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Offline Filtration: Key To Establishing And Maintaining Oil Cleanliness It’s an especially cost-effective approach to one of your biggest lube-handling challenges, but it has to be done correctly. Ray Thibault, CLS, OMA I & II, Contributing Editor


5 Ways To Cut Costs While Shooting Your Maintenance Effort In The Foot You’ll want to check out these sure-fire ways to do in your program. Raymond L. Atkins, Contributing Editor


Improving Rolling-Mill Lube-Oil Performance And Useful Life Steel mill operators know all too well how crucial it is to protect the premium oils that keep their processes up and running. Larry Edwards, Aaron Hoeg and Richard Trent, Hy-Pro Filtration


DEPARTMENTS 5 28 29 31 32

From Our Perspective Solution Spotlight Problem Solvers Information Highway Supplier Index

Designing For Stiction, Among Other Things Here’s what it takes to boost gear-pump reliability in remote locations. Jane Alexander, Editor, with Kevin Delaney, Tuthill Pump



April 27-30, 2010 Hyatt Regency O’Hare • Rosemont (Chicago), IL MARCH/APRIL 2010


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March/April 2010 • Volume 11, No. 2 ARTHUR L. RICE President/CEO

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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 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.



Ken Bannister, Contributing Editor

Say What You Mean… Mean What You Say!


s I ate my sandwich in a small restaurant on the road to nowhere recently, I became intrigued by a large sign stating “Our Goal and Objective is to Create the Comfort of Home for Every Guest!” Looking around at the austere surroundings, the tired plastic tablecloths and the apathetic waitress in a dirty smock, my thoughts wandered from the margarine-soaked, processed-chicken offering in my hand to the question of what the restaurant owner could have been thinking when posting this sign. Could this dismal environment really have been his/her personal interpretation of “Home Comfort?” If so, the intended objective had been achieved—only the owner should have stipulated “the Comfort of My Own Home. . .” If, however, the owner’s intent were universal, he/she certainly failed in achieving the expressed goal and objective with me (and, I bet, with the majority of the restaurant’s patrons, not to mention most individuals reading this column). When asked about the sign’s origins, the waitress informed me that it had been posted by the restaurant’s previous owner, and that the current ownership—to put it kindly—neglected things. The point of a goal or objective is to be tangible, measurable, current and relevant to its entire intended audience. The restaurant’s stated goal and objective missed on all counts! Setting goals and objectives allows us to give meaning to improvement initiatives and programs by stating our intent and measuring our success in carrying out that intent. Often thought of as mysterious—and as a financial anchor to the organization—the maintenance department is well served through the setting of goals and objectives that throw light on maintenance activities by defining and quantifying the department’s impact on both operations and the corporation as a whole. This impact can be spelled out in economic, wellness (safety) and environmental terms that have universal audience appeal.


Goals and objectives become slogans and statements of aspiration for their owners. Thus, broad and subjective statements such as “Keep Machinery Working!” can dilute a message significantly when the call to action can be met even if the machinery has been “band-aided” and is operating at only 40% of its design efficiency. A stronger, more effective way of saying things would be to proclaim: “Operating at Greater Than 95% Design Efficiency!” or “Delivering Greater Than 95% Asset Availability!” In both cases, a tangible and concise measurable is stated as the goal or objective. Asset reliability objectives can be expressed in terms of downtime-reduction or Mean-Time-Between-Failure (MTBF) targets, in days—not hours! Improved lubrication practices allow us to target goals and objectives not only in equipment effectiveness (i.e. uptime, throughput, availability, reliability), but in terms of energy reduction by tracking kWh consumption before and after the start of a lubrication initiative. Energy reduction can be translated into an economic or dollar-saving target/deliverable, as well as an environmental target/deliverable, by linking kWh usage with Kg–CO2 emissionreduction figures. By cleverly crafting multiple targets for the same lubrication program initiative, the maintenance department is able to “say what it means” to a wider audience that includes operations, management and shareholders/stakeholders of the enterprise. By working toward, documenting and achieving defined goals and objectives, we vindicate and validate the improvement process. At the same time, we help others understand the impact that lubrication programs and the role of maintenance have on them, by telling them that “we mean what we say!” On a more personal note, weary road warrior that I am, I guess I’ll have to strike another restaurant off my list of meal stops. . . | 5


Moving Toward Better Handling. . .

Offline Filtration: Key To Establishing And Maintaining Oil Cleanliness While itâ&#x20AC;&#x2122;s an especially cost-effective approach to one of your biggest lube-handling challenges, it must be done right. Ray Thibault, CLS, OMA I & II Contributing Editor



n entire five-part series of articles dealing with the importance of oil d ccleanliness in machinery reliability aand Best Practices in achieving these goals has been published in LMT (starting in 2008 and concluding in Jan./Feb. 2009). In this article, we revisit the topic by focusing on offline filtration as it applies to hydraulic systems and gearboxes.



Clean oil makes a big difference in reliability, resulting in major bottom-line savings. Utilize offline filtration to help meet your cleanliness goals economically. Offline filtration of hydraulic systems A typical hydraulic circulation system normally has three filter placement options: pressure line, return line and offline (Fig. 1). In some cases, a control-circuit filter is installed before the servo valves (Fig. 2). Many people once considered the pressure-line filter to be the most important in the circuit—because it protects the valves, the most sensitive components in a hydraulic system. These days, it is widely accepted that the proper use of offline filters, in conjunction with pressure-line and return-line filters, can achieve high levels of cleanliness at a reasonable cost. By maintaining a constant level of cleanliness in the reservoir, the pressure-line filter’s main function becomes protection against pump failure. Therefore, a coarser, lessexpensive filter can be used. Offline/kidney-loop filters offer the following advantages:

■ Application flexibility ◆Self-contained systems that are capable of being permanently mounted or used on a filter cart ◆Minimal floor space required ◆Adaptable to filtration of oil entering or leaving reservoir ◆Adaptable to filtration of new oil in tote or drum that is being added to a reservoir ◆Ideal places to add temperature-control devices ◆Use of water-removal elements as part of the system ■ Positive impacts on overall system

■ Constant flow through the filter (which is not the case in some hydraulic applications involving variable displacement pumps)

◆Allows meeting of cleanliness targets ◆Extends life of pressure- and return-line filters

■ Low pressure resulting in the selection of finer media at a reasonable cost (which allows for target cleanliness levels to be achieved) ■ Serviceability where the filter can be changed without interrupting system flow ■ Reliability (because the system will see constant flow at low pressure)

Positive-impact examples. . . A recent example of the effectiveness of using an offline filter in combination with other filters was in a hydraulic system using a 3 micron control-circuit filter and a 10µ return-line filter. By changing to a 3 micron return-line filter, the particles ≥4 micron were reduced tenfold and the control-circuit filter could have been changed to a coarser grade to achieve the previous cleanliness target.

Offline Filter

Fig. 1. A typical hydraulic circulation system normally has three filter placement options: pressure line, return line and offline. (Source: Hy-Pro Filtration) MARCH/APRIL 2010

Fig. 2. In some hydraulic systems, a control-circuit filter is installed before the servo valves. (Source: Hy-Pro Filtration) | 7


(Fig. 3 Source: Des-Case)

(Fig. 4 Source: HY-PRO))

Fig. 3 and Fig. 4. Examples of permanently mounted offline filtration systems

An injection-molding plant had 10 machines that were down an average of 10% of the time because of servo-valve problems. The pressure-line filter sent 21+/18 oil to the servos. Since installing a 30-gal. recirculating loop supplying 13/10 oil to the servo, and installing an offline system in the 550-gal. working reservoir supplying 14/11 oil to the system, the machines have seen less than 1% unscheduled down time. This has resulted in over $1,000,000 in yearly savings, not including reduced waste from unexpected shutdowns. Types of offline systems. . . There are three types of offline systems to clean fluids. The most common is the permanently mounted system that can operate 24/7. Once installed, it is the easiest to work with. There is, however, some equipment where installation may be difficult because of available space. Some suppliers offer skid- or panel-mounted systems that can be attached to the equipment as illustrated in Fig. 3 and Fig. 4. Two types of portable systems are utilized. The most common is the filter cart (available from different suppliers in a range

of sizes). Another portable system utilizes large totes with a mounted offline filter system. These totes are transported to the equipment where they can supply clean oil from the tote—or have oil from the reservoir pumped into the tote where it is cleaned during recirculation through an offline filter until the cleanliness target is met. As shown in Fig. 5, there also is an offline system that can be installed on the tops of drums or small totes to filter new oil through dual filtration. A filter cart represents the most common type of portable offline filtration system. Manufactured by a number of suppliers, these carts also come in a range of sizes (Fig. 6 and Fig. 7). Filter carts normally have two filters—A and B. The A filter is coarser than the B filter. As an example of filter selection, one manufacturer of servo valves requiring ISO cleanliness of 15/13/11 recommends the use of ß12=200 and ß3=200 filters. The A filter is coarser at 12 micron while the B filter is finer at 3 micron. In some cases, a water filter is used as the A filter to remove free and emulsified water. Reaching the target cleanliness code calls for the fluid to be turned over seven times in the reservoir. (The amount of turnover is related to the initial cleanliness of the oil.) Filter carts for hydraulic fluids with ISO VG ≤ 68 commonly have flow rates of 2, 5, 10 or 20 gpm. Although filter carts appear easy to use, they have the following disadvantages: ■ They’re often purchased, stored and never used. ■ Cross-contamination can result from using the same cart for different fluids without proper flushing. ■ Carts designed for low-viscosity hydraulic fluids are sometimes used inappropriately on high-viscosity gear oils.

