particles in the sample. After flushing, P1 was filled with new oil. It was then run for 12 hours with vibration and infrared thermographic readings taken to identify any bearing defects. The results of a subsequent oil sample evaluation are shown in Table III. Table III. P1 Bearing Housing Oil Sample After Flushing & Change-Out
Test ISO Cleanliness Code Viscosity, cSt Fe (ppm) Cu (ppm) Pb (ppm) Zn (ppm) Sn (ppm)
Results 23/20 34.3 68.2 207 40.4 18.8 9.8
The flush and new oil brought the viscosity back in range, but wear metals were still high. The question was where were they coming from, and would they fail the pump if it had to be run for 10 days during the outage? Infrared thermography showed no problems in the pump; the vibration readings, though, turned up the following results: www.LMTinfo.com | 7
CONDITION MONITORING
Identifying the problem Electron Beam
early helped investigators
Electron Gun
take all the right steps in dealing with it. Anode n All readings low n Bearing defect frequencies very low n Possible very early innerand outer-race defects (spike energy)
Magnetic Lens To TV Scanner
n Bearing pre-Stage 1 failure The investigators, therefore, began trying to identify the source of the wear metals and the effect on the pump’s reliability. The first step was to determine the metallurgy of the pump components and to utilize a powerful technique in the determination of the wear particles’ composition by element and amount. These particles were evaluated with use of a scanning electron microscope (SEM), as depicted in Fig. 1. SEM utilizes electron versus light to form an image of the particle, thus allowing for accurate determination of the element and its percentage in a particle. The samples were prepared with the use of a glass ferrogram slide and a patch. Each of the preparation techniques had its advantages and disadvantages, and the results are a composite of both. Before the results of SEM could be utilized, a comparison needed to be made to the actual composition of the pump components that could cause the wear. The pump and its components are illustrated in Fig. 2. Continued on Page 12
Scanning Coils
Backscattered Electron Detector
8 | LUBRICATION MANAGEMENT & TECHNOLOGY
Secondary Electron Detector Stage
Specimen
Fig. 1. A scanning electron microscope (SEM) used to evaluate composition of wear particles by element and amount (courtesy of Slater)
MAY/JUNE 2010
New from WD-40 Company: BLUE WORKS™ Industrial Grade, specialty maintenance products. Ask your distributor for details on how you can experience outstanding performance from a line that meets your rigorous technical requirements.
For a free sample,* visit BlueWorksBrand.com/sample and enter Offer Code LMP
* While supplies last. Offer available to Industrial Professionals only. Offer not available in Alaska or Hawaii. Please see online Sample Request Form for full details. Š2010 WD-40 Company
For more info, enter 63 at www.LMTfreeinfo.com
50-State VOC compliant
CONDITION MONITORING
Bearings & Cage
Slinger Ring
Ring Spacer Inboard Deflector Inboard Cover
Fig. 2. The problematic cooling-water pump (P1) and its components (courtesy of Slater)
Individual manufacturers were contacted to obtain the exact metallurgy of the components they supplied for the P1 unit. (Table IV lists the elemental composition of these components.) Table IV. P1 Component Metallurgy
(According To Component Manufacturers)
Element, Slinger Ring Inboard Inboard SKF % Ring Spacer Deflector Cover Bearings Fe 0.15 99.0 0.3 95.0 98.0 Cu 87.0 85 Pb 0.3 5.0 Zn 1-3 1.0 Ni 1.0 5.0 Sn 10.0 Mn 0.4 0.3 Cr 1.4 Si 0.05 2.0 0.025 P 0.05 0.04 0.025 After matching the SEM results with the component metallurgy, the investigators concluded that the wear came from the inboard cover (bronze) and the deflector (grey cast)—components that have only a minor impact on 12 | LUBRICATION MANAGEMENT & TECHNOLOGY
pump performance. The next question was whether the high levels of abrasive wear generated by these two components would affect bearing life. The ultimate feasibility of utilizing P1 as a backup without repair had to be established. An outage was scheduled and not enough time was available to repair the pump. Each day of delay would cost $1 million. That’s why it was so crucial to determine if the pump could last a maximum of 10 days (or 240 hours). The L10 rating of the bearing based on its dynamic load was 5,000,000 hours under ideal conditions. The penalty for a contaminated lubricant reduced the factor by about 500. The L10 life of the bearing was calculated to be 96,700 hours with the contamination penalty. Stage 1 failure of a bearing means there is probably 10% L10 life remaining—which meant P1’s bearings had about 10,000 hours of life left in them. Since the maximum life required for these bearings to function in the pump for the outage was 240 hours, there was a safety factor of 40 or more. Based on the bearing calculations, it was determined that no repair was required until after the outage. The following recommendations were made: n Vibration readings were to be taken at least once per day during the outage to detect early signs or acceleration of bearing damage. MAY/JUNE 2010
CONDITION MONITORING
n P1 was to be scheduled for teardown and inspection of its bearing-housing components soon after the outage. n All parts were to be in stock for repair. After the outage, the P1 unit was repaired. At that time, the major problem was found to be in the inboard defector disks. Improper installation of these disks was resulting in metal-to-metal contact, which, in turn, was generating high levels of wear metals. All the right steps Because of the enormous consequences of failure, nuclear power plants require an extremely high level of equipment reliability. This case history is a good example of a highly competent reliability group utilizing the proper predictive maintenance tools to identify a problem early—and make the right decisions to deal with it. As noted in this example, criticality is not based simply on the size of the equipment. The condition of a centrifugal cooling-water pump with a small lubricant reservoir— a pump used only during outages—was the key factor in
whether an outage would be on schedule and not incur a large penalty for any delay. While oil analysis was the main tool, infrared thermography and vibration analysis were also utilized in arriving at the correct conclusion. Identifying the individual components in the bearing housing and contacting the OEMs for complete metallurgical information was a key step. The use of SEM, a very sophisticated tool not normally used in oil analysis, supplied the comprehensive information necessary to determine exactly which components were causing the wear particles in the system. Case closed. LMT Acknowledgement The author thanks Kevan Slater, one of the most practical and knowledgeable reliability professionals in the industry, for his assistance in the preparation of this article. In addition to Figures 1 and 2, Slater also supplied Tables I, II, III and IV. Contributing Editor Ray Thibault is based in Cypress (Houston), TX. An STLE-Certified Lubrication Specialist and Oil Monitoring Analyst, he conducts extensive training in a number of industries. Telephone: (281) 257-1526; e-mail: rlthibault@msn.com.
