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JANUARY/FEBRUARY 2010 www.LMTinfo.com | 3

ContentsJANUARY/FEBRUARY 2010 • VOL 11, NO. 1 • WWW.LMTinfo.COM

ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS

CONDITION MONITORING

FEATURES

10 Oil-Analysis Data Evaluation Until you understand what you’re looking at and looking for, you’re no better off

than before you implemented your oil-analysis program.Ray Thibault, CLS, IMA I & II, Contributing Editor

16 ■ Big Money Talks

17 ■ Saving Energy With Sealing Systems

21 How To Begin Measuring Maintenance Effectiveness: Part IV Lucky you! Th ere is one KPI that comes close to taking into account almost all variables in a production process. What is it?

Raymond L. Atkins, Contributing Editor

31 Food Grade Lubricants What’s it take to move products around and through our food chain safely and effi ciently? Th ese leading suppliers have a number of answers. Th ey off er eff ective solutions for a wide range of food grade needs.

UTILITIES MANAGER

THE FUNDAMENTALS DEPARTMENTS 5 Publisher’s Note

6 My Take

8 From Our Perspective

24 The Green Edge

34 Solution Spotlight

35 Problem Solvers

37 Information Highway

38 Supplier Index©

ALE

XEY

STIO

P —FO

TOLIA

.COM

www.MARTSconference.comP LU S !Case History Presentations

Trend-Setting SeminarsPractical How-To Workshops

Latest Products & ServicesAn opportunity to take exams for CMRP and CLS Certifi cation

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

MMARTS fMMARTS f

Don’t Miss Don’t Miss TheThe Capacity Assurance Conference!Capacity Assurance Conference!

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Registration Is Now Open!Registration Is Now Open!

http://www.LMTinfo.com

January/February 2010 • Volume 11, No. 1

ARTHUR L. RICEPresident/CEO

[email protected]

BILL KIESELExecutive Vice President/Publisher

[email protected]

JANE ALEXANDEREditor-In-Chief

[email protected]

RICK CARTERExecutive Editor

[email protected]

KENNETH E. BANNISTERRAY THIBAULT, CLS, OMA I & II

RAYMOND L. ATKINSContributing Editors

RANDY BUTTSTADTDirector of Creative Services [email protected]

GREG PIETRASEditorial/Production Assistant

[email protected]

ELLEN SANDKAMDirect Mail

[email protected]

EDWARD KANEReprint Manager

800-382-0808, ext. [email protected]

Editorial Offi ce1300 South Grove Ave., Suite 105

Barrington, IL 60010847-382-8100 / FAX 847-304-8603 www.LMTinfo.com

Lubrication Management & Technology (ISSN 1941-4447) 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 offi ces. 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 2009. No part of this publication may be reproduced or transmitted without written permission from the publisher. Annual subscription rates for nonqualifi ed 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: [email protected]. 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.

SubscriptionsFOR INQUIRIES OR CHANGES CONTACT JEFFREY HEINE,

630-739-0900 EXT. 204 / FAX 630-739-7967

4 | LUBRICATION MANAGEMENT & TECHNOLOGY JANUARY/FEBRUARY 2010

www.LMTinfo.comApply for a free, one-year subscription at

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PUBLISHER’S NOTE


I recently spent time putting my old wooden sailboat away after a season on Lake Michigan. As I worked, I began to realize how similar sailing is to magazine publishing. Exhilarating,

yet challenging.In sailing, preparation is crucial before you set

out on any trip. Those of us with a passion for this pastime know that once you’re away from shore, things can change quickly and dramatically— from clear skies and smooth waters to hurricane-like conditions in a matter of minutes. Adequate prepa-ration involves maintaining the right attitude and mindset to plan for whatever adversities might arise. Again, it’s much like publishing.

The last few years have been tremendously challenging for most businesses; B2B magazines have been hit especially hard. Successfully navi-gating the turbulent business climate has required having a sailor-like mentality and understanding that our chosen course, just like winds and waves, may change, regardless of what we want.

In talking with executives across numerous industries, I hear plenty of nostalgia for what was—and for the old ways of doing business. Tech-nologies have changed, and so have spending patterns. Most of these executives, however, continue to long for a return to the “simpler” business era of the past. It’s not going to happen.

I was born into this business. My father also was an executive in B2B publishing—a very successful one! Tough challenges and rapidly changing conditions have always been part of our lives. My dad’s consistent response? “Attitude is EVERYTHING. Stop complaining and do SOMETHING.”

At Lubrication Management & Technology, we’re not complaining. We are constantly doing SOMETHING. It goes without saying that our publi-cations and Websites have been greatly enhanced. Print and online improvements are just part of the story, though. We’re doing new things in other areas, too. For example, check out several things on tap for MARTS 2010 (www.MARTSconference.com):

■ Actor, author and manufacturing activist John Ratzenberger, one of this year’s featured keynoters, will speak about his “Nuts, Bolts & Thingamajigs” foundation that brings students and manufacturing together.

■ Futurist and fi nancial professional Bob Chernow will offer predictions for manufacturing, tech-nology, the economy and other key issues.

■ A gala “Reliability Gives Voice to Autism” event will kick off MARTS. This collaboration with the Autism Society will feature dinner and live entertainment, while raising awareness and funds for the cause.

MARTS, though, is just one of many exciting information-packed learning venues on the horizon. Stay tuned for updates on other confer-ences that we co-sponsor/co-produce, including:

■ Energy Summit 2010, promoting solutions for energy effi ciency and sustainability across industry (www.energysummitonline.com)

■ IMEC 2010, an International Maintenance Excellence Conference (www.imec.ca)

The good news about the current business climate is that it has fueled an explosion of creativity in Media. In our case, we’re merging the best of what we have been doing over the years, while transitioning and embracing the countless opportunities ahead of us. Like my old wood boat, the design and structure are solid and fast, but new technologies make it safer and more fun.

Some fi ght the future and long for the past. Not us! We’re embracing the future and building on past successes as we sail into 2010 and beyond. LMT

Bill Kiesel, Publisher

Sailing Into 2010 & Beyond


MY TAKE

I �� wrote about this topic in my January 2010 column for LMT’s sister publication, Maintenance Technology (MT). Please indulge me as I go over it again here. I think it fi ts.

As I mentioned in MT, I had spent much of New Year’s Day blubbering over the receipt of one of those “Who’s Packing Your Parachute?” e-mails. The message focuses on what is said to be an actual

event in the life of Charles Plumb, a U.S. Navy pilot shot down over Vietnam. He ejected from his plane, parachuted into enemy hands and spent six years in a Communist Vietnamese prison. Having survived the ordeal, Plumb returned home and began lecturing on lessons learned from his experience. Sometime later, as the story goes, he was approached in a restaurant by another diner, who called Plumb by name and said that he knew about his days fl ying jets from the Kitty Hawk. As it turned out, this guy—a person heretofore unknown to Plumb and someone he might never have come in contact with—had been the individual who packed the parachute that saved the former pilot’s life years before.

While I can’t vouch for the veracity of all the details, the story does make great food for thought. In the end, the recipient (that’s YOU) is encouraged to refl ect on and thank the people in your life who have worked on packing your “parachute” by sending this inspirational chain-letter type of message on to as many of them as you can.

Receiving this e-mail from someone you know can really touch your heart. This time around, though, the experience was especially moving for me. The sender was one of my little brothers—the toughest, sternest, hardest-driving one. Brilliant and decisive, with arguably the best head for business in our entrepreneurial family, he’s always been the sibling that the rest of us (both older and younger) have looked up to. I never could have envisioned this high-fl ying wing-walker EVER needing a parachute, much less thinking of me as someone who had done any folding and tucking on it. I thank him for that and lots of other things, too, including reminding me that we shouldn’t wait to show our appreciation for the countless, often unknown, parachute packers in our lives, personal and otherwise.

That brings me to my point. On behalf of Lubrication Management & Technology, I thank all of you—readers, contributors, advertisers, suppliers and other friends of this magazine—for helping pack OUR parachute. Whoever you are, wherever you are, please know that we are well aware that your loyalty and strong, ongoing support are what give us the ability to get out there and really “fl y” in this space!

We know that the last couple of down years have been extremely rough on you. We also know that a full economic recovery is not necessarily going to be a done deal this year. No matter.At LMT, we’re committed to serving your critical information needs—and those of future genera-tions of lubrication management professionals and suppliers to the industry—for many years to come. In short, we look forward to helping pack YOUR parachute(s) for a long, long time!

Best Wishes for a Happy & Prosperous 2010! LMT [email protected]

Parachute Packing

Jane Alexander, Editor-In-Chief

The future of manufacturing is in the hands of today’s young people.