Fig. 55. EExample Fi l off an offl ffliine system that h can bbe iinstalled ll d on the tops of drums or small totes to filter new oil through dual filtration (Source: Des-Case)


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■ Poor contamination-control practices, such as storing carts in dirty environments and not properly preventing contamination of the hoses, can cause problems. Offline filtration of gearboxes In the past, clean oil was not considered to be an important issue with gearboxes. Because so many of them run in dirty environments with high-viscosity oils, users have assumed that effective filtration is impossible. Times have changed, however, as evidenced by the importance gearbox OEMs have placed on clean oil for longer life. Wind-turbine gearbox manufacturers want to see new oil that is 16/14/11 or cleaner—and want oil maintained in the system at no more than 18/16/13. Offline filtration systems (both permanent and portable) have been able to filter high-viscosity oil down to very good cleanliness levels. Still, keeping gear oils clean is a challenge because of the following factors: ■ Oils are typically high-viscosity (ISO VG 220-460). ■ Most don’t have filtration (or only have strainers). ■Many are used in dirty environments (in coal-mill pulverizers, for example).

(Fig. 6 Source: HY-PRO)

(Fig. 7 Source: Des-Case)

Fig. 6 and Fig. 7. Examples of filter carts that are available in range of sizes from various manufacturers

the viscosity doubles to 927 cSt. Viscosity affects port sizes, but affects the element size and selected media even more. If your housing selection is on the borderline of being too small— as determined by the clean element pressure drop—go up a size. This will allow for a finer filtration if needed, or handle a higher-viscosity fluid. Consult closely with your filter manufacturer during this selection process.

■ Many are not fitted with breathers. ■Dirty oil and gearbox failures are accepted as a common practice. ■ There can be problems in draining and refilling gearboxes with new oil, including: ◆Gearbox drain is 1~2” above gearbox sump low point. ◆Before a drain machine is turned off, suspended contaminant falls out of the oil and settles in sump. ◆Oil is drained without many of the suspended solids. ◆New oil (dirty?) is added and the vicious cycle continues. Selecting the right type of filter and housing is critical for effective gearbox filtration. The key factor in the selection process is viscosity. Viscosity is expressed either as centistokes (cSt) or with the old system, which is Saybolt Universal Seconds (SUS). The conversion factor from one system to the other is SUS/5~cSt. For example, a 1500 SUS fluid has a kinematic viscosity approximately 300 cSt and has an ISO VG of 320. You need to consider the temperature at which the fluid will be filtered. Even small temperature differences can have a major impact on viscosity. For example, if a mineral gear oil with a viscosity of 460 cSt at 40 C (104 F) is filtered at 30 C (68 F), 12 | LUBRICATION MANAGEMENT & TECHNOLOGY

Successful examples. . . When it comes to gearbox filtration, how quickly you reach your targeted goal will depend on the flow rate, the initial fluid cleanliness and the viscosity. The following examples are based on real-world situations. An ISO 460 VG gear oil in a 275-gal. sump in a coalpulverizer gearbox filtered with a 6 micron absolute filter at a flow rate of 6.5 gpm produced the results in Table I. Table I (Source: Fluid Solutions)

Time in Hours Starting 2 4 6 8 24

ISO 4406-1999 Cleanliness Code 20/14 17/12 15/11 14/10 14/10 13/10

In many cases, if the correct filter is selected, the target cleanliness can be reached quickly depending on the size of the reservoir and the flow rate though the system. Typically, turning the sump over at least seven times will reach the cleanliness goal. One of the disadvantages of a portable system—such as a filter cart—is that once it is removed from the system in a dirty environment, the oil will quickly become contaminated. Therefore, proactive measures, such as installing desiccant MARCH/APRIL 2010


breathers to minimize moisture and particles, should be taken. Despite such actions and removing the filter cart, in the case of the coal-pulverizer gearbox, oil quickly jumped two ISO codes in the > 6 micron particles (see Table II ). Table II (Source: Fluid Solutions)

Time in Days Initial 2 4 6

ISO 4406-1999 Cleanliness Code ≥ 6 micron ≥ 14 micron 17/13 19/13 19/14 20/14

The economics. . . What does clean oil do to the economics of an operation? Consider the example of a coal mill where a skid-mounted offline filtration unit was installed on a pulverizer gearbox that had been utilizing only a strainer for filtration. A ß5=1000 filter was installed for filtration of an ISO 460 gear oil. As a result, the initial oil cleanliness level of 21/15 was brought down to 13/11—a 99.42% decrease. The box below shows yearly savings following installation of the filtration system and desiccant breathers. (By the way, each of this mill’s five coal-pulverizer gearboxes had previously required an annual rebuild.) Lubricant Cost Savings Gearbox Rebuild Savings

$15,600 $3,656,000

Total Yearly Savings


Clearly, there are major cost savings from keeping gear oil clean through proper proactive measures and the right filtration system—savings that can go straight to your bottom line. Conclusion Clean oil makes a big difference in equipment reliability, resulting in major bottom-line savings. This was illustrated with a few examples in this article. There are many more. Utilize offline filtration to help meet your cleanliness goals economically. Work closely with your filter manufacturer to establish a cost-effective program. Be sure to set meaningful goals before embarking on your program, and measure progress by monitoring your oil cleanliness through particle counts. Ideally, have your own particle counter. If this is not possible for your operations, work with your oil-analysis laboratory to obtain timely reports. Closely monitoring and improving the program is essential for success. No longer accept the notion that gear oils are necessarily dirty. The technology through offline filtration is now available to give you very clean oil. Work with your filter manufacturer to develop the right system for your operations. Finally, while filter carts can be important equipment in achieving your cleanliness goals, they MUST be used MARCH/APRIL 2010

properly (something that comes through proper training). There are many suppliers of filter carts, so choose wisely— especially when it comes to filtering gear oils. LMT Acknowledgements; The author wishes to thank Mike Boyd, of Fluid Solutions; Mike Skuratovich, of Eastern Oil; and Brian Gleason, of Des-Case, for their assistance with this article. 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: Meet Critical Lube-Related Training Requirements At MARTS 2010 Contributing Editors Ken Bannister and Ray Thibault are two of the Applied Technology All-Stars who will be up at bat at MARTS this April. For more information on or to register for their special lube workshops (including one that helps participants prepare for the CLS Certification Exam), visit:

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5 Ways To Cut Costs While Shooting Your Maintenance Effort In The Foot

You may not have asked for it, but here’s a list of some sure-fire ways to do in your program. Raymond L. Atkins Contributing Editor


t is quite an achievement to attain lasting success in plant maintenance. So much so, that once a modicum of reliability has been reached in a production facility, the maintenance organization responsible for this achievement would want to solidify its gains. It wouldn’t want to mess with success. It would be loathe to “fix” that which “ain’t broke.” It would be inclined to leave well enough alone. You can bet that if the maintenance manager were in the budgetary decision loop, this is exactly what would occur. As we all know, maintenance reliability doesn’t just happen. Despite the old saw to the contrary, for anybody in our line of work, it is NOT better to be lucky than good.