For more info, enter 64 at www.LMTfreeinfo.com MAY/JUNE 2010
www.LMTinfo.com | 13
© FOCALPOINT—FOTOLIA.COM
A CLEAN PUNCH
Contamination never quits, nor should you when it comes to fighting it. Revisiting and, perhaps, rethinking how your site stores and handles new lubricants is a great way to strengthen your punch. Jarrod Potteiger Des-Case Corporation
D
eveloping and implementing a world-class contaminationcontrol program is a sizable undertaking that usually requires significant modifications to machinery—as well as changes in procedures and methodologies that can take years. You don’t need to wait that long, though. To quickly punch up your facility’s contamination-control efforts, make sure you’re storing and handling new lubricants correctly. Is new oil clean? No. Typically, new lubricants are unsuitably dirty for most applications. There are, of course, exceptions: A few manufacturers offer a specified maximum particle count, and some suppliers filter bulk oil as it is dispensed. It is imperative that new oil be properly cleaned prior to use. A new drum of lubricating oil will often have a particle count of roughly 19/16/13 or higher. That means every cubic centimeter of oil in the drum contains between 2500 and 5000 particles that are at least 4 microns in diameter—that’s about one billion particles for the whole drum. How do you fight this contamination? #1: Get it clean. The first step is to filter “new” oil to an acceptable level—the method for doing so depends on the method of delivery. If the lubricant comes in drums, each drum can be filtered using a filter cart. Filtering new oil as it is applied to a reservoir or dispensed into a transfer container is an excellent and inexpensive way to ensure the oil’s cleanliness when it arrives at your site. Another popular approach involves the use of a comprehensive lubricant management system like the one in the figure on the next page. (This addresses a number of storage and handling issues at once). These systems can be configured with a wide range of options, including separate pumps and filters for different lubricants; high-quality desiccant breathers to prevent subsequent contamination to the fluid;
14 | LUBRICATION MANAGEMENT & TECHNOLOGY
MAY/JUNE 2010
A CLEAN PUNCH
fittings and spigots that minimize contamination; and flow meters to measure and track the amount of oil dispensed. Using such a system, users can easily clean new oil, maintain its cleanliness, prevent cross-contamination and track consumption by product type without having to engineer the process from scratch. #2: Keep it clean. Keeping oil clean is not difficult if you use the right tools. While it certainly helps to have an enclosed storage area with climate control, these elements are not essential for maintaining fluid-cleanliness. Common-sense measures, such as good housekeeping, wiping fittings, using dust covers, etc., go a long way in keeping dirt out of stored lubricants. The best way to prevent dirt and moisture from entering a tank or drum, though, is with a high-quality desiccant breather. Remember this: When you remove five gallons of oil from a drum, you pull in five gallons of air. If that air is not clean and dry, the oil won’t be clean and dry. The desiccant breather prevents most particles and moisture from entering the drum. Quick-connect hydraulic fittings provide an effective means to remove and/or circulate the oil with a filter cart or drum topper without exposing the oil to the ambient atmosphere. #3: Transfer it clean. Keep in mind that it really doesn’t matter how well you filter your new oil or how clean it’s kept in storage if you dispense that oil into a dirty container. There are several acceptable options for delivering oil to machinery—some much better than others. For large reservoirs, the best transfer method is to use fixed plumbing to pipe the machine-reservoirs to the storage tanks. This tactic, however, is only feasible for very large systems; it’s too expensive and impractical for small equipment. For other large systems or those with a moderate-size reservoir, the best method is usually to pump oil directly into the sump from a drum or tote tank using a filter cart. Portable filter carts are one of the most versatile and effective tools available for lubricant transfers and decontamination. One important thing to remember when working with these carts is to use the right fittings on the equipment sumps to make the fluid transfer or decontamination efficient and effective. Additionally, it’s important to consider using units that are dedicated to specific oil types—thus preventing cross-contamination of lubricants and avoiding the labor-intensive process of flushing carts to switch products. Some manufacturers allow you to color-code your filtration unit to help identify which cart should be used with a particular lubricant. As a side benefit, most users find that performing an oil change with a filter cart only takes about half as much time as doing the job with conventional methods. MAY/JUNE 2010
Yet another filter cart option is to combine the storage tank and the filter cart. These types of “top-off” carts offer a convenient solution to performing oil changes and top-ups on small- to medium-size sumps. In addition to performing fluid transfers, they can be used as traditional filter carts for remediation tasks; this eliminates the need for separate units for transfer and filtration. Finally, for those applications with very small sumps or those that are located in situations A comprehensive lubricant that make a filter cart or management system. top-off cart impractical, standard oil cans are acceptable, as long as they meet certain criteria. A good-quality oil-transfer container should be plastic, sealable, color-coded or marked for product type— and it must be cleaned on a regular basis. (It should also have an opening large enough to allow the inside of the container to be cleaned effectively.) When using top-off containers, remember to avoid funnels whenever possible. Many of the new containers utilize hand pumps that eliminate the need for funnels. Don’t forget to wipe the container nozzle and the fill port area on the reservoir before transferring the oil. Even a minute amount of material around the fill port can add millions or billions of particles to the oil in the reservoir. It’s a knockout. World-class contamination control can’t happen in the absence of good lubricant-handling practices. Any good storage and handling policy or system has several common elements: good filtration, high-quality breathers, filter carts and a highly conspicuous tagging or color-coding system to avoid cross-contamination of products. When these four items are addressed, the fight is almost over. LMT Jarrod Potteiger is a product and educational services manager for Des-Case Corporation, headquartered in Goodlettsville (Nashville), TN. E-mail: jarrod.potteiger@descase.com; Internet: www.descase.com. For more info, enter 01 at www.LMTfreeinfo.com www.LMTinfo.com | 15
MARTS 2010 RECAP
MAINTENANCE and RELIABILITY TECHNOLOGY SUMMIT
ANOTHER SUCCESS ALL THE WAY AROUND
T
he 2010 MARTS (Maintenance & Reliability Technology Summit) wrapped up on April 30 at the Hyatt Regency O’Hare Hotel in Rosemont, IL. This year’s event, the 7th in an increasingly successful series of these conferences, spanned almost an entire week with 13 full-day Workshops and 32 one-hour Conference sessions devoted to issues of maintenance, reliability and energy efficiency, among others. The 200+ maintenance professionals in attendance got to learn from and network with a number of internationally known experts in the field and a host of noted practitioners, consultants and manufacturers with deep industrial insight. One of this year’s very special highlights was Keynote speaker John Ratzenberger, the well-known actor, director, author and champion of the skilled trades. He spoke for nearly 90 minutes on topics ranging from his New England upbringing and hardwork ethic to the life philosophy he’s gained through acting. It was while he was working on his Made in America television series that he became keenly aware of the shortage of trained industrial workers. This realization, in turn, inspired him to establish the Nuts, Bolts & Thingamajigs Foundation (NBT) that encourages youngsters to consider manufacturing as a career choice. Following his talk, Ratzenberger autographed copies of his book We’ve Got It Made in America for long lines of enthusiastic attendees. Other highlights included Keynoter Bob Chernow, a futurist and financial professional, who provided an analytical look into tomorrow’s business environment, and the “Reliability Gives Voice to Autism” dinner and gala that kicked off MARTS week. The dinner raised funds and awareness for autism with comments from MARTS attendees who have been affected by autism, and top-flight entertainment. Preparations are already underway for next year’s successful MARTS. Look for details in upcoming issues, or on www.MARTSconference.com. LMT
1 (1) John Ratzenberger during his compelling Keynote and (2) later talking with attendees while he autographs copies of his book, We’ve Got it Made in America.