Nuts, Bolts & Thingamajigs, the foundation of the Fabricators & Manufacturers Association International 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 fi rst step to a career. Hundreds of students learn this each year at NBT summer manufacturing camps.

When students are ready for career training, there are scholarships from NBT for those who attend technical schools, community colleges and universities to obtain specialized training needed for the highly skilled manufacturing work 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 www.nutsandboltsfoundation.org or call 815-381-1338

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 www.martsconference.com for more information.

Don’t Miss Out!


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FROM OUR PERSPECTIVE

Ken Bannister, Contributing Editor

Over the holidays, I had chance to visit with some old friends. They were thrilled to inform me of their teenage son’s recent work promotion to the position of plant

lubrication technician, in charge of his facility’s lubrication program. Intrigued that a world-leading robotic manufacturing organization would trust its entire program to a high-school-prepared, teenaged veteran of its organization—a three-month veteran, that is—I couldn’t wait to hear how the company had prepared him for this important position.

When I congratulated the young man on his new job, I was saddened, but not surprised to fi nd out that he and his employer believed that his organizational skills are what gave him the ability to step into his new role. The fact is that he had “shadowed” the position for three days to see if he thought himself suitable, after which he felt confi dent he knew enough to organize the lubrication program better than his predecessor. In the shadowing process, he had picked up some real pearls of wisdom from the previous “lubricator,” who successfully instilled in him that “oil is oil, and grease is grease; you just got to get plenty in there!”

Ironically, when I offered him a seat in a lubri-cation fundamentals course to help him gain an understanding of lubricants and their applica-tion, he politely refused, stating that after several weeks on the job, he already knew enough about lubrication. Besides, he thought he would likely be moving on to another position once his reorganization of the lubrication program was completed!

I am dismayed at the pervasiveness of this one-dimensional view of the lubrication management process. Countless management, engineering and maintenance professionals—and non-professionals—share it. It’s one of the greatest paradoxes in today’s maintenance busi-ness: Lubrication management continues to be a victim of misunderstanding and ignorance,

wherein the act of lubrication is considered an elementary task requiring only the most basic knowledge, simplistic thinking and rudimentary skill sets.

With virtually no formal lubrication training offered in yesterday’s or today’s apprenticeship and engineering programs, few individuals entering the lubrication management arena have in-depth knowledge and problem-solving expe-rience in the fi eld to fall back on. Many, though, are rich in opinion based on myths and old wives’ tales perpetuated on a daily basis—lubrication myths and tales that too often go unchallenged.

Fortunately, this situation need not continue! The fact that you are reading this magazine today tells me you are a perfect advocate to help raise the profi le of lubrication management in your company and your profession. Thus, I challenge all Lubrication Management & Technology readers to assist me in making 2010 the year in which we change the perception of lubrica-tion. Let’s put in place lubrication management programs that deliver increased equipment reliability, increased equipment availability, increased environmental compliance, reduced maintenance and reduced energy consump-tion—all for minimal corporate cost.

Our publication will do its part by continuing to bring to you innovative articles and value-added technology news to help you inform, sell, implement and monitor your lubrication management initiatives. Good Luck! LMT

[email protected]

The Lubrication Challenge!

EDITOR’S NOTE: Meet and learn from Ken in person at MARTS 2010, where he again will be presenting his highly acclaimed all-day workshop “Lubrication for Industrial Facilities,” on Tuesday, April 27. To register for this invaluable professional-development opportunity, visit www.MARTSconference.com


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Until you understand

what you’re looking at

and looking for, you’re

no better off than before

you implemented your

oil-analysis program.

Ray Thibault, CLS, OMA I & II Contributing Editor

© ALEXY STIOP —FOTOLIA.COM

Oil-Analysis Oil-Analysis Data EvaluationData Evaluation

My last article discussed the importance of imple-

menting an oil-analysis program and some strate-

gies for building one that’s top-notch (“Developing

An Effective Oil-Analysis Program,” pgs. 12-16, LMT,

Nov./Dec. 2009). Previous articles had covered proper sampling

techniques and the relevant tests used in oil analysis. This article

focuses on understanding and applying the data generated by

an oil-analysis report in order to identify potential problems

and be able to take corrective actions before a serious situa-

tion develops. Emphasis here will be on industrial applications

only, NOT on mobile equipment where oil analysis is also used

extensively. Incorporating actual data from a plant, key factors

(by equipment type) that need to be considered when evalu-

ating an oil-analysis report will be noted.



Oil analysis can be likened to a blood test during an annual physical. A blood test provides important information on a person’s health; oil analysis supplies vital information on the health of your machinery. None of this information, however, is of any value unless you are able to understand and apply the data contained in the reports generated by these analyses. The following details will help you do so.

Report formatAlthough oil-analysis laboratories may use a variety of report styles, there are many similarities in how the data is reported.

Oil analysis looks at two primary oil conditions that could cause equipment problems.

1. Chemistry changes can be caused by the oxidation or thermal degradation of the oil. This is usually detected by measuring the acid number and the oil viscosity.

2. Contamination, primarily from particle or water ingres-sion, can dramatically affect equipment life. Addition of the wrong oil is also a form of contamination. Primary tests to measure contamination are particle counts for solid components and Karl Fischer for water. Atomic emission spectroscopy (AES) detects metallic contaminants such as dirt ingression by measuring the silicon level and changes in metallic additive levels, which may indicate lube mixing.

The report is broken down into two major components:

■ Sample/equipment information is at the top of the report. It includes all pertinent information on the sample and the equipment type. This information is on every report and is developed from details the user provides to the labo-ratory when fi lling out the equipment form. Furnishing complete information will aid in identifying problems and making meaningful recommendations.

Fig. 1. Information on a collected sample that the user supplies to the oil analysis lab

Fig. 2. A sample oil analysis report

Site

Area

Unit

Equip

Descrip

Sample Pt Key

Fld in Use

Fld Grade

Last Fld Chng

Equip Type

Cooled

Cooling Src

Filtered

Filter Size

Sump Cap

Lub Sys

Lubed Comp

Bear Types

Gear Types

Centrifugal Fan/Blower

y

Cooling Tower Water

y

15u

850 gals

Pressurized

OB & IB Sleeve Bearings

Sleeve

Sample Information Equipment InformationYour Plant

Area 1

Unit 1

Main Air Blower

1 MAB Compressor Lube Oil

555-0999

Your Brand ISOVG 32

ISOVG 32

05/04/2004

Physical and Other TestsTAN Flash ISO Code KF Color 4u 6u 14u 21u 38u 68u

0.24 390 1220 2 0.12 390 21/18/16 226 2 16774 2109.3 448.2 320.1 105.2 220.1 395 17/16/14 102 2 1042 462.3 162.7 58.6 44.2 18.30.09 395 17/16/13 93 2 998.4 455.1 66.1 43.2 22 10.60.07 395 17/15/11 85 2 950.7 293 18.6 11 8.2 6.60.06 395 16/13/08 66 2 480 77.3 2.3 1.3 0.3 0.20.15 360 20/18/16 100 20.2 340 21/19/17 200 40.05 395 13/11/07 43 0 41.6 13.5 1.3 0.5 0 0

Wear Metals Iron Coppe Tin Lead Chrom Nicke Alumi Titan Silve 18 0 0 0 0 0 0 0 0 12 0 0 0 0 0 0 0 0 40 0 0 0 0 0 0 0 0 20 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 10 10 10 10 5 5 10 5 5 20 20 20 20 10 10 20 10 10 0 0 0 0 0 0 0 0 0

Additive Metals Calci Magne Zinc Phosp Bariu Molyb Antim 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Contaminant Metals Silic Sodiu Boron Potas Vanad 15 82 0 44 0 8 36 0 24 0 4 18 0 11 0 0 4 0 6 0 0 1 0 2 0 0 1 0 0 0 10 40 10 15 10 20 40 20 30 20 0 0 0 0 0



■ Test results are presented in the body of the report. Recom-mendations, when needed, are either at the top after the equipment section or at the bottom of the report.

◆ Most reports list the data horizontally by date, with the latest on either the top or bottom. (Some labs may list their data vertically, with the latest on the left.)

◆ Emission spectroscopy (usually located right after the sample/equipment section) is separated into three groups: wear metals, additives and contaminants. It’s a crucial part of any oil-analysis report measuring metallic elements in ppm (parts per million), but only particles <10 micron are detected. Thus, additional techniques are needed to measure large wear particles.

■ Physical tests for oil condition and contamination are usually near the bottom of the report. These include tests for viscosity, water, acid number, FTIR (Fourier Transform Infrared), particle counts and ferrous density. Analytical ferrography is on a separate page.