Unfortunately, the maintenance manager frequently is not the only person involved in the maintenance budgeting equation. Consequently, when the economy slows down and times get hard, the reward for a successful maintenance effort can sometimes be expressed as budget cuts. The irony here, of course, is that when a maintenance organization has truly found its stride, it may not seem busy enough to suit upper management. Historic measures of maintenance efficacy—heroic last-minute saves, quick turnarounds on emergency breakdowns and manly all-nighters—are not visible to others in the organization, who may begin to wonder what “those maintenance people” are doing with their time. After all, everything is running along smoothly and quietly, just as it should. “Do we really need all of them?” 14 | LUBRICATION MANAGEMENT & TECHNOLOGY



As another old saying goes, the squeaky wheel gets the grease. By the same token, if that wheel isn’t squeaking, it can be lost in the economic shuffle once the word comes down from corporate to cut costs. If the wheel is rolling as designed; if it is aligned properly; if its PMs are current; if it has been properly maintained by competent maintenance professionals to ensure against surprises and runtime failures; and if it was properly engineered to begin with, installed by a capable contractor and is being supported by a committed staff of professionals who know the process and the equipment, the keepers of the purse might decide that maintenance is as good a place as any to cut costs. When a company is under economic duress, however, financial decisions that look promising in the near term can have longterm negative impact on the health of the process. Such is the case with the following five sure-fire methodologies—they’re guaranteed to trim dollars from your maintenance budget immediately. Remember, though, that each of these tactics has a hidden cost for your organization in reliability and efficiency, as well as a real cost in dollars that will have to be repaid with interest down the road. #1: Suspend training One of the best methods to employ if you want to have an immediate short-term positive impact on your maintenance budget is to suspend or cancel your training program. Since it’s often difficult to see instant results from training programs, they are often put at risk during economic downturns. Assuming that you’re currently devoting 5% of paid maintenance time to training, that you work a 40-hour week, that you have a workforce of 20 technicians and that your technicians are paid an average of $15 per hour, you can save over $600 per week beginning the very first week, not counting the actual costs associated with training modules, materials and teachers. If your backlog requires attention, these manhours can be scheduled to other tasks. Or you can simply have your technicians work shorter weeks and take the savings all the way to the bottom line. On the other hand, the first time that a $10,000 bearing goes out because it was not installed properly—due to lack of training—the cost of the replacement part plus production downtime and maintenance overtime will wipe out these savings and more. #2: Reduce staff This popular cost-cutting tactic—aka “Slash and Burn”— is the hands-down favorite in many organizations. While not the approach typically taken by surgical teams, flight crews or fire departments (thankfully), it’s a method that most other industries and enterprises turn to at one time or another. Depending on the geographic location of the facility and the type of industry involved, huge short-term savings can be reaped using this approach, and real money can go straight to the bottom line. If you choose this approach, the tricky part is trying to select which of the current roles and MARCH/APRIL 2010

responsibilities on your maintenance team are not actually necessary to the organization’s continued success. To do so, you must assume that you’ve been overstaffed all along, or that you have some unnecessary roles in your organizational structure. Upon making these types of assumptions, you also must acknowledge that you somehow didn’t notice such conditions existed within your organization until the economy slowed and you were faced with reducing your budget. Finding yourself in this situation, incidentally, begs speculation about what you have been doing with your time (but that’s a question for another day). Luckily, the decision to eliminate personnel will probably be made for the maintenance manager by someone who is not actually acquainted with the organizational structure—with just a flick of the pen, based on dollars, not sense. Therefore, the cut won’t really be the maintenance manager’s fault. It will, however, be his/her problem when the plant grinds to a halt and ceases to make product. #3: Postpone or cancel PMs In any well-run maintenance organization, 50 – 70% of the technicians’ time is spent on PMs and inspections. This represents a deep well from which you can draw buckets upon buckets of savings, the dollar amounts of which can be quite large. Say your equipment is humming along nicely, and you have a total of 300 hours of PMs coming up for the next week. If you can somehow suspend the laws of maintenance and convince yourself that the reason your operations are running so well has nothing whatsoever to do with your current PM program, you can, with impunity, cut some or all of these hours from the schedule from time to time, particularly on those machines that aren’t giving you any trouble. It’s like finding thousands of dollars of free money just lying on the plant floor! Think about it: If you don’t do 150 hours of next week’s PMs—again assuming an average wage of $15 per hour— you can save well over $2000 that week in maintenance salaries alone. That’s without even considering the other costs associated with your PM program, such as parts and materials. If you continue doing this week after week— picking machines that are running well and skipping their PMs—you’ll be into real savings in no time flat. Great! You’ll need that money when it comes time to pay the piper: Sooner than you might imagine, there won’t be any well-running equipment to skip. # 4: Only fix what you have to fix Also known as the “Baling Wire & Duct Tape Method,” this cost-cutting avenue is based on the principle that a machine center—or even an entire process—will continue to run long after it has ceased to run well. This method assumes that the business gets paid on uptime, not throughput or quality, and relies heavily on the fervent hope that if the maintenance department somehow can just keep things patched together until the economy gets better, | 15

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“then we’ll be able to afford to fix it right.” It also assumes equipment systems do not wear or break, and even if they somehow did, that replacement parts and components would be free. The problem with this methodology is clear to the maintenance professional—when robbing Peter to pay Paul, that guy Peter will, at some point, want to get his money back. Any machine or process that is not well-maintained will run less and less efficiently over time. It will cease to do what it was designed to do in the manner it was designed to do it in. As it is patched and re-patched, the reliability issues compound, and the machine becomes less and less able to do what it is supposed to do. Eventually, it becomes so out of spec that nothing short of a major overhaul and refit will salvage it. #5: Practice reactive maintenance Best described as the “Laissez Faire Method,” this technique is based on the theory that your maintenance department will spend less money in the short run if it simply sits around waiting for something bad to happen. Oddly enough, if you’ve had any success at all in building an effective maintenance organization over time, you’ll actually spend a good deal less money using this particular strategy—well, at least for a while. The reactive maintenance technique is exceptionally easy to employ. Just hunker down out of sight somewhere and wait to see what happens. The savings associated with this approach have to do with the “don’ts.” When you base your maintenance strategy on running to failure each and every time: ◆ You don’t plan.

◆ You don’t lube.

◆ You don’t schedule.

◆ You don’t perform failure analysis.

◆ You don’t hold high expectations.

◆ You don’t perform PdM inspections.

◆ You don’t follow up.

◆ You don’t track KPIs.

◆ You don’t write SMPs.

◆ You don’t review safety.

Basically, you don’t do anything at all except hope that the plant doesn’t suddenly get quiet. The problem with this approach is that, sooner or later, the plant will—suddenly get quiet, that is—and the longer you employ this method, the more likely this becomes.

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Stop the shooting There you have the five best methods available for doing in your maintenance program. Each will have a positive short-term effect on the maintenance budget— and each will have a negative long-term effect on your process. The use of just several, or all of them at once, is a guaranteed recipe for failure. Granted, these are extreme examples of poor maintenance management. They were written that way to make a point. Still, as you read back over them, you should ask yourself if you are as removed from these practices as you think. In tough economic times, maintenance managers are under intense pressure to deliver reliability on time and under budget. In your daily search for ways to accomplish this, be sure you don’t end up shooting yourself in the foot! LMT Ray Atkins is a retired maintenance pro (and award-winning author) based in Rome, GA. He spent his last five years in industry as a maintenance superintendent with Temple-Inland. Web:; E-mail: raymondlatkins@ (Editor’s Note: This article is based on Ray’s Conference presentation for MARTS 2010. You read him regularly in “The Fundamentals;” here’s your chance to meet him in person. For details, visit




Don’t Miss The Capacity Assurance Conference! New Speakers!

Critical Topics!

Powerful Presentations!

The premier educational event for maintenance professionals, MARTS 2010 covers the widest range of topics in its history. With 32 one-hour Conferences and 17 full-day Workshops, MARTS offers valuable, job-critical information for:

MARTS 2010 Highlights: * Keynote Speaker John Ratzenberger – the actor, author and manufacturing activist will speak about Nuts, Bolts & Thingamajigs, his foundation that brings students and manufacturing together.

Plant and Facility Managers Maintenance Engineers and Managers Maintenance Team Leaders and Members Plant Operators and Engineers Reliability Engineers and Managers ... at the comfortable Hyatt Regency O’Hare hotel, 10 minutes from O’Hare Airport in Rosemont, IL.

* Futurist and financial professional Bob Chernow, who will offer predictions for manufacturing, technology, the economy and other key issues. * A special “Reliability Gives Voice to Autism” event that kicks off MARTS 2010 with a worthy cause. It will feature dinner and live entertainment while raising awareness and funds for autism. * Solid representation from industry experts such as Christer Idhammar, Bob Williamson, Doc Palmer and many others, including Enrique Mora, who will present a Spanish-only Workshop on TPM.