2
3 (3) Ratzenberger greets Ali Sturman, associate manager Certification & Education for the Society for Maintenance & Reliability Professionals
10 (10, 11 & 12) Attendees visit with MARTS exhibitors.
16 | LUBRICATION MANAGEMENT & TECHNOLOGY
MAY/JUNE 2010
THE CAPACITY ASSURANCE CONFERENCE
MARTS 2010 presenters at work: (4) Tara Denton, Life Cycle Engineering; (5) Bill Livoti, Baldor Electric Co.; (6) Hugh Blackwood, U.S. Navy (retired); and (7) Applied Technology Publications contributing editor Bob Williamson
4
5
7
6
(8) John Ratzenberger with editorin-chief Jane Alexander and (left to right) contributing editors Bob Williamson and Ken Bannister.
8
11
MAY/JUNE 2010
(9) Team MARTS members (left to right) Tom Madding, Bill Kiesel, Jim Hanley and Art Rice with a restored 1946 “Whizzer” motorized bicycle.
9
12
www.LMTinfo.com | 17
www.nskamericas.com 1.800.675.9930
When you think “Innovation”, you think about a better way to do the job. We think about industryspecific solutions to your motion and control challenges, like NSK’s Molded-Oil™ bearings. This innovative product not only delivers high performance in water and dust contaminated applications, but also extends bearing life and eliminates the need for relubrication. When it comes to innovative products designed to increase efficiency in food industry applications, Think NSK.
B A L L
B E A R I N G S
|
R O L L E R
B E A R I N G S
|
L I N E A R
M O T I O N
P R O D U C T S
For more info, enter 65 at www.LMTfreeinfo.com
|
T E C H N I C A L
S E R V I C E S
BIG MONEY TALKS XX UM William C. Livoti
Understanding Power Factor
I
f your organization is focusing to any extent on cutting energy consumption, driving sustainable growth and reducing operating costs, it’s a good idea to review power factor. Here’s a very brief explanation. The power factor (PF) of an AC electric power system is defined as the ratio of the real power flowing to the load to the apparent power, and is a number between 0 and 1 (frequently expressed as a percentage, e.g. 0.5 pf = 50% pf). Real power is the capacity of the circuit for performing work in a particular time. Apparent power is the product of the current and voltage of the circuit. A PF of 1.0—or “unity power factor”—is the goal of every electric utility. If the PF is less than 1.0, the utility has to supply more current to the user for a given amount of power use. In so doing, it (the utility) incurs more line losses. Industrial facilities tend to have a “lagging power factor,” where the current lags the voltage (like an inductor). This is primarily the result of having lots of electric induction motors; as seen by the power supply, their windings act as inductors. Capacitors have the opposite effect; they can compensate for the inductive motor windings. The significance of power factor lies in the fact that utility companies supply customers with voltamperes, but bill them for watts. The relationship can be stated as:
watts = volts x amperes x power factor Power factors below 1.0 require a utility to generate more than the minimum volt-amperes necessary to supply the power (watts). This increases generation and transmission costs. Utilities may impose penalties on customers that do not have good power factors on their overall buildings. Watts—or real power—is what a customer pays for. VARS (volt-ampere reactives) are the extra “power” transmitted to compensate for a power factor less than 1.0. The combination of the two is called “apparent” power (VA or volt-amperes).
VOLUME VOLUME 52 // NO. NO. 22
A low PF is expensive and inefficient—some utility companies may charge additional fees when it’s less than 0.95. A low PF reduces the electrical system’s distribution capacity by increasing the current flow and causing voltage drops.
The significance of power factor lies in the fact that utility companies supply customers with volt-amperes, but bill them for watts. Think of it this way: Based on personal experience, many of us would acknowledge that a mug of draft beer typically has a “head” on it. Let’s say your favorite pub institutes a new policy—you pay only for beer, not foam. While foam is simply aerated beer, it’s not really usable. So, if your mug is half full of foam, you’ll pay half the price. This is the same principle as electricity generation: The consumer pays just for the beer (real power), not the foam. Main benefits from power factor correction ■ The utility’s electrical load is reduced, thereby allowing it to supply surplus power to other consumers, without increasing generation capacity. ■ Most utilities impose low PF penalties; by correcting the power factor, penalties can be avoided. ■ High PF reduces load currents, which leads to considerable savings on hardware, such as cables, switchgear, substation transformers, etc. UM Bill Livoti is a fluid power and power industry engineer with Baldor Electric Company. He also is vice chair of the Pump Systems Matter (PSM) initiative. Telephone: (864) 281-2118; e-mail: wclivoti@baldor.com
| UM1 | 19 UTILITIES UTILITIES MANAGER MANAGER
UM ENERGY AUDITS
On the hunt for big bucks...