■ The sample report in Fig. 2 also lists the new oil reference sample to compare with the used oil. Many labs don’t report this data, which gives good insight on the condition of used oil. New oil reference samples should be updated yearly.

■ Oil analysis reports include a severity rating. Most compa-nies have a two tier code: abnormal or caution and critical or warning. One laboratory has a four tier severity code from 1-4. The data in the report is color coded to refl ect the severity. Most companies use red for critical.

■ The report in Fig. 2 includes the lab’s watch and warning limits. (Most laboratories don’t include this information.)

Problem diagnosisAs noted here, the following factors, per specifi c equipment type, refl ect how oil-analysis data can be used relative to problem identifi cation.

Hydraulic Equipment...

■ Cleanliness is a key component in smooth operation. Thus, particle counts should be closely monitored.

■ Pump wear is not a common problem and is usually exhibited through increased copper levels resulting from wear of slipper shoes, swash plate and pressure plates.

■ Aluminum occurs in gear pumps from housing wear.

■ Iron/chrome indicate the presence of cylinder rod wear, usually from abrasive particles.

Report evaluation:Information in Table I comes from an actual oil-analysis report. Only pertinent data from the report is presented.

This report indicates sudden high iron and copper wear for a hydraulic system. The copper could be coming from the pump and the iron/chromium indicates cylinder rod wear. (The particle count increased as a result of abrasive particles being introduced into the system; these particles caused the wear.) Further investigation with analytical ferrography was conducted to identify the wear mode and types of particles present. The results showed the presence of the following:

■ Excessive siliceous, iron oxide and nonmetallic debris

■ Cutting wear particles, indicating severe abrasion wear

■ Excessive amounts of large fi brous masses consisting of cellulous and synthetic glass fi bers.

Report conclusions:The sudden increase in particles was linked to the sudden increase in wear. Analytical ferrography concluded that the particles came from a sudden filter rupture releasing a large number of abrasive particles into the system. (This was confirmed when the system was checked and the filter rupture was found. Whenever there is a large increase in particle counts, the filter integrity should be checked.)

Steam/Gas Turbine Equipment...

Wear metals are not common and are fl agged at very low levels. Many systems have large fl uid reservoirs, and even a small amount of metallic wear can indicate a serious problem.

Table I. Actual Hydraulic Equipment Oil Analysis Findings

Emission Spectroscopy, ppmDate Sampled Iron Copper Chromium Zinc Phosphorous Silicon

2/25/08 20 10 1 472 235 23

1/20/08 3 2 0 480 230 4

12/20/07 0 0 0 482 236 0

Physical/Other TestsDate Sampled Viscosity Acid # KF Water, ppm ISO PC

2/25/08 32.4 0.66 201 23/21/19

1/20/08 31.8 0.41 155 18/15/13

12/20/07 31.8 0.42 59 16/14/12

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■ Turbine oils normally contain no metallic additives. Any presence of metallic additives usually indicates lube mixing. For example, if zinc and phosphorous are found in turbine oil it indicates the addition of hydraulic oil. Some turbine oils may contain phosphorous as an anti-wear package. Be sure to run a new oil reference on your oil to see what additives are present.

■ Turbine oils are in systems for extended periods (especially steam-turbine oils). Other non-routine tests, such as RPVOT (Rotating Pressure Vessel Oxidation Test), water separability, etc. are conducted periodically to determine their condition.

■ A major problem with steam-turbine oils is water incur-sion through a steam leak. Water levels should be closely watched in turbine oils—and kept below 200 ppm.

■ Varnishing in gas turbines has become a major issue and many oil-analysis laboratories have developed extensive testing packages to measure the varnish potential of the oil. Discussion of these tests is beyond the scope of this article.

Report evaluation:

The report refl ected in Table II notes several serious problems:

■ High iron wear

■ High tin wear along with copper wear, indicating the wiping of a Babbitted bearing

■ Viscosity increase of 15% over new oil reference

■ High level of water ingression at 1220 ppm

Additional tests performed with the use of analytical ferrog-raphy indicated the following results:

■ Large number of red oxides signifying rust through water incursion

■ Large number of siliceous particles

■ High alloy steel particles indicating shaft wear

■ A few large Babbitt particles and a large number of smaller ones

Report conclusions:A serious condition existed due to higher-than-normal wear caused by steam incursion into the bearing housing. The introduction of water and particles resulted in Babbitted bearing wear and corrosion. Find source of steam incur-sion and repair. Consider changing oil because the high acid number along with viscosity increase signifi es oil is becoming highly oxidized. If oil is not changed, remove water through vacuum dehydration. (In this case, the oil was changed and the steam leakage problem resolved. No further problems were experienced.)

Stationary Enclosed Gearboxes...

■ High iron wear—usually around 100 ppm—is common in gearboxes and varies by type and manufacturer. Oil-anal-ysis labs are able to establish more accurate condemning limits if they are provided with complete information, such as type, OEM, model number, sump capacity and fi ltration, if any, on the gearbox being analyzed.

■ DR (Direct Reading Ferrograph) and PQ (Particle Quanti-fi er) tests are typically used to measure ferrous density and should be considered routine for unfi ltered gearboxes.

■ High copper levels are common for worm gears because the yellow metal ring gears are sacrifi cial.

■ Analytical ferrography is a valuable test to use for the prevention of major gear failures.

■ Typical EP gear oils have 300-350-ppm of phosphorous.

Don’t depend entirely on your oil-analysis lab for recommendations.

You know your equipment and its history better than a lab does.

Table II. Actual Steam/Gas Turbine Equipment Oil Analysis Findings

Emission Spectroscopy, ppmDate sampled Iron Copper Tin Silicon

5/13/09 12 7 38 10

4/12/09 2 0 4 4

3/10/09 2 0 0 0

Physical Tests/Other TestsDate sampled Viscosity, cSt @40C Acid # KF Water, ppm

5/13/09 36.6 0.26 1220

4/12/09 35.0 0.12 99

3/10/09 31.4 0.06 93



Report evaluation:

This report indicates the onset of severe wear as evidenced by the large jump in FDRL (which measures ferrous parti-cles > 5 microns). Analytical ferrography results indicated the following:

■ Heavy accumulation of carbon steel wear particles

■ Large striated gear wear detected, indicating severe root/tip sliding wear

■Large carbon steel particles, which were indicative of heavy pitch-line fatigue

■ Excessive number of copper particles indicating heavy bearing/cage wear

Report conclusions:Severe gear and bearing wear is occurring and will lead to an impending failure unless corrected.

(It actually turned out that portions of the gearbox had to be replaced, but the problem was identifi ed early enough to order the parts and install with minimal downtime. A sudden failure would have resulted in a minimum of six weeks down-time and much higher repair costs. The problem was identi-fying the root cause in this large heavily loaded gearbox. No problem was initially identifi ed with the lubricant. Viscosity, acid number and contaminants were all normal. Conse-quently, it was assumed the problem was mechanical—but this was not found during the repair process. Upon further investigation, it was determined that the OEM recommended the wrong viscosity oil. The initial recommendation of an ISO 220 was too low for the speed and load conditions. The EP package of the oil, with 100 ppm of phosporous, also seemed low. The gearbox was repaired and ISO 320 EP oil was used, resulting in no further problems.)

In summaryThe ability to read and understand an oil-analysis report is vital for making decisions on your equipment. Don’t depend entirely on your oil-analysis lab for recommenda-tions. You know your equipment and its history better than a lab does. There can be a great discrepancy among the laboratories when it comes to recommendations. Because of the large number of samples analyzed daily, their recom-mendations are exception-driven by a computer. Some labs have analysts who look at the exception data and make the recommendations. Many reports will simply recommend that the oil should be changed—which, in many cases, doesn’t address the root cause problem.

The more knowledgeable you are in understanding the data in your report as it relates to your equipment, the easier it is to work with an oil-analysis technical expert. You know your equipment and he/she knows testing. Together, you can come up with the right solution to the problem.

Here are several key points to keep in mind:

■ Most reports will not show any exceptions. Review reports based on the criticality assigned to the report by the laboratory. Study all reports that show some abnor-mality. Call your laboratory for clarifi cation of critical warnings you receive.

■ When an action step is recommended relative to a problem, rectify that problem as soon as possible. Many a catastrophic situation has developed as a result of the corrective action step(s) recommended by a laboratory not being taken in a timely manner.

■ If a critical situation develops with no warning, resend the sample for testing. Don’t base a major equipment decision on one sample point.

■ Lube mixing is a common problem. You need to send in a new oil reference yearly to get meaningful comparisons on the condition of the used oil. Look at the viscosity and metallic additives to identify lube mixing.