APRIL 27-30, 2010 Hyatt Regency O’Hare, Rosemont (Chicago), IL Or Call Tom Madding: 847.382.8100 x108 MARCH/APRIL 2010



What is MARTS? The Maintenance & Reliability Technology Summit is a four-day educational experience and professional development opportunity for maintenance and reliability professionals working in industry. Components include two days of full-day Workshops, two days of one-hour Conferences, two Professional Development Courses and Certification Examination opportunities. All sessions are presented by practitioners and other industry experts who have signed on to share their knowledge about industrial skills, not to sell products or services. Attendees interested in learning about products and services have ample opportunity to meet with MARTS exhibitors, located in common areas. For exhibition opportunities, contact Tom Madding: 847.382.8100 x108

MARTS 2010 Basics Location: Hyatt Regency O’Hare, Rosemont, IL Dates: Tuesday through Friday, April 27-30, 2010 Workshop Days: Tuesday and Friday (17 full-day Workshops offered) Conference Days: Wednesday and Thursday (32 one-hour Conferences offered; see schedule on next page) Professional Development Course 1: Certified Lubrication Specialist (CLS) Review, Tuesday through Thursday Professional Development Course 2: Taking Command of Your Maintenance Process: Is to provide a comprehensive from Certifieducational cation to Implementation, training, and professional Tuesday and Wednesday development opportunity for Certifi cation Exam Day (for technicians, CLS and CMRP): maintenance and reliability Friday engineers, supervisors and managers Note: interested in takingfacilities. an exam must in allIndividuals industries and major register directly with STLE (CLS) and SMRP (CMRP). Link to these sites at


MARTS 2010 Workshops Workshops are full-day, intense explorations of a given topic. Most run from 8:00 a.m. to 3:00 p.m., with an hour for lunch (included in price). See for addition details and to register.

Pre-Conference Workshops: Tuesday, April 27, 2010 Lean Equipment Management: The Prescription for Rapid and Sustainable Gains Robert M. Williamson, Founder, Strategic Work Systems, Inc. Liquid Gold: Implementing a Winning Lube Strategy for Maximum Gain Ken Bannister, Principal Consultant, Engtech Industries, Inc. Fundamentals of Mechanical Seals / Mechanical Seal Division of the Fluid Sealing Association (FSA) Best Practices in Compression Packing & Gasketing / Compression Packing and Gasket Divisions of the Fluid Sealing Association (FSA) Leading Organizational Change / Scott Franklin, Principal Consultant, Life Cycle Engineering Getting Started with Predictive Maintenance / Mike Gilley and Mike Dixon, Principals, Fox River Systems Reliability Centered Maintenance / Anthony “Mac” Smith, Senior Consultant, AMS Associates 4 Lean Tools to Revolutionize Your Maintenance System (Part I) / Ed Stanek, President, LAI Reliability Special Spanish-Language Workshop: How to Prevent or Revert Failure in Your TPM Implementation / Enrique Mora, President,

Post-Conference Workshops: Friday, April 30, 2010 Lubrication for Profit: Best Practices for Lube Selection and Application on Process Machinery / Ray Thibault, CLS, OMA I & II; Lubrication Training & Consulting Motor System Maintenance and Management / Howard Penrose, Ph.D., CMRP; Vice President, Engineering and Reliability, Dreisilker Electric Motors, Inc. Contractor Management Strategy / Dirk Frame, Managing Partner, and Jerry Wanichko, Manager, T.A. Cook Consultants, Inc. Ensuring Reliability Through Systematic Work Control / Dave Krings, CMRP, BSME; President, Using SMED to Transform Your Lean Enterprise / Enrique Mora, President, Maintenance Planning and Scheduling / R. D. (Doc) Palmer, PE, CMRP; Partner, People and Processes, Inc. IR Thermography for Electrical and Mechanical Systems / R. James Seffrin, Director, Infraspection Institute 4 Lean Tools to Revolutionize Your Maintenance System (Part II) / Ed Stanek, President, LAI Reliability MARCH/APRIL M MAR MA ARCH/ CH CH/ H/AP APRIL APRIL APR IL2010 20 201 010 0 MARCH/APRIL 2010

The Capacity Assurance Conference! MARTS 2010 Conferences

Conferences are one-hour presentations, given by an expert in the field. Accompanied by a PowerPoint presentation, they include ample time for Q&A, and are divided into six categories: Data Management Lubrication Strategy Green Maintenance & Reliability Technology

See the schedule below for Conference offerings and other Conference-Day activities: WEDNESDAY APRIL 28 (17 Conferences) 7:00 a.m. to 8:00 a.m. Continental Breakfast 8:00 a.m. to 8:45 a.m. Keynote Address John Ratzenberger, actor, director, author and spokesperson for the Nuts, Bolts & Thingamajigs Foundation 8:45 a.m. to 9:30 a.m. Break / Exhibits 9:30 a.m. to 10:30 a.m. Data Management Interoperability Between Plant Design and Other Systems for Reduced OPEX and Improved Maintenance, Turnarounds and Reliability Adrian Park, Intergraph Process, Power & Marine Green The Two New Legs of Lean Bill Adams, Blue Strategies Group, and Bill Livoti, Baldor Electric Co. Strategy Reliability and Maintenance Management: From Good to Great Christer Idhammar, IDCON, Inc. 10:40 a.m. to 11:40 a.m. Technology Understanding Torque Measurements and Torsional Analysis Trent Martz, IVC Technologies Maintenance & Reliability Where’s Your Reliability Policy? Robert M. Williamson, Strategic Work Systems, Inc. Strategy Forward to the Basics! (Designed for the Rocket Scientists and Over-Achievers Among Us!) Jeff Shiver, People and Processes 11:40 a.m. to 1:00 p.m. Lunch / Exhibits


THURSDAY APRIL 29 1:00 p.m. to 2:00 p.m. Lubrication How to Kill a Bearing / Ken Bannister, Engtech Industries, Inc. Green World-Class Companies Need World-Class Motor Management and Maintenance Noah Bethel, PdMA Corp. Strategy 5 Guaranteed Ways to Cut Costs While Shooting Your Maintenance Effort in the Foot Ray Atkins, MT Contributing Editor Maintenance & Reliability Total Process Reliability the ‘Columbia Way’ Gregory Folts, Marshall Institute, Inc. 2:10 p.m. to 3:10 p.m. Technology Ultrasound for Condition-Based Monitoring and Energy-Efficiency Improvement / Mike Gilley and Mike Dixon, Fox River Systems Maintenance & Reliability How to Make Your TPM Implementation a Total Success Enrique Mora, Strategy Planning Maintenance With Production Support / John Crossan and Randy Quick, Manufacturing Solutions, Intl. 3:10 p.m. to 3:40 p.m. Break / Exhibits 3:40 p.m. to 4:40 p.m. Maintenance & Reliability RCM Lessons Learned: An Update Mac Smith, AMS Associates, and Joe Saba, JMS Software Green How to Reduce the Payback Period for Energy Efficiency Projects / Ralph Semyck, Siemens Industry, Inc. Strategy Change Behavior to Achieve Results: High Impact Learning Tara Denton, Life Cycle Engineering (LCE) Strategy Life Cycle Costing Management for WorldClass Asset Managers / Ali Zuashkiani, Centre for Maintenance Optimization and Reliability Engineering, University of Toronto 4:40 p.m. to 6:00 p.m. Reception / Exhibits

(15 Conferences)

1:00 p.m. to 2:00 p.m.

7:00 a.m. to 8:00 a.m.