ENERGY
Making Energy Audits Feasible Target in on these tools, techniques and useful resources. Kate Anderson, ActionEco, with support from Colin Plastow, Fluke
S
omewhere, there’s a technician climbing up onto a facility roof with a thermal imager. Inside, the head of operations and the HVAC person are calculating the effect of raising or lowering indoor temperatures just a bit. Someone else is over in the side office with six months of electricity bills, analyzing usage patterns and rate fluctuations. They’re all on a hunt—but not for critters. The big bucks these hunters are hoping to harvest are associated with increased operating efficiencies and reduced energy consumption. They’re tracking everything, looking for savings anywhere they can find them…hidden in a vent that’s stuck open… in inefficient lighting…in a chiller that’s running an hour a day more than necessary… We’ve all heard and/or read the exhortations: “You can find annual savings of $200,000, $500,000 or more, in the unlikeliest of places.” “You can save 18% on energy costs with minimal capital investments.” “You can discover enough immediate savings to pay for an energy audit and the recommended system upgrades.” Alas, many people have dismissed such claims as fantasy. Some may think that their operations are too lean and don’t have the budget or the staff to find the savings. “We’ve already cut everything we can cut. Management will never approve this use of time and money.” On the flip side, contractors may be hearing “not now” from clients that are already stretched too thin. Here’s the missing ingredient: We know more now than we did, even a few years ago, about where to look for unnecessary waste. We also know how to quantify the dollar value of that opportunity. That allows you to create a more accurate proposal that’s more likely to be approved and achieved. 20 | UTILITIES MANAGER
Size for who you are The big dollars are usually associated with audits at large facilities with lots of heavy machinery and little preventive maintenance. The energy audit team collects data ahead of time, spends three to five days inspecting, decides what to change, then implements fixes, updates and process improvements. Depending on the facility, the inspections may cover everything from motors and drives to electronic equipment usage patterns to wastemanagement practices. If you can do a comprehensive audit, you should—and not just because the overall dollar amount will be larger and quicker to achieve. By inspecting multiple areas in the same time period, you’ll also notice common waste patterns and find ways to leverage improvements across multiple systems. But some facilities find that three days and a full team of experts and tools is just too much. For them to get started, it might make more sense to tackle one system at a time. This is fine, as long as you circle back to see how changes in one system have affected other areas. VOLUME 5 / NO. 2
ENERGY AUDITS UM
$$
$ $$$
$ $$$ $
Top Places To Look For Energy Waste The leanest companies often find the best value in outsourcing all or part of their energy inspection to a contractor that specializes in energy audits. Then, as improved practices reduce the immediate troubleshooting load, existing staff can retrain on system upgrades and inspection practices. Contractors can add particular value by knowing all the local, regional and national tax incentives, providing ROI for system upgrades, mastering the more complex power-logging tools and, simply, having enough tools, expertise and people to get the job done. Build and pitch your plan If you run into opposition in getting a complete audit approved, you may need a more convincing proposal. What you may not realize is that much of the savings can be discovered up front, using a power logger and your computer.
Almost all audits find equipment turned on but not in use, inefficient lighting technologies or usage and HVAC systems that are not optimized.
$$$ $$ $
Biggest opportunities: Lighting, compressed air, steam systems Medium opportunities: HVAC, motors and drive Smaller long-term opportunities: Building envelope, waste/recycling, IT/electronics
Applying Energy-Audit Tools Tool
Application
Power logger
Conduct load studies; perform energy consumption testing
2. Review utility bills.
Clamp meter or clamp accessory
Make branch circuit and individual load evaluations; take quick power measurements
3. Plug that data into energy calculators.
Thermal imager
Scan electrical, electro-mechanical, process, HVAC and other equipment for hotspots noting inefficiencies; scan buildings for leaks
Logging digital multimeter
Monitor power usage cycles; measure pressure and temperature
Infrared thermometer
Scan motors, insulation, steam pipes, ducts, breakers, connections and wires
Air meter
Evaluate and adjust ventilation levels; verify HVAC controls
1. Tabulate the kind of equipment in use and log how often it’s deployed.
4. Quantify and monetize the savings opportunity. With reasonably solid numbers and a return-on-investment schedule, management is more likely to approve and support an energy audit. For calculators and other tools to estimate ROI and build your proposal, see the reference list on the next page. There’s no need to reinvent the wheel! Learn what others have done and apply their best practices. UM Continued on page 22 VOLUME 5 / NO. 2
UTILITIES MANAGER | 21
UM ENERGY AUDITS
Online Resources While the Internet is full of great information on energy audits, finding it can take some time. Here’s a head start. Use these sites to get reports on successful audits, online tools, best practices, technology evaluations, even financial incentives. • EPA Energy STAR, www.energystar.gov, has calculators, guidelines, checklists, schedules, how-tos and many other tools for designing and implementing energy plans and audits. • American Council for an Energy Efficient Economy, www.aceee.org, convenes conferences and workshops for energy-efficiency professionals, conducts technical and policy analyses and offers advice for program managers.
Integrity
• Building Owners and Managers Association, www.boma.org, offers a sustainable operations Webinar series for training on operational cost savings and evaluating green building opportunities.
ice
Customer Serv
• Consortium for Energy Efficiency (CEE), www.cee1.org, has a database of companies that manufacture CEE and Energy STAR equipment. An energy and efficiency think tank, CEE is a good source for technology reviews. • Commercial Building Tax Deduction Coalition, www.efficient buildings.org, explains tax deductions for energy-efficient building expenditures made by a building owner. • Database of State Incentives for Renewables and Efficiency, www.dsireusa. org, is a comprehensive source of information on state, local, utility and federal incentives that promote energy efficiency.
Dedication
• U.S. Department of Energy, www.energy.gov, is the gateway to thousands of pages of how-to energy-audit information.
Systems
• U.S. Department of Energy’s Energy Efficiency and Renewable Energy Network, www.eere.energy.gov. Click on “Industry” on the left of the page for industrial and operations information and research. • Tax Incentives Assistance Program, www.energytaxincentives.org, provides information about federal income tax incentives for energy efficient products and technologies.
Technical A b
ility
Why would you need to use any other lab? Contact Herguth Laboratories, Inc. today to find out what sets us apart.
• OpenEco, www.openeco.org, has assembled helpful news, resources and calculators. • FacilitiesNet, www.facilitiesnet.com/energyefficiency, is focused squarely on facilities.