■ Finally, work closely with other condition-monitoring specialists (i.e., vibration analysts) in your plant to confi rm potential problems. LMT

Contributing Editor Ray Thibault is based in Cypress (Houston), TX. An STLE-Certifi ed Lubrication Specialist and Oil Monitoring Analyst, he conducts extensive training in a number of industries. Telephone: (281) 257-1526; e-mail: [email protected]

Table III. Actual Enclosed Stationary Gearbox Oil Analysis Findings

Emission Spectroscopy, ppmDate sampled Iron Copper Nickel Phosphorus

12/01/06 150 33 5 111

11/05/06 39 16 1 109

10/05/06 22 11 1 116

Physical Tests/Other TestsDate Viscosity, sampled cSt @40C Acid # FDRS FDRL KF Water,ppm

12/01/06 226.5 0.49 88.8 142.3 129

11/05/06 219.8 0.40 22.4 66.8 138

10/05/06 221.4 0.43 16.9 38.4 140

Proposed Legislation:The Economic Impact

William C. Livoti

BIG MONEY TALKS

UM1 | UTILITIES MANAGER VOLUME 5 / NO.1

UM

If I were a bettin’ man, I would put money on Congress getting SOME type(s) of energy-effi -ciency/climate-change legislation into law in the not-too-distant future. While I’m not about to

offer an opinion on the possible cause of possible climate change, I do want to discuss the economic impact of proposed bills that are attempting to deal with it. Upon passage, in whatever form, what would these types of measures mean for U.S. industries? Think higher energy costs passed on to customers by the utilities. Just what we need!

Where will additional costs come from? Scrubbers…The cost for a new-technology scrubber system for the typical pulverized coal plant is roughly $550M—and it wouldn’t lead to one penny in revenue for the utility. In fact, a scrubber will draw an addi-tional 2% to 5% in auxiliary power.

Replacement of obsolete plants…If a climate bill were to pass in its latest form (at the time of this writing in mid-December 2009), a number of older (pre-1970s) coal-fi red plants will be unable to meet the new emission standards or fi nd it too costly to get into compliance. We could build new plants, but what kind? Fossil, nuclear, renewable? How long will it take to add enough capacity to replace the old units? And, let’s not forget the need for even more future capacity…

Carbon capture and sequestration…This tech-nological advancement has captured the interest of both the DOE and the EPA as a possible solu-tion to environmental problems with fossil-fired power plants. Although actual implementation costs are yet to be determined, they’re bound to be high. As with new scrubbers, additional auxiliary power will be required, thus reducing a plant’s output—and the utility’s profit margin as well. (At the recent PowerGen 2009 event, engineers involved with the development of this new technology noted that capturing and seques-tering 90% of the CO2 from a power plant would add 2¢/kWhr to the bus bar costs.)

What are our options?The legislation that’s under debate has me very concerned—for industry’s economic future and my own. However, rather than try living off the grid, I suggest that we make every effort to run our plants as effi ciently as possible and take the time to fully understand the content of impending energy-effi ciency/climate-change-related bills.

Remember, too, that we can control the impact of whatever may come out of Washington by being proactive—don’t wait until the “horse is out of the barn!” Among other things, implement energy-effi ciency programs NOW. Seek out suppliers that promote/provide energy-effi ciency studies NOW. Optimize and/or replace your existing energy-hog equipment and systems to increase the effi ciency of your operations NOW.

For more information on current and proposed energy-effi ciency/climate-change legislation and standards that will defi nitely change the industrial landscape, please join noted energy expert Bill Adams (of Flowserve and the Pump Systems Matter [PSM] initiative) and me at MARTS 2010. Our joint presentation, “The Two New Legs of Lean: Energy Effi ciency & Reduction of Greenhouse-Gas Emis-sions,” will show you what you’ll need to comply with if you want to stay in business, as well as some successful strategies for doing so. (Please go to www.MARTSconference.com for the complete conference schedule.) UM

Bill Livoti is a fl uid 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: [email protected]

Remember that we can control the

impact of whatever may come out

of Washington by being proactive.

SEALING SYSTEMS UM

VOLUME 5 / NO. 1 UTILITIES MANAGER | UM2

The numbers don’t lie.

Choosing the wrong

sealing system can be a

real drain on an operation’s

process effi ciency, not to

mention its reliability,

environmental compli-

ance and, ultimately, its

overall profi tability.�

In the world of process equipment economics

and reliability, the energy effi ciency of sealing

systems is frequently regarded as being unim-

portant and insignifi cant. A careful look,

however, reveals that sealing systems are often key

factors in establishing system effi ciency, reliability

and emission-control improvements. Upgrading

these systems can greatly help a process plant in

these types of improvement initiatives, as well as

in its carbon-footprint and total life-cycle-cost-

reduction efforts. Take, for example, mechanical

seal and compression packing applications.

Saving Energy With

Sealing Systems

Special To Utilities ManagerFrom The Fluid Sealing Association (FSA)

© NEDIM—FOTOLIA.COM

SEALING SYSTEMSUM

UM3 | UTILITIES MANAGER VOLUME 5 / NO. 1

Mechanical seals…Mechanical seals are found in the majority of centrifugal pumps today —particularly in those handling volatile, hazardous or valuable fl uids.

Available in a wide variety of types, arrangements and materials, mechanical seals create an extremely restrictive leak path perpendicular to the axis of the shaft between two rubbing seal faces. Leakage is normally not visible and frictional heat is carried away by the pumped fl uid surrounding the seal. When conditions around the seal are too severe, support systems are applied to create an artifi cial environment for the seal. These conditions often include abrasiveness or poor lubricity of the pumped fl uid and high temperatures. (Recent design and material technology developments have focused on development of seals that perform in applications without the need for additional support systems to achieve environmental control.)

Seals are energy-effi cient devices, but some of the basic, more popular seal support systems in use today can consume large amounts of energy—in some cases exceeding the power output of the pump driver. Sealing system energy losses should, therefore, be carefully considered in any pump system assessment.

Compression packing…Packing creates an adjustable, close-clearance leak path parallel to the axis of the shaft. Some leakage must be maintained to lubricate and cool the packing material, but frictional heat is always present due to the large surface area in contact with the shaft. When the pumped product is abra-sive or the packing needs additional cooling, a clean external fl ush is typically piped into the stuffi ng box. This fl ush is part of the sealing system and can indirectly consume large amounts of energy—that’s why it should be considered in any energy assessment.

Sealing system effi ciencyTo take advantage of energy-reduction opportunities, we must fi rst determine the energy consumption of the sealing systems used in process equipment. While the focus is typically on pumps, process equipment that incorporates these systems includes compressors, mixers, dryers and all equipment with a rotating or reciprocating shaft that passes through the wall of a pressurized vessel or housing.

One approach is to analyze the overall sealing system’s Life Cycle Costs (LCC) (i.e. all cost contributors, including energy consumption). A useful tool in such an analysis is available on the FSA website (www.fl uidsealing.com). This free “Seal Life Cycle Cost Estimator” software enables simplifi ed comparative analysis as to what sealing system is more cost effective. The contribution of energy is an inte-gral component of any analysis.

The “Seal Life Cycle Cost Estimator” tool can be used to analyze sealing systems as simple as a packed pump with no environmental controls, to those that incorporate complex double, tandem and multi-stage mechanical seal arrangements with their own separate lubrication systems, auxiliary pumps, motors and heat exchangers. Users can make total-cost comparisons, as well as comparisons for energy consumption and cost.

MethodologyTo compare sealing system energy consumption and oper-ating costs, three steps should be taken:

1. Identify the points where energy is consumed and label them on a schematic diagram.

2. Prepare a spreadsheet showing the sources, forms and amount of energy consumption.

3. Defi ne current costs for various sources of energy consumed by the sealing systems. These will be primarily electrical in nature, from prime movers such as motors, and thermal, from a variety of sources. Examples include the cost of cooling water and various forms of energy needed to power the sealing system and replace heat energy consumed in the process system.

Sealing system schematic…The sealing system schematic helps to determine the source of the energy consumed. The most apparent source is electrical energy from the drive motor, the most common prime mover.

When just this source is examined, large differences in the electrical energy consumption between various mechanical seal types can be seen as shown in Figure 1. Differences in frictional characteristics of the four types of mechanical seals cited produce signifi cant differences in the power consump-tion of the motor. While these are relatively large differences

Why Consider Sealing Systems In Energy Effi ciency?It’s simple: they are seldom analyzed or evaluated.

The area where a shaft penetrates the casing of a fl uid

handling device, such as a pump, is a potential leak path.