Maintenance & Reliability Plant Floor Reliability: A Four Senses Approach / David Rosenthal, MEMC Electronic Materials

Continental Breakfast 8:00 a.m. to 8:45 a.m. Keynote Address Bob Chernow, Futurist/ financial expert 8:45 a.m. to 9:30 a.m. Break / Exhibits 9:30 a.m. to 10:30 a.m. Strategy Using Web 2.0 Technologies and Social Media to Continuously Improve Maintenance and Reliability Jeff Shiver, People and Processes Maintenance & Reliability The Development of Condition-Based Maintenance in a Service Company Howard Penrose, Dreisilker Electric Motors Green Reducing Compressed Air Leaks Hugh Blackwood, U.S. Navy (retired) Strategy The Right Part at the Right Time at Cost-effective Prices Richard R. Rosales, ABB 10:40 a.m. to 11:40 a.m. Maintenance & Reliability Prospering in a Lean Maintenance Environment Ed Stanek, LAI Reliability Systems Green An Easy Approach for Applying Today’s AC Drives / James Mullinix, Vacon Strategy O&M Peer Networking Bob Gibson, Scientech

Strategy Maximizing Human Resources Performance within the Maintenance Organization / Michael Gehloff, General Physics Corp. Lubrication Benchmark Your Lube Program Through Oil Analysis Stacy Heston, POLARIS Laboratories Open Discussion Group Topic TBA / Bob Williamson 2:10 p.m. to 3:10 p.m. Data Management How to Make Your CMMS Interoperate With the Real-Time Enterprise C.C. (Cliff ) Pedersen, Pedersen Enterprises Inc. Technology Infrared Thermography: What’s Hot in PdM / Jim Seffrin, Infraspection Institute Strategy Applying Disruptive Learning Techniques in a Manufacturing Environment Mitch Stansloski, Pioneer Engineering Strategy Trends in Turnarounds / John Elliott and Jerry Wanichko, T.A.Cook Consultants, Inc. 3:10 p.m. to 4:00 p.m. Break / Exhibits 4:00 p.m. to 5:00 p.m. Plenary Session / Closing Remarks

Maintenance & Reliability Classical RCM: Try It, You Are Bound to Like It / Tim Allen, AMS Associates 11:40 a.m. to 1:00 p.m. Lunch / Exhibits www ww w.LMTi L Ti LM Tinffo Tin o com m | 19 9

The Capacity Assurance Conference! APRIL 27-30, 2010

MAINTENANCE andd RELIABILITYTECHNOLOGY RELIABILITY TECHNOLOGY SUMMIT MARTS 2010 Professional Development Opportunities Two professional development courses are offered at MARTS 2010. These are designed for managers looking for in-depth, focused reviews, and technicians who want to build their skill sets. Courses are held Tuesday through Thursday. Professional exams for Certified Lubrication Specialist (CLS) and Certified Maintenance Professional (CMRP) are offered on Friday. Individuals interested in taking an exam must register directly with STLE (CLS) and SMRP (CMRP). Link to these sites at or see below. 3-Day Review Course: Certified Lubrication Specialist (CLS) Review Instructor: Ray Thibault, Lubrication Training & Consulting Dates: Tues., April 27 through Thurs., April 29 Times: 9:00 a.m. to 4:00 p.m. (except Tues., April 27: 8:00 a.m. to 3:00 p.m.) Cost: $1,195 Your designation as a Certified Lubrication Specialist (CLS)— one of the most prestigious certifications in industry—not only positions you well in a different environment, it allows you to better resolve lubrication problems in your facility. Topics include bearings & gears; pneumatics & fluid power; fluid conditioning & analysis; seals; lubricant programs; and storage & handling. Exam strategies will be addressed and practice exams will be conducted. (Course enrollment does not ensure certification.)

2-Day Review Course: Taking Command of Your Maintenance Process: from Certification to Implementation Instructor: Dave Krings, CMRP, BSME; President, Dates: Wed., April 28 and Thurs., April 29 Time: 9:00 a.m. to 4:00 p.m. Cost: $995 This comprehensive review of the latest maintenance best practices is designed for busy maintenance professionals looking to either prepare for certification exams or integrate these concepts into their maintenance programs. Taught in a humorous format that makes content both fun and easy to understand, participants will learn how to apply world-class maintenance practices from beginning stages to sustaining improvement after high reliability is achieved. (Course enrollment does not ensure certification.)

Exam: Certified Lubrication Specialist (CLS) Administered by the Society of Tribologists and Lubrication Engineers (STLE). Date: Friday, April 30 Time: 8:30 a.m. to 11:30 a.m. Cost: Varies Note: You must register separately with STLE to take this exam at MARTS 2010. Register online at or call 847.825.5536.

Exam: Certified Maintenance & Reliability Professional (CMRP) Administered by the Society for Maintenance & Reliability Professionals (SMRP) Date: Friday, April 30 Time: 8:30 a.m. to 10:30 a.m. Cost: Varies Note: You must register separately with SMRP to take this exam at MARTS 2010. Register online at or call 800.950.7354.

MARTS 2010 Fees and Packages Special FSA Package - $ 1,995.00

FSA Workshop Package - $ 695.00

Includes 1 FSA Pre-Conference Workshop, MARTS Conference and 1 Post-Conference Workshop

Includes 1 Pre-Conference FSA Workshop

Special Summit Package - $ 1,550.00

Lubrication for Profit Workshop - $ 545.00

Includes 1 Pre-Conference Workshop, MARTS Conference and special Post-Conference Workshop “Lubrication for Profit”

Includes “Lubrication for Profit” Post-Conference Workshop only

FSA/Conference Package - $ 1,590.00

Includes 3 days of intense training based on STLE’s CLS program

Includes 1 FSA Pre-Conference Workshop and MARTS Conference

2-Day Workshop: Taking Command of Your Maintenance Process: from Certification to Implementation- $ 995.00

Summit Package - $ 1,450.00 Includes 1 Pre-Conference Workshop, MARTS Conference and 1 Post-Conference Workshop

3-Day Certified Lubrication Specialist Workshop - $ 1,195.00

Includes 1 Pre- or Post-Conference Workshop and MARTS Conference

2-day review of the latest maintenance best practices is designed for busy maintenance professionals looking to prepare for certification exams or integrate these concepts into their own maintenance optimization programs

Conference Package - $ 895.00

Certification Exams - Costs Vary

Combo Package - $ 1,190.00

Includes MARTS Conference.

Two Workshop Package - $ 890.00 Includes 1 Pre-Conference and 1 Post-Conference Workshop only

One Workshop Package - $ 495.00 Includes 1 Pre Pre- or Post-Conference Post Conference Workshopp

Individuals interested in taking the CLS exam or the CMRP exam must register directly with STLE (CLS) and SMRP (CMRP). Links are available at and are also listed on page 18 All packages include continental breakfast, lunch and Wednesday night’s MARTS Reception. For Group Rates, call 847.382.8100 x108.

APRIL 27-30, 2010 Or Call Tom Madding: 847.382.8100 x108 For more info, enter 66 at




Improving Rolling-Mill Lube-Oil Performance And Useful Life Steel-mill operators know all too well how crucial it is to protect the condition of the premium oils that keep them up and running. Larry Edwards, Aaron Hoeg and Richard Trent Hy-Pro Filtration



igh-demulsibility lubricant is used for back-up roller-bearing lubrication in both cold- and hot-rolling mill steel production applications. Some of the oils used in these applications are referred to as SD (super demulsibility)—which can come at a premium price. Morgoil® * is this type of product.

Manufacturers of steel-mill equipment and components (i.e. Danieli, Morgoil®) commonly specify fluid brands and trade names that are qualified and recommended for use with them. That’s because steel mills encounter very high amounts of water and particulates in lube applications. For example, a mill might have a single tank for oil return and supply, or there might be a twin tank setup where the return tank is a settling tank connected to a supply tank. Free water is regularly drained from these tanks—in fact, it is common practice to drain hundreds of gallons of water per day or shift, depending on the condition of the bearing seals and chocks. Specified oils, such as Morgoil, are formulated for excellent demulsibility, or the ability to shed water in the presence of gross free water. Their demulsibility is a function of quality base stock and the oil’s ability to remain chemically stable. One blender defines the maximum suitable water level as 500 ppm (0.05%) to ensure optimum lubrication, viscosity and useful oil life. In the field, it’s not unusual to encounter rolling-mill oils that look like chocolate milk or mud (cloudy), with water levels from 3000 ppm (0.3%) up to 150,000 ppm (15%). Once the oil begins | 21


Proper care of the oil can help an operation both justify the use of premium products and move beyond the acceptance of high levels of water and particulate as the norm. losing demulsibility and the “emulsified” water increases, the oil may be replaced based on analysis data, or left in the system until the mill experiences bearing failures ($30,000 each). Depending on the amount of water in the oil, the viscosity will change. In an extreme case, oil-analysis reports revealed that ISO 460 oil viscosity with 7000 ppm was 445 cSt and with 133,000 ppm had dropped to 330 cSt. When viscosity drops, the lubricating film is compromised, yielding thin film—which, of course, can lead to greater risk of particulate contamination damage and metal-to-metal contact between bearing and bearing housing. As the lubricating film becomes thinner between the rolling surface and the housing, there is an increase in heat that can vaporize the water and cause further damage to the bearings and oil. The combination of high “emulsified” water and high particulate levels creates a perfect storm for bearing failure and reduced oil life. Analyzing the problem/finding a solution Achieving and maintaining ISO cleanliness codes below recommended maximums can improve reliability, minimize component damage and extend useful oil life. The same can be said for controlling water contamination. A suitable target ISO cleanliness code is 18/16/14, yet typical ISO codes found in steel mills can range between 24/23/20 and 21/20/18. System filtration is usually done via cleanable strainer baskets featuring large perforated holes or pleated cartridge elements with wire mesh media, unless the cleanliness has been addressed by adding finer side-loop filtration. In addition to the increases in emulsified water caused by oxidative oil degradation, the particles and free water can combine loosely to increase the amount of water in the oil that will not readily demulsify. The free water can act as a powerful solvent looking for molecular partners, and can form loose bonds with the suspended particles. The suspended particles can invite more water into the oil in which they are suspended. An emulsion is a bond that can be chemically strong and unbroken by settling. Although centrifuges have traditionally been used to remove free water, they do little to treat the emulsified and dissolved water that causes damage in bearings and shortens fluid life. Centrifuges also require frequent maintenance, and are often neglected due to other heavy demands on maintenance personnel. 22 | LUBRICATION MANAGEMENT & TECHNOLOGY