Kate Anderson is editor of ActionEco.org, an online education and advocacy community that demonstrates the business benefits of sustainable business operations and maintenance best practices. Colin Plastow is industrial product manager for Fluke. To learn more about the products and services referenced in this article, including Fluke’s energy audit training offered through the company’s Energy Answers program, e-mail: colin.plastow@fluke.com.
1-800-OIL-LABS • www.herguth.com For more info, enter 66 at www.LMTfreeinfo.com
22 | UTILITIES MANAGER
For more info, enter 251 at www.LMTreeinfo.com
VOLUME 5 / NO. 2
BOOSTING YOUR BOTTOM LINE
Building Blocks Of Motor Management
M
otor management—understanding your motors, their operating conditions and costs and what you are going to do when they fail—can reduce downtime, save money and lower carbon emissions at your facility. Some facility managers have already mastered the practice. They know how many motors they have, where they’re located, their size and nameplate efficiencies, their load factors and number of runhours. They keep track of each motor’s age and maintenance history and have plans in place for what is going to happen with every one of those units when they fail. Yes, such facility managers definitely are out there… For the rest of us, the following set of motormanagement building blocks from the Motor Decisions MatterSM Campaign can help. Motor inventory A motor inventory is a list of every motor in a facility, its size, nameplate efficiency, operation, load factor, run-hours and maintenance history. With this resource alone, you can ensure that the most efficient motors are the most often used; track “problem” motors (those with histories of repeated failure); and identify candidates for cost-effective replacement. Many vendors and service providers can help facilities assemble motor inventories. Ask a vendor or service provider in your area for assistance. Check out http://www.easa.com/find/active_members for motor service providers. Repair/replace decision guidelines It is easier to manage a plan than a crisis. Know in advance what will be done with every motor upon failure, and label the motor accordingly. The information in your motor inventory— nameplate efficiency, age, run-hours and maintenance history—will assist you in determining the cost-effective choice. (A free Motor Decisions Matter calculation spreadsheet can help you do this in three easy steps.)
MAY/JUNE 2010
Purchasing specification Once the decision to replace a motor has been made, know what type of unit you’ll be purchasing as the replacement. Because energy costs represent 95% of the lifetime costs for most motors, NEMA Premium® efficiency motors may save your facility money in many applications. Keep in mind that a motor failure is also a good opportunity to make sure the size and type of motor are appropriate for the application. Best-practice repair specification Ensure that motors are returned to their nameplate efficiency by specifying best-practice repair. Without this type of specification, a repair could result in a unit that operates less efficiently. Take the time to check out the best-practice repair resources that are available through the Motor Decisions Matter initiative, and contact your motor service provider to develop a specification for your facility. Motor Decisions Matter provides motor users with a variety of free tools and information, including the “Simple Savings Calculator,” “Motor Planning Kit” and numerous case studies from facilities throughout the United States and Canada, at www.motorsmatter.org. LMT For more info, enter 02 at www.LMTfreeinfo.com
The Motor Decisions Matter (MDM) campaign is managed by the Consortium for Energy Efficiency (CEE), a North American nonprofit organization that promotes energysaving products, equipment and technologies. For further information, contact MDM staff at mdminfo@cee1.org or (617) 589-3949.
www.LMTinfo.com | 23
A SPECIAL GREEN EDGE LUBE SHOWCASE
High-Viscosity Bio-Based Lubes
F
ormulated from renewable, biodegradable vegetable oils, the LubriMatic Green™ products from Plews/Edelmann are designed to replace and mix readily in conventional petroleum products for a more environmentally friendly lubricant. With its high viscosity index, bio-based oil is less likely to “thin down” at high temperatures, which leads to lower operating temperatures and a higher degree of lube safety, especially in high-speed applications. Plews/Edelmann Dixon, IL
For more info, enter 30 at www.LMTfreeinfo.com
Ceramics-Industry Lubricant
H
utch 101 Green is a non-soap, water-based lubricant with all the benefits of oil-based formulations, but none of the downsides. The company says this environmentally safe product designed to meet the needs of the ceramics industry also costs less than oil-based lubes. Hutch 101 Fort Worth, TX For more info, enter 31 at www.LMTfreeinfo.com
Soy-Based Alternatives To Conventional Hydraulic Fluids
E
LM notes that its Biotechbased SoyFluid™ Hydraulic Industrial (ISO 46 & 68) oils are formulated with optimized USA-grown natural seed oils that surpass the lubricity of most conventional oils. They’re particularly suited for use near water, as well as in forests and other environmentally sensitive areas. Environmental Lubrication Mfg., Inc. Grundy Center, IA For more info, enter 32 at www.LMTfreeinfo.com
Replacements For Your Petroleum-Based Gear Oils
U
nited Bio Lube’s Bio Gear Oils are non-hazardous, high-performance gear lubricants engineered as drop-in replacements for petroleum-based formulas. Meeting the newest OEM industrial requirements for premium, heavy-duty energy-conserving gear oils, they’re compounded with an environmentally friendly zinc-free additive that meets API Service Classifications for Ashless GL-3, GL-4 & GL-5 type gear lubricants. United Bio Lube Palo Alto, CA For more info, enter 33 at www.LMTfreeinfo.com
DOES YOUR COMPANY HAVE A GREEN EDGE? E-mail your product and service news to: gpietras@atpnetwork.com For information on advertising in the Green Edge section,contact JERRY PRESTON at: Phone: (480) 396-9585 / Fax: (480) 264-4789 / E-mail: jpreston@atpnetwork.com For more info, enter 67 at www.LMTfreeinfo.com
24 |
LUBRICATION MANAGEMENT & TECHNOLOGY
MAY/JUNE 2010
A SPECIAL GREEN EDGE LUBE SHOWCASE
High-Pressure Hydraulic Oils For Marine Service
M
arine-Safe Hydraulic Oils from Lubriplate are a line of high-performance, antiwear products for use in high-pressure equipment that operates in environmentally sensitive areas. The biodegradable oils are formulated with premium-quality USP white mineral oils and an ashless “zincfree� antiwear additive system. Non-toxic to aquatic life, they exceed U.S. EPA LC50 test requirements adopted by the U.S. Fish and Wildlife Service and the EPA.