Either a seal chamber or stuffi ng box with a mechanical

seal or compression packing is adjacent to this area. Both

are central components in a sealing system that ensures

containment of this leak path. The type of system will

determine energy consumption, among other things.

SEALING SYSTEMS UM

VOLUME 5 / NO. 1 UTILITIES MANAGER | UM4

they do not include the energy consumption of the auxiliary components of the entire sealing system. When all these sources of energy consumption are included a quite different perspective develops.

Example mechanical seal system analysis… Figure 2 shows one of the more popular, but least effi -cient, sealing systems for environmental control and protection of mechanical seals. This type of system is used in hot oil pumping service. Typical application specifi cs include:

■ Single stage, end suction centrifugal pump (API 610 Compliant)

■ Provides heat to various area of the plant

■ Process fl uid — Hydrocarbon @ 315 C (600 F)

❍ Specifi c gravity 0.8

❍ Specifi c heat 1.67kj/kg-ºC (0.4BTU/lb-ºF)

■ System pressure — 345 kPa (50 psi) in seal chamber

■ Pump shaft — 3600 rpm, 50 mm (2.0”) diameter in seal area

■ Pump driver — 50 hp (typical)

■ Sealing devices

❍ Mechanical seal or

❍ Compression packing

■ Heat lost at the pump must be replaced at the system boiler/heat exchanger

Origin of energy consumption…The initial perception from Fig. 1 may be that most of the sealing-system energy consumed is by the drive motor in overcoming the frictional heat created by rubbing contact between the stationary and rotating faces of the seal. As shown in the schematic, that portion represents less than 1% of the total power consumed by this sealing system, refl ecting the relative effi ciency of the mechanical seal itself.

Sources: Mechanical Seals for Pumps: Application Guidelines, pgs. 154-156, published by Hydraulic Institute, 2006; and FSA “Seal Life Cycle Cost Estimator” tool, www.fl uidsealing.com

0

1

2

3

4

1.000 2.000 3.000 4.000

Shaft Size (inches)

HP

0

1

2

3

kW

Single Unbalanced Dual Balanced Single Balanced Dual Dry Gas Seal

Fig. 1. Frictional power consumption of mechanical seals( @1750 RPM @100 psig )

ENGTECHIndustr ies Inc.


http://www.engtechindustries.com

SEALING SYSTEMSUM

UM5 | UTILITIES MANAGER VOLUME 5 / NO. 1

Fig. 2 Least energy-effi cient mechanical seal system (Source: Mechanical Seals for Pumps: Application Guidelines, pgs. 250-251, published by Hydraulic Institute, 2006)

It is also notable that the total power consumed by this least-energy-effi cient system, 47.4 kW (63.5 hp), exceeds that of the drive motor itself. Virtually all of that is due to the power required to replace heat lost through dilution of the pumped fl uid.

Based on an FSA study of over 28,000 seal applications where pumping temperature exceeds 200 C (400 F) this is a realistic case. Over 20% of the mechanical seal applications surveyed employed this API Piping Plan 32.

To show that sealing systems represent an opportunity for signifi cant improvements in energy effi ciency, we can look at more-current types of energy-effi cient systems. The power consumption of many of these proven—but much less frequently applied—systems is less than 50% of this least effi cient example. Dry gas seals, one of the latest technolo-gies and most effi cient sealing systems, consume 0.5 kw (0.7 hp)—about 1% of this least-effi cient system. They also effec-tively provide a zero emission seal.

ConclusionSealing system energy assessments should be an important part of any plant energy assessment. Selection of an energy-optimized sealing system can lead to signifi cant overall plant energy savings that go right to the bottom line. While not covered here, systems with much greater energy-effi ciency than the example illustrated are available. Consultation with your mechanical seal or compression packing manufacturer will enable selection of the most energy effi cient system for your application. UM

Low Temperature Seal with API Plan 32 – Cool External Flush

7.6lpm (2 gpm) kerosene fl ush @ 38 C (100 F)

Q1= 351 W (1,200 BTU/hr) frictional power consumed by seal

Q3= 47 kW (160,000 BTU/hr) power required to replace heat lost through dilution of the pumped fl uid

Sealing System Power Consumption = 47.4 kW

The Fluid Sealing Association (FSA) is an international trade association whose membership represents over 85% of the manufacturing capacity for fl uid sealing devices in North America. Its Mission Statement notes that the association seeks to promote a safe, clean environment for society and be recognized as the primary source of technical information; infl uence and support development of related standards; and provide education in the fl uid sealing area. The FSA Web site (www.fl uidsealing.com) provides an ideal place for seal users to fi nd technical articles, obtain publications and learn out about upcoming seal training opportunities. There, too, is where you can download the “Seal Life Cycle Cost Estimator,” discussed in this article. (The FSA will be offering 2 full-day workshops at MARTS 2010, one on mechanical seals, the other on compression packing and gasketing. Please visit www.MARTS conference.com for details.)

About FSA. . .


ATP List ServicesEllen Sandkamwww.atplists.com

1300 S. Grove Ave., Suite 105, Barrington, IL 60010847-382-8100 x110 / 800-223-3423 x110

[email protected] / [email protected]

Customized, Targeted Lists For

Your Marketing Needs


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Raymond L. AtkinsContributing Editor

We have discussed several KPIs over the course of this

series, each of which has measured one or more

components in the overall production process. These

various metrics have been presented as the tools

management can use in measuring the health of portions of the

process. Still, the question arises: Is there a single metric that takes

into account all of the variables in a given production process?

There is one that comes close. It’s known as “TEEP,” which stands

for Total Effective Equipment Productivity.

TEEP is an ideal or best-case benchmark against which a production process is measured. It is the comparison between the theoretical capacity of a machine versus that machine’s actual performance. TEEP uses as its litmus test the hypothetical output of a machine if it ran perfectly, all the time. As an example, suppose you have a machine in your process that is rated to produce one part per hour. TEEP assumes that if it were to run continuously at the capacity determined by the machine manufacturer’s OEM specifi cations, this equipment would produce 24 parts per day, 365 days per year—and that this benchmark is the number against which your actual performance should be measured. Consider the number to be an absolute (whether it can actually be obtained), like absolute zero or the speed of light. The formula for this calcula-tion is Actual Parts per Unit of Time X Total Time/Theoretical Parts per Unit of Time = TEEP.

How To Begin Measuring Maintenance Effectiveness

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Lucky you! There is one

KPI that comes close

to taking into account

almost all variables in

a production process.

What is it? Read on.

Part IV

Recapping Parts I – IIIAs we’ve noted throughout this series, key performance indicators (KPIs) are the metrics that an organiza-tion chooses to use as their measures of process performance. They can vary among industries and among individual processes. To begin managing by metrics, an organization must fi rst collect meaningful and pertinent data—information that is important to the operation of the business—which is then converted into one or more KPIs. These tools can be used to immediately evaluate the performance of a process variable, as well as provide a means for tracking that variable over time.

A SPECIAL SUPPLEMENT TO LUBRICATION MANAGEMENT & TECHNOLOGY


Now, don’t throw the magazine away and reach for the television remote. It’s not as diffi cult as it sounds. I’ll say it in English this time: TEEP is the number of good widgets you are making in a given time period compared to the total number of widgets the machine is capable of making if it ran perfectly at its rated capacity during that same period of time.

Let’s look at the machine we just referenced. You have a process that produces widgets, and your primary machine is an old, but well-maintained widget-maker that is rated at one unit per hour. Your plant works two eight-hour shifts each day over a fi ve-day work week, with the weekend being devoted to maintenance efforts. Your process continually achieves uptimes above 90%, and you seldom have any quality issues. Last week, the plant produced a total of 77 widgets at this machine center during your 80 planned production hours.

The TEEP percentage for this rather rosy scenario would be as follows: 77 actual widgets produced X 168 total hours in the week/168 possible widgets = 77%. What does this number tell us? Basically, a TEEP percentage of 77% indicates that 23% of this particular process capacity was unrealized—even though this same process is running exceptionally well when evaluated by less stringent measures. (FYI: a handy TEEP calculator is available to you at http://www.downtimecentral.com/oee.shtml.) By the way, if your particular process is achieving a TEEP percentage above 75%, that is an excellent number, and you may take a moment to congratulate yourself.

“But wait,” you say. “I don’t want to run three shifts, seven days a week. I’m producing between 70 and 80 widgets per week. That’s world-class output within my particular industry, especially considering the equipment I have, and that’s all the widgets I can sell, anyway. So why would I want to compare myself to a standard that makes no sense for me?”