Vacuum dehydration, including high-efficiency particulate filtration, must be applied to properly address the whole water issue of dissolved, emulsified and free water. Removing water and particles with vacuum dehydration will improve demulsibility and fluid cleanliness of the oil for improved bearing lubrication, increased bearing life and longer oil life. Other benefits include less roll-stand leakage, decreased oil consumption, elimination of the need for decanting and reduced environmental impact. In their chemical structure, high-demulsibility oils are relatively stable and not looking for molecular partners. The hydrogen in water, however, is actively seeking partners (H-O-H)—it is the friendliest molecule the oil encounters. Likewise, many suspended particles in the oil are looking for molecular partners, so they will join with the water. The particulate contamination in the oil is the catalyst that intensifies the entrainment of the water in the oil along with the increase in emulsified water that is caused by continuing degradation of the oil, which is accelerated by the increase of emulsified water. The rising levels of water not only lead to an increase in the rate of oxidation, they also contribute to the formation of various acids that form as the oil molecules breakdown. The acids attack and degrade the seals, hoses, pumps and metal surfaces. When there is a high percentage of water in the oil (free, emulsified, and dissolved), the immediate concern is for controlling the free and emulsified water and particulate contamination as these do the most damage to bearings. A parallel target should be minimization of the ingress of the free water through leaky seals and chocks to reduce regular decanting of free water and lube oil losses that occur as oil is carried down the drain while draining water. Water in rolling-mill oil is inevitable; defining success is important in the battle to extend the life of bearings through proper lubrication—and to also extend oil life. Striving to achieve and maintain low levels of water and particulate in the oil, both quantifiable goals, will increase reliability and ultimately improve bottom-line profitability. Proper care of the oil can help an operation both justify the use of premium products and move beyond the acceptance of high levels of water and particulate as the norm. That’s more important than ever, since increasing oil prices have put the cost of replacing lube-system oil in the range of $100,000 to $300,000, depending on the system volume and type of oil used. MARCH/APRIL 2010


Change in Water Level PPM after VUD 35000

Water Level PPM

30000 25000 20000 15000 10000 5000 0 9-5 AM

9-5 PM







Real-World Results Proper oil condition can be the difference between uptime and unplanned downtime. It’s an enormous issue for steel mill operations. Consider the following: In a recent application, a Hy-Pro Vacuum Dehydrator (VUD) was installed on an 8000-gal. rolling-mill lube reservoir to prevent the type of frequent bearing failures that were costing the operations $30,000 per occurrence. The VUD had an immediate impact, reducing water levels from 29,000 ppm (2.9%) to 17,735 ppm (1.7735%) during the first day. Within two weeks, the water level of the system had stabilized at 383 ppm (.0383%). Since the water has been reduced to acceptable levels, the mill has not had a bearing failure. Prior to the installation of the VUD, the mill was decanting water every shift. The VUD was installed on the decanting line and the daily practice of decanting the reservoir was ceased, decreasing oil consumption by 25,200 gallons (~$201,600 annually). The mill is no longer topping off lube reservoirs, oil consumption is limited to roll-stand changes and roll-stand labyrinth seals are no longer leaking. The oil lost during decanting would accumulate in a sealed retention pond from which it had to be periodically skimmed/ reclaimed. Subsequent to the installation of the VUD, pond oil, recovery efforts and costs decreased significantly. In another successful application, Hy-Pro installed a VacU-Dry V20 model vacuum dehydrator with high efficiency glass media elements on a 12,000-gal. single tank Morgoil® system where the water concentration was over 7000 ppm (0.7%) emulsified. The oil was dark and had the appearance of chocolate milk. The mill was regularly draining free water from the reservoir that contained residual oil. The Vac-U-Dry was connected to the reservoir drain line and the free water was no longer drained. Within two months of this installation, the water concentration had dropped from 7000 ppm (0.7%) to < 30 ppm (0.003%). Mill personnel have

mentioned that when viewing the oil in the lube window in the bearing supply line, “it actually looks like oil again.” This specific mill is no longer draining free water, thereby saving valuable maintenance man hours and not losing oil (which is common in the decanting process). Oil-analysis indicates that the oil is no longer operating under alert conditions for water concentration. Particle counts also show fluid cleanliness trending toward acceptable levels. Today’s advanced vacuum dehydrators are designed for 24/7 unattended operation with automatic water drainage and large particulate filter elements to improve oil cleanliness while removing all forms of water in oil (free, emulsified and dissolved). Maintenance intervals for vacuum dehydrators are much longer than those of other technologies, thus easing the burden on maintenance personnel. In addition to addressing the contamination issues, it is also important to combat sources of water and particulate contamination if possible. Achieving optimum oil health requires the removal of water and particles as the particles are a catalyst for increasing the amount of entrained water that leads to increased oxidation, the formation of acids and low viscosity. Hy-Pro equipment has been used in the reclamation of rolling-mill lube-oil where oil that once had been condemned was reclaimed to extend its useful life. LMT Acknowledgements The authors wish to thank Ray Thibault, CLS, OMA I & II, for his assistance in the preparation of this article. To learn about Hy-Pro’s complete line of products and services, visit *Morgoil®’ is a registered trademark of the Morgan Construction Company For more info, enter 01 at

MARCH/APRIL 2010 | 23


That’s what it takes to boost gear pump reliability in Putting it as simply as remote locations. possible, application of Jane Alexander, Editor new design principles with Kevin Delaney, Tuthill Pump

in capacity-assurance technologies is boosting usability and productivity.

This article first ran in the March 2010 issue of Maintenance Technology


Designing For Stiction, Among Other Things


or internal gear pumps, a compressor lube-oil application might be viewed as an ordinary, nothing-special situation. Consider, though, internal gear pumps on screw compressor skids used for natural gas exploration in some of the most remote and desolate parts of the world. Reliability is a must with these critical units. That’s because maintenance crews can be hundreds—if not thousands—of miles away. Dispatching a crew by helicopter may be the only way to address an emergency downtime requirement. But difficult logistics are just part of the problem. Throw in a few more challenges, beginning with high thrust load because of system pressures that can run up to 400 psi. Add high radial loads due to side-mounted belt drives on some installations. Then top it all off with the need for the pump to be capable of starting up cold at -20 F. Got the picture? Tuthill Pump’s HG upgrades for its GlobalGear line of internal gear pumps have met these types of challenges and more. This upgrade package is being supplied to several of the major compressor skid suppliers, with installations dating back two years that have an operating record of no reported failures. HG upgrades address reliability issues for both bearings and mechanical seals individually, and for an integrated combination of bearings and seals.