Low-Temperature Food Grade Grease
I
NOX-mx6, distributed by GreenTech Lubricants, is a food grade, fully synthetic, extreme pressure grease suitable for use in below-zero temperatures, especially in the refrigerated, frozen food and beverage industries. This non-toxic grease can operate
from -30 C up to short bursts of 300 C without breaking down, and meets US FDA and USDA requirements. Green-Tech Lubricants, Inc. Greenfield, IN For more info, enter 36 at www.LMTfreeinfo.com
Lubriplate Newark, NJ For more info, enter 34 at www.LMTfreeinfo.com
Biodegradable High-Temp Grease Formulation
B
io-High Temp 180 E.P. Grease from Renewable Lubricants is a high-temperature, biobased grease characterized by a super-high-viscosity-index base. Containing no heavy metals or other environmentally undesirable additives, such as chlorine, barium or lead, its performance is supported by an environmentally friendly extreme pressure additive. This multipurpose, lithium complex grease also provides good cold-temperature mobility. Renewable Lubricants Palo Alto, CA
For more info, enter 35 at www.LMTfreeinfo.com
MAY/JUNE 2010
For more info, enter 68 at www.LMTfreeinfo.com www.LMTinfo.com | 25
SUPPLY CHAIN LINKS
Sustainability And Your Facility: It’s All About Choices You’re not alone in this ongoing journey. M. Randi Young, LEED AP Grainger
O
ne of the critical emerging issues on customers’ minds (and some of the most common questions they’re asking us) involve how to operate and maintain sustainable facilities. Organizations everywhere are constantly looking for ways to operate in a more environmentally responsible manner than before—and also cut operating expenses. Maintaining and operating a sustainable facility is achieved by looking at the essential areas of the operation. Sustainability industry experts, such as the United States Green Building Council (USGBC), look at the environmental-savings categories of a building’s exterior, water efficiency, energy and atmosphere, materials and resources and indoor environmental quality. Each of these components represents a critical element when it comes to reducing carbon footprint and the use of natural resources. But there’s an additional element to remember when attempting to operate a sustainable facility: behavior. One could argue that buildings don’t use power or water or generate waste—people do. By better understanding the decision process that employees go through as they discard items or use water and energy, you can help identify what steps need to be taken in order to drive toward more sustainable choices. Utilizing efficient lighting within your facility, for example, will provide value in reduced energy costs and better light quality. Couple that with good choices for how the lighting 26 | LUBRICATION MANAGEMENT & TECHNOLOGY
MAY/JUNE 2010
SUPPLY CHAIN LINKS
Listening To Customers For 83 years, Grainger has been serving businesses and institutions across a variety of industries by helping them save time and money related to their maintenance, repair and operating supplies needs. Today, the company remains committed to listening to its customers and helping to collaboratively find the most cost-effective solutions for their evolving business needs. With more than 8000 green products across a broad array of categories, Grainger definitely provides the product solutions that organizations need to “go green,” including those that help save energy, reduce water usage, improve indoor air quality and reduce waste. In addition to products, Grainger is educating business professionals on how to embrace energy-efficient solutions in their operations. Through supplier partnerships and its recent acquisition of Alliance Energy Solutions, the company offers training, needs assessments and audits in areas such as energy, water, green cleaning and waste reduction. Grainger also diligently looks for ways to reduce its own environmental impact. From adopting Leadership in Energy and Environmental Design (LEED) standards for all new construction, to completing certification as an EPA SmartWay shipper partnering with carriers to reduce transportation emissions, the company is helping to preserve the natural resources within the communities where it does business. Currently, Grainger operates 12 LEED-certified facilities, 10 being LEED Gold. For more information about Grainger’s green products and solutions, visit www.grainger.com/greeninfo.
is used and you’re on track for even more savings and less harmful environmental impact. Simply shutting the lights off when the last person leaves a room or leveraging sensors to judge when lighting is required would make an even bigger impact on bottom-line costs. The same is true when looking at the other key areas of a building that use natural resources and energy, or contribute to waste. When responsible actions are coupled with the right equipment, sustainability and cost savings are likely to follow—as will the culture change necessary for lasting impact. Another piece to consider is the relationship between the personal comfort of employees while inside the building and worker productivity. This is an important consideration as you make changes in your facility. Alterations in filtering or outside air intake can affect the indoor air quality. Updated lighting or individual lighting controls can add to comfort. MAY/JUNE 2010
And the use of natural cleaning materials can reduce the toxins that enter the air, as well as reduce harmful chemicals going into watertreatment systems. All of these factors impact productivity of the employees occupying the affected space in a gainful fashion. Generally, that impact is positive, but it’s important to continuously engage employees for input and feedback with regard to improvements. The path to sustainability does not have a “final destination,” rather it’s an ongoing journey. With a commitment to continued learning, as well as partnership with experts who can help you achieve your sustainability goals, the journey is sure to be an enjoyable and beneficial one. LMT M. Randi Young is a solutions development manager with Grainger and a LEED AP. For more info, enter 03 at www.LMTfreeinfo.com www.LMTinfo.com | 27
SOLUTION SPOTLIGHT
Cool Solution For Hot Problems
Orival’s technology at work in a cigarette-manufacturing operation
Automatic self-cleaning screen-filters provide cooling-system protection and more.
C
ooling towers dissipate both ambient and process heat in most large manufacturing facilities. These structures facilitate the transfer of unwanted energy (heat) from a transport liquid (usually water) to the atmosphere. Problems with efficient heat transfer, equipment protection and pathological risks to employees can most often be traced to an issue with suspended solids. These solids can originate in the process, in the piping, from the atmosphere or from internal biological growth. Common methods of maintaining minimal suspended solids in a cooling system are side-stream filtration, a process that cleans only a portion of system flow; cyclonic devices, which typically treat all water in a system, but are best at removing high-specific-gravity solids; and granular media filtration, which is also used to treat all water, but is best at removing low-specific-gravity organic solids. Orival offers yet another method—automatic selfcleaning screen-filter technology—that can be used for all system water. Trapping both organic and inorganic solids, regardless of specific gravity, this process also requires minimal energy and little or no coolant liquid for the selfcleaning process. Fully automatic self-cleaning screen filters use weave-wire screens as the filtering media. These provide a positive removal system and eliminate all particles larger than the filtration degree of the screen from the cooling system, and many smaller particles as well. This is due to the filtration effect of the filter cake that builds on the screen element surface between cleaning cycles.