Why, indeed? TEEP is not for everyone. It’s a strategic measure that is used in, among other things, determining the need for capital outlay. Suppose that the giant widget plant down the road—your main competition, perhaps—has a big fi re or some other issue that causes a serious curtail-ment in its ability to turn out product. This leads to a widget shortage, and the price per unit skyrockets. At last, you can sell as many of the things as you can produce—and pretty much get your own price. Your unfortunate competitor will be limping along for at least a year, and as you look for ways

to take advantage of what could be an extremely profi table time for your business, your eyes might drift to and linger upon the 23% of your unrealized capacity (as determined by your 77% TEEP).

There are several options open to you at this point. You can weed out the few rejects and breakdowns you have and push your TEEP to 80%. You can add a third shift and increase your TEEP or add an extra production day to do the same. You can go to a seven-day/24-hour schedule if you have high confi dence in your maintenance program’s ability to work around the extra demands you are placing upon the process. You can even attempt to speed up your widget-maker—if such an action can be undertaken economically, and provided you keep in mind that there are often unforeseen consequences to running a process in excess of its rated capacity. Regardless of what you do, the TEEP measure is the benchmark that lets you know how much additional production is available without addi-tional capital expenditure (such as adding more machines, replacing older equipment, etc.).

Benchmarking against what?Since we are on the subject, we should spend a few moments discussing the concept of benchmarks, which are those standards—sometimes theoretical—against which we measure and track our own performances. What should these numbers be? What is “world-class?” Who decides?

There is a consensus among maintenance consultants and scholars alike that benchmarks should be challenging but achievable—and I agree with that guideline. As for the actual numbers, however, there is little agreement. Benchmarks differ across industries, across plants and across machine centers. Take uptime as an example.

For years, a production uptime percentage above 80% was considered to be a good effort, and 85% was thought to be outstanding. As maintenance practices and machine technology have improved, the best of the best have continued to ease their uptimes in the direction of 88%, then 90% and fi nally to 95% or higher.

The issue for each plant and for every manager is to benchmark their own processes against achievable goals—and to encourage small but steady increments of improve-ment in their own unique process. Aspiring to a challenging benchmark should be a positive experience for the entire organization. To illustrate this point, let’s go back to the widget industry for a moment.

TEEP is not for everyone. It’s a strategic measure that is used in,

among other things, determining the need for capital outlay.


A SPECIAL SUPPLEMENT TO LUBRICATION MANAGEMENT & TECHNOLOGY

Suppose you are the production manager for the original widget plant in your organization (the old workhorse), and you have the task of operating technologically obsolete machinery that has been poorly maintained for much of its history. The factory runs uptimes in the mid-70s and makes a small profi t. Further assume that upper manage-ment has determined that large capital outlays are not in your facility’s future. Times are hard, and they’ll continue to run the plant as long as it pays to do so. But, if you drop into the red, that may be all she wrote. Under conditions such as these, it is probably not wise to benchmark yourself against the leading plant in your industry—a brand-new, technological marvel that consistently posts uptime percent-ages in the mid- to high-90s.

It’s not a case of never being able to get there from here. If you establish a proper PM (preventive maintenance regimen), initiate PdM (predictive maintenance) as budgets allow, do realistic, honest root-cause analyses (RCAs) for every process failure, work safely and begin a conscientious training program, you can wash away most sins over time. There is, however, another component you must consider.

If you are consistently running uptime percentages in the mid-70s and are benchmarking against a goal of 95%, you may fi nd that your rate of improvement drops over time. Specifi cally, your organization may develop a morale problem, because the goal is perceived as being out of reach. If your process has consistently run uptimes in the 75th percentile and through world-class techniques you are

able to raise this average to 80%, you have achieved a huge gain in effectiveness. Conversely, if the new and improved 80% uptime is compared to a 95% goal, it still seems as if the organization has an impossibly long way to go. If, though, the benchmark were 85%, then your people have moved halfway toward their goal—a goal they perceive as being reasonable and achievable. Remember, as goals are reached, new, higher ones can be set. Thus, by making each new goal plateau achievable, you are not limiting the long-term potential of the company, particularly if you reward the attainment of these plateaus as they are reached.

Use your metrics effectivelyTo manage by metrics, you must fi rst make the conscious decision to gather accurate data that is meaningful to your organization. The accuracy of your data is the critical component of the process. You must then convert the data into KPIs that your organization is capable of maintaining. Put simply, the gathering and manipulation of data into a useable form is an important job that must be performed by personnel who realize this fact and who are capable of performing the task. Finally, your KPIs should be bench-marked against realistic numbers. You must learn to walk before you can begin to run. LMT

Ray Atkins is based in Rome, GA. E-mail: [email protected]; visit his Website: www.raymondlatkins.com; or hear him speak at MARTS 2010 (www.MARTSconference.com)

Applied Technology Publications, SUCCESS by DESIGN and the Autism Society of Illinois are joining together in an effort to give voice to autism during MARTS 2010.

Originally planned as a publishing awards event, we have expanded the scope of this occasion to raise awareness and funds for autism, a growing disorder that has already touched the hearts and lives of countless professionals in the industrial engineering, reliability, main-tenance, energy and environmental sectors. Collaboration with the Autism Society was specifi c in that this organization is out on the front line 24/7, providing immediate support and services to families affected by autism. It’s a type of challenging endeavor with which MARTS attendees can well identify as they, themselves are on the front line keeping critical infrastructure and industrial operations up and running no matter what.

Kicking Off MARTS 2010 With A Worthy CauseThese “Reliability Gives Voice To Autism” activities will take place at the Hyatt Regency O’Hare on the evening of April, 27, 2010, starting with a cocktail reception at 5 p.m, followed by a gala charity dinner, live entertainment and door prizes. You won’t want to miss this exciting and worthy event, which also helps kick off MARTS 2010!

We look forward to having you join us and others across the Reliability Community in giving “Voice To Autism” at MARTS 2010!

For more details, including information on sponsorship opportunities, visit:

www.MARTSconference.comOr contact:

Bill Kiesel, Publisher of Maintenance Technology and Lubrication Management & Technology magazines at:

[email protected]; or: 847.382.8100 x116

ReliabilityGivesVoice

To

at MARTS 2010Autism

w


reen workspace altera-tions come in all stripes, from big ones that can help produce signifi -

cant savings after a payback period to smaller ones that generate savings immediately—and cost little or nothing upfront.

The U.S. General Services Admin-istration (GSA) recently explored and tracked a number of facility and work-space green alterations to determine their effectiveness and savings. While the GSA study focused on federal offi ce space, the strategies it followed are effec-tive in nearly any work environment, including industrial space.

Tiny tweaks capture big benefi tsThe fi rst suggestion by the study’s

authors—which involves turning up the thermostat in summer—is something that any business can easily do. By adjusting summer HVAC output from 74 to 78 F, average energy costs for cooling were cut by 4%, or 10.6 cents per sq. ft. annually in the GSA sample. A side benefi t was that the change also increased employee satisfaction: More than 60% of employees said they were uncomfortable working in the colder temperature.

Another easy, cost-saving measure involved replacing HVAC-system fi lters on schedule, and with high-performance fi lters. The GSA study estimates that 30% of the facilities examined inspected their fi lters too infrequently. By checking maintenance records to ensure proper replacement,

and using fi lters with a Minimum Effi ciency Reporting Value rating of 13 or above, the GSA study predicts these facilities would cut overall HVAC energy expenditures by 2%.

Finally, by replacing bulky CRT monitors with LCD units, businesses can quickly cut their energy use. CRT monitors draw nearly three times the energy of LCDs: 75 watts compared with 20-25 watts of peak energy. LCD screens were also found to produce appropriate brightness levels more consistently—something that current research suggests might improve perfor-mance of visual tasks.

For additional information about the study and other energy-saving alterations for the workplace, visit www.gsa.gov LMT

THE GREEN EDGE


DOES YOUR COMPANY HAVE A GREEN EDGE?E-mail your product and service news to: [email protected]

For information on advertising in the Green Edge section, contact KATHY JAROS at:

Phone: (847) 382-8100 ext. 117 / Fax: (847) 304-8603 / E-mail: [email protected]

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Little Things Add UpFor Green-Minded Companies

Thinking small is not always bad.