How these upgrades work for bearings Bearings are typically selected to handle either primarily axial or radial loads. In the compressor-lube applications described, the pump will see both high axial and radial loads. Axial load will be thrust caused by the combination of system pressure and differential pressure. Radial load will be the combination of load caused by differential pressure and whatever side load applied to the sheaves if belt-driven. To deal with this combined axial and radial load situation, Tuthill uses an upgrade bearing arrangement of back-to-back, matched-pair, single-row, angular contact bearings (supplied by SKF) that are installed with heavy press interference fit to the rotor shaft. With the bearings held in place in a bearing cap, rotor-end clearances can be set by adjusting the bearing cap location with a jackingbolt and locking-bolt arrangement similar to what is used in ANSI process pumps. Compressor stations are high-vibration types of environments. Using press-fit bearings and the jacking-bolt/ locking-bolt arrangement serves to lock the rotor position in place—and is not dependent on small set screws or locknut tabs to keep the rotor securely in place. Another major advantage of this arrangement is that the bearings only need to be lubed every 15,000 hours. With the pumps running continuously, this makes for an 18-month-between-scheduled-maintenance interval. How these upgrades work for seals Sealing cold lube oil in a startup condition presents two special challenges. A high moment of inertia condition arises when cold lube oil surrounding the rotary portion of the mechanical seal creates a huge drag effect. This holds the rotary portion of the seal in place, while the shaft on which the rotary seal face is attached is instantaneously accelerated from a standing start to whatever the operating speed of the pump is. Unless the seal is specifically designed to withstand this high moment-of-inertia starting condition, there will be seal failures due to broken or bent drive pins and/or fractures in the drive faces as the motor-driven shaft breaks free and the seal breaks in pieces. The other challenge is that thickened cold lube oil is a poor lubricant. For a brief period, the seal faces essentially run dry because the thickened oil is unable to penetrate into them. With this brief moment of run dry, seal faces of like materials can gall and seize as one piece welded together. “Stiction” is a term that has come into recent use to describe this phenomenon. If the seal faces do seize and weld together, the result will be seal failures due to broken or bent drive pins and/or fractures in the drive faces. To address this cold-lube startup situation, Tuthill now incorporates an upgraded, heavy duty slurry-type seal that has thick cross-sections on the pieces and drive MARCH/APRIL 2010

An upgraded, heavy duty slurry-type seal with thick crosssections on the pieces and drive components withstands high torque conditions in cold-lube startup situations.

components to withstand high starting-torque conditions. Positive drive is used on the rotary with a grade of 400 series stainless set screws, and the stationary is pinned in place in the gland. With this design, the compression springs of the rotary unit are on the atmospheric side—thus, there’s no opportunity for clogging of the springs. Moreover, the faces of the heavy duty slurry seal are of dissimilar hard materials that are guaranteed not to weld together. This heavy duty slurry seal is a balanced seal to reduce face loads during operation, and an API plan 13 vent to suction is used to circulate lube oil into the seal chamber. The seal chamber is an oversized stuffing box to provide clearance for the lube oil to properly cool and lubricate the seal faces. For larger pump sizes with significant cantilevered loads, the GlobalGear pump incorporates oversized shafts and bearings that reduce deflection up to half and extend seal life. A proven problem-solver The proven reliability of the GlobalGear pump with the HG upgrades is the result of careful attention paid to the design details—not just of bearings and seals, but of the entire pump assembly as an integrated unit. Despite the high starting torque requirements for compressor lube-oil applications, broken shafts or gear teeth aren’t encountered with this type of gear pump. The shafts are made of a higher strength AISI 4140 steel, and idlers and rotors are made of ductile iron ASTM A536, grade 80-55-06 that provides a degree of strength and resistance to breaking similar to that of steel gears. | 25


This API 676-compliant GlobalGear upgrade features a back pull-out of the bracket and rotor assembly.

Making the Difference with Innovative Excellence

High Purity Polyol Esters (POEs) • Extend Machinery Life • Lower Energy Costs • Reduce Friction • Severe Temperature and H1 Available

1.800.521.9891 Call for your local distributor

The GlobalGear pump itself is API 676-compliant, and features a back pull-out of the bracket and rotor assembly. For high system-pressure requirements, high-pressure flanges are supplied—generally 250# ANSI flanges for cast iron construction or 300# flanges for cast steel construction. Maintenance made easy While design life is usually longer, it is recommended that the bearings and seals be renewed every five years. For scheduled periodic maintenance of the compressor stations, crews work on all types of different equipment. Seals and bearings are what generally wear out quickest. The mechanical seal and ball bearings of the HG GlobalGear can be replaced with a cartridge-style pump drive module, allowing fast and easy renewal by a non-specialized crew. Even more interesting is that the cost of the cartridge-style pump drive module is in line with that of some API cartridge-seal-only assemblies. For many gear-pump applications, reliability may not be as crucial as it is for remotely located natural gas exploration compressors—and “stiction” may not be the hidden seal killer. On the other hand, Tuthill’s successful experience with reliability-driven design upgrades on compressor lube-pump applications means that design options are now available to dramatically improve gear-pump reliability in a wide range of applications. From another perspective, if your operations have stacks of unfilled work orders piling up, planned bearing and seal renewal that can be done quickly by a non-specialized crew could offer an interesting and very cost-effective option. LMT Kevin Delaney is vice president of Marketing for Tuthill Pump, headquartered in Alsip, IL. E-mail: kdelaney@

For more info, enter 67 at

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& Innovation Summit 2010 Energy & Innovation Summit 2010 is designed to help participants understand energy efficiency, build successful business models, get practical advice on funding as well as implementing efficiency efforts. Attendees will learn what really works from global and national leaders and how to get on the path to success in the energy efficient economy. Day 1: INNOVATION SUMMIT Hear from experts and learn from case studies and skill training on energy innovation in products, processes, and new business models Day 2: ENERGY EFFICIENCY SUMMIT Get latest updates on energy efficiency initiatives including ISO-50001and learn from case studies and manufacturers of energy efficiency products Day 3: ENERGY TRAINING SEMINAR Get hands-on training from industry experts to meet the new ASME/ANSI standards


MAY 18-20, 2010 7:30 am — 5:00 pm

Amway Grand Plaza

Grand Rapids, Michigan

REGISTER NOW! So Much To Learn And Discuss! How to innovate with new opportunities in the energy sector Status of energy efficiency, ISO-50001 & proven paths to success Training to meet the new ASME/ANSI standards

So Much You Can’t Afford To Ignore! Interested in showing customers how to reduce energy costs with your company’s products? Call Kathleen Hoyle at (269) 352-4583 for information on sponsorship opportunities.


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Consider The Lowly Hand Pump Special to LMT from GoatThroat Pumps

GoatThroat SCP-6500 Conductive Plastic Pump


onsider the lowly hand pump. You see them used everywhere across industry—anywhere you find process equipment and systems—in applications ranging from the transfer of boiler room chemicals and oils to solvents and degreasers. They have countless capabilities, including helping your operations “green” up in more ways than one! A Google search will generate more than three million listings under “chemical spills” and more than five million for chemical-spills equipment! The lists include everything from spill kits, containers, pigs, absorbents, drum accessories, gloves, safety kits, leak diverters and spill and drain barriers and wipers to, of course, pumps that act like vacuum cleaners. Eliminating fugitive inventory loss from spills (plus the requisite labor and materials for their cleanup) or vapor emissions can go a long way toward improving your “green” footprint in the immediate environment and save your company plenty of the other green. Using pumps— including today’s state-of-the-art hand pumps—that offer long service life will deliver even greater financial results. The GoatThroat line of pumps is designed for the safe transfer of more than 900 liquids, including both oils and corrosive fluids from containers of all sizes, and for emptying 55-gal. drums in keeping with Resource Conservation and Recovery Act (RCRA) Ready Standards. These polypropylene pumps offer a life expectancy of 10 to 15 years, and the only maintenance involved is a simple O-ring change once or twice during the life of the pump. The estimated “pump longevity” reduces the cost of ownership to less than $30 per year. Several styles of these pumps are now available to help facility managers meet increasingly stringent safety programs.


Oh, what it can do today!

GoatThroat VSD-6800 Vapor Degreaser Pump

Remember, too, that handling fluids once instead of via multiple transfers also is a big cost saver. One company is now using a GoatThroat Pump with a remote discharge nozzle and a pneumatic adapter to deliver liquids to a sump above the head of the employee. Before, personnel would transfer from a 55-gal. drum to a 5-gal. bucket, then lift and pour the 5-gal. container into the sump. With the change to more efficient equipment, there are no more injured backs. Product specifics One of the newest GoatThroat offerings, the SCP-6500 Static Conductive Line, allows users of flammable liquids to ground the pumps, making them safe for use with class 1 and class 2 flammables. Because of the highly evaporative nature of solvents, another GoatThroat product, the VSP-6800 System, helps save inventory by delivering the fluids directly to the point of use. While it can be operated by hand, a BGA Shop Air Adapter can be added to the system to increase ease of use when shop air is present. Selecting the right product Users should consider all aspects of fluid transfer and inform themselves about all available methods. In this way, they’ll be sure to select the right pumping solution—and help ensure operator safety and no material loss. GoatThroat Pumps Westcott Distribution, Inc. Milford, CT For more info, enter 31 at MARCH/APRIL 2010