28 |
LUBRICATION MANAGEMENT & TECHNOLOGY
The filtration improvement can be loosely quantified as removing particles down to about 1/10 the size of the screenfiltration degree when the filter cake is at its thickest. This 1:10 relationship, as employed in screen-filtration systems, is called the capture ratio. An efficient suction-cleaning principle allows the filter cake to be removed completely from the screen surface within seconds, without touching the cake or screen. During the suction-cleaning cycle, the filtration process is uninterrupted, thereby providing filtered water downstream at all times and eliminating redundant equipment. Water and chemical losses are minimized, and organic and inorganic solids are removed with equal efficiency. Since only a small pressure differential occurs across the screen element, extrusion of soft organic material through the screen is prevented. If a problem should occur with the filter, a controller will open a built-in bypass valve to provide continuous water flow. The controller will then send a signal to notify personnel. Routine maintenance of automatic self-cleaning screen filters is minimal, consisting of a monthly inspection of the rinse valves (to see that they are seating properly) and an annual inspection of the screen and hydraulic piston. An occasional manually induced cleaning cycle is recommended to assure proper operation. Orival, Inc. Englewood, NJ For more info, enter 37 at www.LMTfreeinfo.com MAY/JUNE 2010
PROBLEM SOLVERS
Control Troublesome Oil Mist And Fumes
J
LM Systems’ Oilmiser™ Vapor Guard (OVG) is designed for machinery like gearboxes and bearing housings that are vented to atmosphere. Under continuous operation and high working loads, oil mist and fumes build up in the air space above the oil. Temperature changes and thermal expansion cause these fumes to exhaust into the workplace and also bring in outside air through the same vent. The OVG helps prevent the serious housekeeping and mechanical problems associated with this situation by way of a central diffuser post inside a sealed aluminum containment chamber. Migrating vapors are dispersed inside the chamber and condensed back into liquid oil that collects at the bottom of the unit. From here, recovered and uncontaminated lube oil is channeled through bleedback holes into the gearbox, where it continues to lubricate.
JLM Systems Ltd. Richmond, BC
High-Performing Metal-Cutting Oil
L
ENOX’s Cycle HD Water Soluble Oil is suitable for a variety of metal-cutting applications. The company says that the product’s advanced extreme pressure (EP), non-harmful additive package leads to outstanding performance in moderate to heavy-duty machining of ferrous and non-ferrous metals. Superior resistance to bacteria leads to both extended sump life and odor control. The fluid is also prepared with smaller oil droplets that prevent separation of the oil from water, leading to a more stable emulsion. LENOX East Longmeadow, MA
For more info, enter 38 at www.LMTfreeinfo.com
Krytox Medical Ad 2008:Krytox For more info, enter 41 at www.LMTfreeinfo.com
Lab-And-Field Wear-Metal Analysis
S
Krytox
Medical
®
Fluorinated Lubricants
pectro’s new Spectroil Q100 Oil Analysis Spectrometer detects and quantifies metals in used (in-service) oils and hydraulic fluids. Capable of helping predict mechanical failures in their early stages, the device is designed to work well in both lab and field. The standard configuration can analyze 22 wear metals, contaminants and additives in 30 seconds. Additional elements can be added at any time.
Spectro Inc. A business unit of QinetiQ North America McLean, VA For more info, enter 39 at www.LMTfreeinfo.com
Eco-Friendly Absorbent Pads, Rolls & Socks
A
ccording to Kafko International, its new eco-friendly Oil Eater Naturals offerings absorb up to 20% more than melt-blown polpropylene products, yet cost less. The line’s Oil Only Pads and Rolls soak up oil and repel water; Universal Pads and Rolls soak up oil, water and other liquids; the Absorbent Socks control larger spills and protect drains. All are available in a variety of weights, finishes and sizes.
Kafko International Ltd. Skokie, IL For more info, enter 40 at www.LMTfreeinfo.com MAY/JUNE 2010
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. Mil-spec, Aerospace and Food Grades (H1 and H2) available! Useful in Vacuum Systems. For technical information, call 203.743.4447 / 800.992.2424 (8AM - 4 PM ET)
m
s
miller-stephenson chemical company, inc. California - Illinois - Connecticut - Canada e-mail: support@miller-stephenson.com www.miller-stephenson.com
For more info, enter 69 at www.LMTfreeinfo.com www.LMTinfo.com | 29
PROBLEM SOLVERS
Electric Grease Lubricator
An Alternative To Standard Oil Sight Windows
T
A
ccording to Esco Products, the standard sight windows on oil reservoirs make it difficult to view the oil level, stain easily and must be replaced often. To take care of those problems, the company now offers a replacement sight window plug called the 3-D BullsEye. It’s a clear cylinder made from one solid piece of acrylic, with threading on one end and a rounded polished end for easier viewing of the oil on the other. NPT sizes of ½”, ¾”, 1”, 1 ¼”, 1 ½” and 2” are available. Esco Products, Inc. Houston, TX
he new KPL-24 Grease Lubricator from Yamada America is a 24-volt electric unit that allows for efficient greasing of heavy-duty equipment without tapping into hydraulic or pneumatic lines. It fits directly onto a 5-gal. grease pail (a 16-gal. unit also is available); works with a hose reel and hand grease gun; and can be used alone or as part of a centralized system. Yamada America Arlington Heights, IL For more info, enter 44 at www.LMTfreeinfo.com
For more info, enter 42 at www.LMTfreeinfo.com
Gel For Tube-Bending Applications
A
Eliminate Lubrication Mistakes
L
ubrication Engineers now offers battery-powered Clear Grease Guns™ that allow 100% visual identification of the lubricant, thus helping prevent cross-contamination. The high-impact, fracture-resistant polycarbonate tubes fit many standard grease guns, making upgrades of existing tools easy and cost-effective. Durable aircraft aluminum collars are available in a variety of colors for secondary identification. Lubrication Engineers, Inc. Fort Worth, TX For more info, enter 43 at www.LMTfreeinfo.com
30 | LUBRICATION MANAGEMENT & TECHNOLOGY
ccu-Lube JL-12 from ITW Rocol North America is an opaque, readyto-use gel formulated specifically for tubebending applications. Pumped or applied by hand directly to the tube or bending mandrels, it leaves a clean coating that won’t build up over time. Formulated to stay where it’s applied, it eliminates the mess of conventional lubricants. No cleaning is required before welding, and the gel is easily cleaned before painting or plating. ITW ROCOL North America Glenview, IL For more info, enter 45 at www.LMTfreeinfo.com MAY/JUNE 2010
PROBLEM SOLVERS
CLASSIFIED
ng in the Classified Section Contact your Sales Rep or KATHY JAROS 8100 ext. 117 / Fax: (847) 304-8603 / E-mail: kjaros@atpnetwork.com
Help? ATP Comfortable,Need U.S.-Made Need A Job? t Services Contact Lisa – Unvalved Respirator
LISA LINEAL: ustomized, LINEAL M is now offering TOLL FREE 877-386-1091 geted Lists a new 8510, N95 model Particulatelisalineal@lineal.com For Your Respirator that’s been www.lineal.com designed for comfort Electromechanical • Electronic keting Needs Recruiting Services
3
and increased wear- Electrical Service & Systems Specialists
w.atplists.com ability. It features a
soft inner material ct: Ellen Sandkam -382-8100 x110 and cup-shape design -223-3423 x110 that make it both
Se Habla Español
RENEW
o@atplists.com In order us to send spacious and durable, along withfor braided straps and an kam@atplists.com
M TECHNOLOGY
can now pick from AINTENANCE 25 models of 3M’s domestically made filtering products.