THE GREEN EDGE

JANUARY/FEBRUARY 2010

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Call Toll Free (800) 504-8577 or by email: [email protected]

www.scalewatcher.com

Applications:Residential • Commercial • Industrial

Patented

Fuel-Cell Industry Could Generate More Than 1MNew Green Jobs

The global fuel-cell industry could create 700,000 green manufacturing jobs over the

next decade, according to “Fuel Cells: Sustainability,” an Industry Review from Fuel Cell Today (FCT), an organization that gathers market-based intelligence on the fuel-cell industry. The group further predicts that more than a million total new jobs could be created during this period to accommodate fuel-cell installa-tion, servicing and maintenance. FCT projects that Asia will domi-nate in terms of manufacturing over the next decade, while key adopter regions, including Europe and North America, will be the prime locations for installation and maintenance jobs. The study also raises a number of issues for the fuel-cell industry itself, which, if not addressed, could be a barrier to fuel-cell adoption, including education, skills and training and supply-chain development.

Fuel Cell TodayHertfordshire, United Kingdom

The North American Wind Service Alliance (NAWSA) has joined with Wind Drives, a wind-turbine

gearbox repair and remanufacturing company, to provide gearbox-oil changeouts, onsite service, PdM services and commissioning of rebuilt gearboxes

to extend wind-turbine life. As the only integrated wind-turbine service network in North America, NAWSA offers a Web-based, single point of contact for all wind-generator concerns, from emergency response to diagnostics and repairs. More than 50 tower-rescue-

trained technicians and support techni-cians throughout the country provide on-site evaluation, removal, installation and support.

NAWSA and Wind DrivesWharton, NJ and Milwaukee, WI

New Onsite Wind-Turbine Service Partnership

THE GREEN EDGE

26 | MAINTENANCE TECHNOLOGY FEBRUARY 2009

THE GREEN EDGE


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EEEEDDDDGGGGEEEEEEEEDDDDGGGGEEEE

Safer, Spill-Proof Transfer Of Flammable Liquids

The newest GoatThroat Pumps for environmentally safe transfer of fl ammable

liquids are in production now. Featuring a lug with a grounding wire on their fronts, SCP-6500 models will be available March 1, 2010. The lug will allow users to ground the pumps, making them safe for use with class 1 and class 2 fl ammables. All compo-nents that come in contact with the pumped fl uid are created with conductive plastic. Available in four models, GoatThroat Pumps fi t containers and drums from 5 to 55-gallons; typically have a service life of 10 to 15 years; and provide for spill-proof, safe transfer of over 850 fl uids and solvents. RoHS compliant, these food grade products are designed to drain containers dry, making them Resource Conservation and Recovery Act (RCRA) empty. They also meet UN safety standards, helping customers meet compliance and environmental requirements.

Westcott Distribution Inc.New York, NY


For more info, enter 35 at www.LMTfreeinfo.com For more info, enter 36 at www.LMTfreeinfo.com

Ludeca Opens Wind Energy Diagnostics & Monitoring Division

Ludeca has opened its LUDECAwind Division to provide

system support services for wind turbines. Services include instal-lation and start-up of condition-monitoring systems, tele-diagnosis services with remote monitoring, laser alignment and geometric measurement systems, continuous alignment monitoring and consulting. The Germanishe Lloyd (GL) Wind certifi ed VIBROWEB XP Wind online monitoring system supplied by Ludeca was developed exclusively for wind-turbine condition monitoring. According to the company, it is an easy-to-install, intelligent and compact unit that operates autonomously without a PC.

Ludeca, Inc.Doral, FL


New Environmentally Friendly Lubricating And Cleaning Items

Nutek has launched a SmartGreen™ offering of lubricating and

cleaning items. The line features extra-large, biode-gradable wipes or towelettes that have soy-based lubri-cants and environmentally friendly cleaners. Unlike tube packages, the company says these wipes can be kept anywhere and not dry out. Simply Soy wipes can be used to clean and lubri-cate tools and other metal surfaces to prevent rust build-up, and are certifi ed for safe use in food areas. Extra-large, heavy-duty Gas Off wipes remove, suspend and absorb gas smells from hands and surfaces. Grime Off removes drips and smears from non-porous surfaces like tools and equipment.

NutekChagrin Falls, OH

Patented-Formula “Green” Spray Lubricant

LiQuifi x, a patented “green” spray lubricant is an effective, easy-to-use, non-aerosol, non-toxic and

odorless formula with low VOCs. Its manufacturers note that the product is the only spray lubricant that meets California standards for indoor air pollution. It contains no PCBs, trichloroethlylenes, dioxins or metals, and has a high fl ash point of 275 F. LiQuifi x complies with new EPA regulations that identify methane and fi ve other greenhouse gases as dangerous to humans and also meets FDA Regulation 21 CFR for incidental food contact.

LiQuifi xStamford, CT

Don’t Miss The Capacity Assurance Conference!

®®®®®®

PRESENTED BY:

MAINTENANCE and RELIABILITY TECHNOLOGY SUMMIT

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 30 one-hour Conferences

and 17 full-day Workshops,

MARTS off ers valuable,

job-critical information for:

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.

* Keynote Speaker John Ratzenberger – the actor, author and manu-facturing activist will speak about Nuts, Bolts & Thingamajigs, his foundation that brings students and manufacturing together.

* Futurist and fi nancial professional Bob Chernow, who will off er 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.

MARTS 2010 MARTS 2010 Highlights: Highlights:


APRIL 27-30, 2010Or Call Tom Madding: 847.382.8100 x108

Hyatt Regency O’Hare, Rosemont (Chicago), IL

www.MARTSconference.com


Is to provide a comprehensive

training, educational and professional

development opportunity for

maintenance and reliability technicians,

engineers, supervisors and managers

in all industries and major facilities.

MAINTENANCE and RELIABILITY TECHNOLOGY SUMMITAPRIL 27-30, 2010

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MARTS 2010 WorkshopsWorkshops 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 www.MARTSconference.com for addition details and to register.

Pre-Conference Workshops: Tuesday, April 27, 2010Lean Equipment Management: The Prescription for Rapid and Sustainable Gains /

Robert M. Williamson, Founder, Strategic Work Systems, Inc.

Lubrication for Industrial Facilities / Ken Bannister, Principal Consultant, Eng Tech 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, LeanExpertise.com

Post-Conference Workshops: Friday, April 30, 2010Lubrication for Profi t: 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 / John Elliott, Senior Consultant and Jerry Wanichko, Manager,

T.A. Cook Consultants, Inc.

Ensuring Reliability Through Systematic Work Control / Dave Krings, CMRP, BSME;

President, Nobreakdowns.com

Using SMED to Transform Your Lean Enterprise / Enrique Mora, President, LeanExpertise.com

Maintenance Planning and Scheduling / R. D. (Doc) Palmer, PE, CMRP; Partner,

People and Processes, Inc.

IR Thermography for Electrical and Mechanical Systems / R. James Seff rin, Director of

Infraspection Institute

4 Lean Tools to Revolutionize Your Maintenance System (Part II) / Ed Stanek, President,

LAI Reliability


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 Certifi cation 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 BasicsLocation: Hyatt Regency O’Hare, Rosemont, IL www.ohare.hyatt.com

Dates: Tuesday through Friday, April 27-30, 2010

Workshop Days: Tuesday and Friday (17 full-day Workshops off ered)

Conference Days: Wednesday and Thursday (30 one-hour Conferences off ered; see schedule on next page)

Professional Development Course 1: Certifi ed Lubrication Specialist (CLS) Review, Tuesday through Thursday

Professional Development Course 2: Taking Command of Your Maintenance Process: from Certifi cation to Implementation, Tuesday and Wednesday

Certifi cation Exam Day (for CLS and CMRP):Friday

Note: Individuals interested in taking an exam must register directly with STLE (CLS) and SMRP (CMRP). Link to these sites at www.MARTSconference.com


The Capacity Assurance Conference!

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MARTS 2010 Conferences Data Management

Green Lubrication Maintenance & Reliability

StrategyTechnology

Conferences are one-hour presentations, given by an expert in the fi eld.

Accompanied by a PowerPoint presentation, they include ample time for Q&A, and are divided into six categories:

See the schedule below for Conference off erings and other Conference-Day activities:

WEDNESDAY APRIL 28 (15 Conferences)

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

Continental Breakfast

8:00 a.m. to 8:45 a.m.

Keynote AddressJohn Ratzenberger, actor, director,author and spokesperson for theNuts, Bolts & Thingamajigs Foundation

8:45 a.m. to 9:30 a.m.

Break / Exhibits

9:30 a.m. to 10:30 a.m.

Data ManagementInteroperability 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, Flowserve, 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.

TechnologyUnderstanding Torque Measurements and Torsional Analysis Trent Martz, IVC Technologies

Maintenance & Reliability Where’s Your Reliability Policy? Robert M. Williamson, Strategic Work Systems, Inc.

StrategyForward 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

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

LubricationHow to Kill a Bearing / Ken Bannister, Engtech Industries, Inc.