Upgraded Line Of Filters, Regulators, Lubricators


RO Fluid Technologies offers an expanded and improved ARO-Flo Series of filters, regulators and lubricators (FRLs) for pneumatic tools and equipment. Their new, completely modular designs ease assembly and allow for additional customization. They come in four series for optimal fit to the application and tools used; T-brackets and panel nuts that previously were optional are now standard; new integral gauge fans allow operators to quickly monitor pressure. Although a number of new safety features have been incorporated into these FRLs, a full line of accessories that promote safer working environments also is available. ARO Fluid Technologies An Ingersoll-Rand business Davidson, NC For more info, enter 32 at

Next-Day Delivery Of Custom Seals


ercules Sealing Products’ “Same Day Seals On Demand” program can provide custom seals, manufactured on the day of order. The product is shipped via UPS red service for guaranteed next-day delivery. Styles include piston, rod and rotary shaft seals, wipers, back-up and guide rings in over 125 standard profiles. Custom profiles are available within a few days. Hercules Sealing Products Clearwater, FL For more info, enter 34 at

Aerosol Spray For Leak Detection


RC’s Leak Detector allows simplified detection of gas and air leaks in pipes and pressurized systems. It works by forming highly visible bubbles over the point of leakage. This non-flammable, water-based formula contains no oils, silicones or harmful solvents, and the 20-oz. aerosol package enables fast and easy application with no waste or spillage. The product can be used on a variety of surfaces for almost all types of gas. Its “no-odor” formula is NSF P1 Registered for use in meat and poultry plants.

CRC Industries Warminster, PA

No Cleaning Or Priming With These High-Temp Threadlockers


enkel offers two new Loctite® threadlockers that withstand consistent operating temperatures up to 360 F. Curing consistently and thoroughly without cleaning, they tolerate oils and lubricants typically found on “as received” threaded fasteners. They also cure without primers on plated, aluminum, stainless and chromated fasteners. Loctite 243™ is a medium-strength threadlocker that can be disassembled using standard hand tools. Loctite 263™ is a high-strength product for applications where permanent assembly is required. Both products provide a leakproof, corrosion-free seal, and prevent fastener loosening due to temperature-induced expansion and contraction.

Henkel Corp. Rocky Hill, CT For more info, enter 33 at MARCH/APRIL 2010

For more info, enter 35 at

Simply & Accurately Measure % FAME In Your Diesel Fuel


iesel fuel containing up to 5% biodiesel meets the ASTM D975 standard, which does not require disclosure of the biodiesel level. A2 Technologies’ method for determining contamination levels of % FAME in diesel fuel utilizes the company’s PAL FTIR analyzer, a sensitive transmission IR sampling interface as specified in EN 14078, and the universal algorithm and sample set specified in ASTM D7371. A2 Technologies Danbury, CT For more info, enter 36 at | 29


Motor Brakes With Oil Shear Technology


ccording to Force Control Industries, the company’s MagnaShear motor brake with oil shear technology stands up well in a range of demanding applications. Proven oil shear technology offers a number of benefits: It transmits torque between lubricated surfaces, thus eliminating wear on friction surfaces. A patented fluid recirculation system dissipates heat, a common problem in dry braking systems. The technology also provides a smooth “cushioned” stop that reduces shock to the drive system. These motor brakes are well suited for operations where a motor is reversed each cycle, including loader/unloader conveyors, pallet-return conveyors, pallet turnover, load spade assembly and unloader assembly. Force Control Industries Fairfield, OH For more info, enter 37 at

Continuous Thermal-Fluid/ Hot-Oil Filtration For Asphalt Plants


iquid Process Systems’ patented Vector Series Model VB10C Thermal Fluid Filtration System was developed specifically for hot- and warm-mix asphalt and associated plants. According to the manufacturer, it continuously filters contaminants on a side-stream basis down to 10 microns. System flow and pressure available from the plant process is used to recirculate thermal fluid or hot oil from the pump discharge through the filter. Clean fluid is then returned to the suction side of the pump. Liquid Process Systems, Inc. Charlotte, NC For more info, enter 38 at

The future of manufacturing is in the hands of today’s young people. Nuts, Bolts & Thingamajigs, the foundation of the Fabricators & Manufacturers Association Int’l is focused on securing the future of manufacturing, innovation and invention in North America. This happens when young people are introduced to the joy and pride of “tinkering”. When a young person learns they can make something useful and practical with their own hands, they’ve taken the first step to a career. Hundreds of students learn this each year at NBT summer manufacturing camps. High school grads can apply for NBT scholarships to study at technical schools or colleges and prepare for the highly skilled manufacturing jobs of the future.

Insure the future of your industry with a gift. Your corporate pledge, personal donation or legacy gift will launch careers for skilled mechanics, electricians, machinists, engineers, laser operators, and so much more. Donate today at or call 815-381-1338

Don’t Miss Out! Meet Nuts, Bolts & Thingamajigs founder and spokesperson, actor John Ratzenberger at the MARTS conference. Attend his keynote at 8:00 a.m. April 28, followed by a book signing. Make a $20 donation to NBT and obtain an autographed copy of his book, We’ve Got it Made in America. Visit for more information.

For more info, enter 69 at




Bearings For Harsh Washdown Conditions


odge® Ultra Kleen ball bearings from Baldor provide extended life in the harsh washdown conditions typically found in the food and beverage industry. They feature the QuadGuard™ sealing system with a triple-lip seal (which offers three points of contact, keeping lubricants in and contaminants out) and a rubberized flinger that provides another barrier to contaminants. The ball retainer, or Maxlife™ cage, has a two-piece design that creates a grease compartment around each rolling element, affording constant contact between ball and grease. The bearings come in stainless steel and polymer housings with all-stainless steel inserts.

Protective Eyewear For Light Industry


vex VersaPro protective eyewear’s lightweight, streamlined design is well suited to light industrial applications, such as machine operation and manufacturing tasks. The products feature tough antiscratch and antifog coatings, and bendable temples and nosepieces for a customized fit. This eyewear meets the ANSI Z87.1- 2003 (high-impact) and CSA Z94.3 safety standards, and comes with a lifetime frame guarantee. Uvex A business of Sperian Protection Smithfield, RI

Baldor Electric Company Fort Smith, AR For more info, enter 39 at

For more info, enter 40 at



For rate information on advertising in the Information Highway Section Contact your Sales Rep or MIKE ANTELL at: Phone: (978) 282-1959 / Fax: (978) 282-9749 / E-mail:

Web Spotlight: LUDECA,



LUDECA, INC. - Preventive, Predictive and Corrective Maintenance Solutions including laser shaft alignment, pulley alignment, bore alignment, straightness and flatness measurement, monitoring of thermal growth, online condition monitoring, vibration analysis and balancing equipment as well as software, services and training. For more info, enter 70 at


Krytox® Fluorinated Greases and Oils are: Chemically inert. Insoluble in common solvents. Thermally stable. Wide temperature range (-103º to 800º F). Nonflammable. Nontoxic. Oxygen Compatible – safe for oxygen service. Low Vapor Pressure. Low Outgassing. Useful in Vacuum Systems. Krytox® offers Extreme Pressure, Anticorrosion and Antiwear properties. Contains no silicones or hydrocarbons. Mil-spec, Aerospace and Food Grades available! 203 743-4447 or 800 992-2424

MILLER-STEPHENSON CHEMICAL CO. For more info, enter 71 at | 31


MARCH/APRIL 2010 Volume 11, No. 2





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

Des-Case Corporation ..................... .................................... 62..................... 4

Energy ......................27


Engtech Industries Inc...................... .................. 64................... 13 Hy-Pro Filtration .............................. 61..................... 2 Inolex Chemical Company .............. ...................................... 67................... 26

OH, KY, TN 135 N. Rocky River Road Berea, OH 44017 440-463-0907; Fax 440-891-1254 JOHN DAVIS

Inpro/Seal Co..................................... ............................... 73................... 34 LUDECA, INC................................... ..................................... 65,70 ........16,31 MARTS .............................................. 66............. 17-20 Miller-Stephenson Chemical Co. ... ................. 71................... 31 Nuts, Bolts and Thingamajigs.......... ........ 69................... 30 Royal Purple ...................................... 72................... 33 WD-40 ............................................... ....................................... 63........Insert,11

Access and

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

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

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.

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

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 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

CLASSIFIED ADVERTISING 31 Waterman Road Gloucester, MA 01930 978-282-1959; Fax 978-282-9749 MIKE ANTELL

32 |



“...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 today.

For more info, enter 72 at

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 or contact 800-447-0524 for your Inpro/Seal Representative.

For more info, enter 73 at

Lubrication Management & Technology MarApr 2010  
Lubrication Management & Technology MarApr 2010  

Lubrication Management and Technology, March April 2010