adjustable M-noseclip. U.S. customers ve., Suite 105, Barrington, IL 60010
3M ssified Section St. Paul, MN OS at:
aros@atpnetwork.com
to you FREE,
we are required by the US Post Office to have a completed and signed renewal form once a year.
You may renew on the Reader Service Card or online at
www.mt-online.com
For more info, enter 46 at www.LMTfreeinfo.com
Oil-Mist System For Multiple Converting Lines
C
onverting-equipment supplier Precision AirConvey (PAC) offers a central oil-mist system for label manufacturers, converters and others relying on oil mist to run pressure-sensitive adhesives or other high-tack materials smoothly through automated trim-removal systems. The PAC central oil-mist system replaces multiple lubricant containers at individual presses with a single reservoir set away from the production area. The labor required to constantly monitor and maintain the proper lubricant levels and flow rate at each press is eliminated, along with the risk of clogged ductwork and associated downtime. Precision AirConvey Newark, DE For more info, enter 47 at www.LMTfreeinfo.com
ENGTECH Industries Inc.
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 info@atplists.com / esandkam@atplists.com For more info, enter 70 74 at www.LMTfreeinfo.com www.MT-freeinfo.com MAY/JUNE 2010
MT-ONLINE.COM | 37
For more info, enter 71 at www.LMTfreeinfo.com www.LMTinfo.com | 31
Index ADVERTISER
MAY/JUNE 2010 Volume 11, No. 3 •
WEBSITE
CIRCLE #
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
PAGE #
ATP Lists ............................................ www.atplists.com .................................... 71................... 31 Cannon Instruments ........................ www.cannoninstrument.com ................ 64................... 13 Des-Case Corporation ..................... www.descase.com/extreme .................... 62..................... 4 Engtech Industries Inc...................... www.engtechindustries.com .................. 70................... 31 Herguth Laboratories, Inc................ www.herguth.com................................... 66................... 22 Hy-Pro Filtration .............................. www.hyprofiltration.com....................... 61..................... 2 Inolex Chemical Company .............. www.inolex.com ...................................... 68................... 25 Inpro/Seal Co..................................... www.inpro-seal.com/CDR ..................... 73................... 34 Miller-Stephenson Chemical Co. .... www.miller-stephenson.com ................. 69................... 29 NSK Corporation ............................. www.nskamericas.com ........................... 65................... 18 OIL Miser........................................... www.oilmiser.com................................... 67................... 24 Royal Purple ...................................... www.royal-purple-industrial.com......... 72................... 33 WD-40 ............................................... www.blueworksbrand.com/sample....... 63........Insert,11
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.
1300 South Grove Avenue, Suite 105 Barrington, IL 60010 PH 847-382-8100 FX 847-304-8603
www.LMTinfo.com
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, CA, CO, DE, FL, GA, MD, MS, NC, NJ, SC, PA, VA, WV, DC 1750 Holmes Drive West Chester, PA 19382 610-793-3093; Fax 610-793-3094 JIM HANLEY jhanley@atpnetwork.com AR, AZ, NV, NM, OK, UT 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 847-382-8100 x116; Fax 847-304-8603 BILL KIESEL bkiesel@atpnetwork.com CT, ME, MA, NH, NY, RI, VT, ON, QC P.O. Box 1059 Osterville, MA 02655 508-428-3331; Fax 508-428-2545 VINCENT LeGENDRE vlegendre@atpnetwork.com IL, IN, KS, LA, MI, MN, MO, OR, TX, WA,WI, BC 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 847-382-8100 x108; Fax 847-304-8603 TOM MADDING tmadding@atpnetwork.com IA, MT, NE, ND, SD, WY, AB, MB, SK 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 847-382-8100 x106; Fax 847-304-8603 ARTHUR L. RICE arice@atpnetwork.com CLASSIFIED ADVERTISING 3629 N. Sonoran Heights Mesa, AZ 85207 480-396-9585; Fax 480-264-4789 JERRY PRESTON jpreston@atpnetwork.com
32 |
LUBRICATION MANAGEMENT & TECHNOLOGY
MAY/JUNE 2010
“...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 72 at www.LMTfreeinfo.com
Inpro/Seal Company has been in the business of bearing protection for rotating equipment for 32 years and counting. We have been supplying bearing protection for the IEEE-841 motors since they were first introduced. It is only logical that we would expand into the field of motor shaft current mitigation to protect motor bearings. The CDR is:
ROBUST Machined entirely out of solid corrosion resistant
and highly conductive bronze, the CDR/MGS is capable of carrying 12+ continuous amps. They are made exclusively by the Inpro/Seal Company in Rock Island, IL, to ensure consistent quality and same-day shipments when required.
RELIABLE The CDR and MGS (Motor Grounding Seal)
products were developed in our own Research and Experimentation Laboratory and then extensively tested and evaluated by professional motor manufacturing personnel. Our standard guarantee of unconditional customer satisfaction of product performance applies. We stand behind our products.
REALISTIC When you order a CDR or MGS from Inpro/Seal, you are assured of the complete responsibility for technology and performance from a single source. We want to earn the right to be your first choice for complete bearing protection.
For more information visit www.inpro-seal.com/CDR or contact 800-447-0524 for your Inpro/Seal Representative.
For more info, enter 73 at www.LMTfreeinfo.com