GreenWorld-Class Companies Need World-Class Motor Management and Maintenance / Noah Bethel, PdMA Corp.

Strategy20 Sure-Fire Ways to Shoot Your Maintenance Eff ort in the Foot / Ray Atkins, contributing editor

2:10 p.m. to 3:10 p.m.

TechnologyUltrasound for Condition-Based Monitoring and Energy-Effi ciency Improvement / Mike Gilley and Mike Dixon, Fox River Systems

Maintenance & ReliabilityHow to Make Your TPM Implementation a Total Success Enrique Mora, Leanexpertise.com

StrategyPlanning 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 & ReliabilityRCM Lessons Learned: An UpdateMac Smith, AMS Associates, and Joe Saba, JMS Software

GreenHow to Reduce the Payback Period for Energy Effi ciency Projects / Ralph Semyck, Siemens Industry, Inc.

StrategyChange Behavior to Achieve Results: High Impact Learning Tara Denton, Life Cycle Engineering (LCE)

4:40 p.m. to 6:00 p.m. Reception / Exhibits

THURSDAY APRIL 29 (15 Conferences)

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

Continental Breakfast

8:00 a.m. to 8:45 a.m. Keynote AddressBob Chernow, futurist/ fi nancial expert

8:45 a.m. to 9:30 a.m.

Break / Exhibits

9:30 a.m. to 10:30 a.m.

StrategyUsing 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

StrategyLife Cycle Costing Management

Ali Zuashkiani, University of Toronto

StrategyThe Right Part at the Right Time at Cost-eff ective Prices Richard R. Rosales, ABB

10:40 a.m. to 11:40 a.m.

Maintenance & ReliabilityProspering in a Lean Maintenance Environment Ed Stanek, LAI Reliability Systems

GreenAn Easy Approach for Applying Today’s AC Drives / James Mullinix, Vacon

StrategyO&M Peer Networking Bob Gibson, Scientech

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

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

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

StrategyMaximizing Human Resources Performance within the Maintenance Organization / Michael Gehloff , General Physics Corp.

LubricationBenchmark Your Lube Program Through Oil AnalysisStacy Heston, POLARIS Laboratories

Open Discussion Group Topic TBA / Bob Williamson

2:10 p.m. to 3:10 p.m.

Data ManagementHow to Make Your CMMS Interoperate With the Real-Time Enterprise C.C. (Cliff ) Pedersen, Pedersen Enterprises Inc.

TechnologyInfrared Thermography: What’s Hot in PdM / Jim Seff rin, Infraspection Institute

StrategyApplying Disruptive Learning Techniques in a Manufacturing Environment Mitch Stansloski, Pioneer Engineering

Maintenance & ReliabilityTitle TBA / T.A.Cook Consulting, 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 and RELIABILITY TECHNOLOGY SUMMITMAINTENANCE d RELIABILITYTECHNOLOGY SUMMITThe Capacity Assurance Conference!

MARTS 2010 Fees And PackagesSpecial FSA Package - $ 1,995.00 Includes 1 FSA Pre-Conference Workshop, MARTS Conference and 1 Post-Conference Workshop

Special Summit Package - $ 1,550.00 Includes 1 Pre-Conference Workshop, MARTS Conference and special Post-Conference

Workshop “Lubrication for Profi t”

FSA/Conference Package - $ 1,590.00 Includes 1 FSA Pre-Conference Workshop and MARTS Conference

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

Combo Package - $ 1,190.00 Includes 1 Pre or Post-Conference Workshop and MARTS Conference

Conference Package - $ 895.00 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 or Post-Conference Workshop

FSA Workshop Package - $ 695.00 Includes 1 Pre-Conference FSA Workshop

Lubrication for Profi t Workshop - $ 545.00 Includes “Lubrication for Profi t” Post-Conference Workshop only

3-Day Certifi ed Lubrication Specialist Workshop - $ 1,195.00 Includes 3 days intense training based on STLE’s CLS program

2-Day Workshop: Taking Command of Your Maintenance Process: from Certifi cation to Implementation- $ 995.00 2-day review of the latest maintenance best practices is designed for busy Maintenance

professionals looking to prepare for certifi cation exams or integrate these concepts into their own

maintenance optimization programs

Certifi cation Exams - Costs Vary Individuals interested in taking the CLS exam or the CMRP exam must register directly

with STLE (CLS) and SMRP (CMRP). Links are available at www.martsconference.com

and are also listed on page 28

3-Day Review Course: Certifi ed 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

Attendees of this course learn how to evaluate and select lubricants, recommend changes, consolidate inventories, conduct a lube survey, and create and manage a used-lubricant analysis program. Technologies covered include bearings and gears, pneumatics and fl uid power, fl uid conditioning and analysis, and seals. The course was developed specifi cally to prepare candidates for the Certifi ed Lubrication Specialist exam. (Course enrollment does not ensure certifi cation.)

Exam: Certifi ed Lubrication Specialist (CLS)

Administered by the Society of Tribologists and Lubrication Engineers (STLE).

Date: Friday, April 30

Time: 9:00 a.m.

Cost: Varies

Note: You must register separately with STLE to take this exam at MARTS 2010. Register online at www.stle.org or call 847.825.5536.

2-Day Review Course: Taking Command of Your Maintenance Process: from Certifi cation to Implementation

Instructor: Dave Krings, CMRP, BSME; President, Nobreakdowns.com

Dates: Wed., April 28 and Thurs., April 29,

Times: 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 certifi cation exams or integrate these concepts into their maintenance programs. An expanded version of the popular “5 Pillars: Maintenance & Reliability Professional Review Course,” this new session off ers more examples of real-life application and provides a general review for various maintenance-industry certifi cations. (Course enrollment does not ensure certifi cation.)

Exam: Certifi ed Maintenance & Reliability Professional

Administered by the Society for Maintenance & Reliability Professionals (SMRP)

Date: Friday, April 30

Time: 9:00 a.m.

Cost: Varies

Note: You must register separately with SMRP to take this exam at MARTS 2010. Register online at www.smrp.org or call 800.950.7354.

APRIL 27-30, 2010

MARTS 2010 Professional Development OpportunitiesTwo professional development courses are off ered 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 Certifi ed Lubrication Specialist (CLS) and Certifi ed Maintenance Professional (CMRP) are off ered

on Friday. Individuals interested in taking an exam must register directly with STLE (CLS) and SMRP (CMRP).

Link to these sites at www.MARTSconference.com, or see below.

All packages include continental breakfast, lunch and Wednesday night’s MARTS Reception. For Group Rates, call 847.382.8100 x108.Includes 1 Pre or Post Conference Workshopp

APRIL 27-30, 2010Or Call Tom Madding: 847.382.8100 x108

www.MARTSconference.com




LUBE SHOWCASE

What’s it take to move products around and through our

food chain safely and effi ciently? These leading suppliers

have a number of answers. They offer effective solutions

for a wide range of food grade needs.

Food GradeFood GradeLubricantsLubricants

Our Editors Select

Part of Chesterton’s line of primary chain lubricants, this clear, non-staining chain formula for use in food processing, beverage, and pharmaceutical plants is NSF registered for direct food contact. It’s suitable for applications

with temperatures from -9 C to 120 C (15 F to 250 F). Chain “stretch” is a result of wear on the pin and bushing, requiring costly chain adjustments or replace-ment. According to the company, conventional lubricants do not penetrate tight tolerances and, therefore, provide minimum benefi t. These Chesterton prod-ucts, though, are formulated to penetrate pin and bushings. This can lead to a doubling of chain life, reduced energy and lubricant consumption and increased load-carrying capability.

A.W. ChestertonWoburn, MA

Chesterton’s 690 FG Lubricant…



LUBE SHOWCASE



Developed for general lubrication of food machinery, these greases have been approved by LGA Bayern as physiologi-cally safe, and by the USDA (NSF) as “H1” lubricants, even if

incidental contact with food products is possible. A select base oil blend with an FDA approved thickener provides good adhesion, fi lm strength and wash-down resistance, even at elevated temper-atures. Drip-free characteristics and an off-white color comple-ment housekeeping efforts. A high-performance combination of food grade additives provides excellent anti-wear protection and, in conjunction with blending techniques, leads to effective rust protection and long grease service life. Castrol will launch these products in the U.S. in April 2010.

CastrolWayne, NJ

Castrol Molub-Alloy®

Foodproof 823 FM™ Greases. . .

This colorless, non-staining, non-drying, biodegradable, aluminum complex H-1 formulation is approved by the USDA for applications in federally inspected meat and poultry plants. Meeting or exceeding

the FDA’s CFR Title 21 Section 178.3750 purity regulation, it is specifi -cally designed for use in food processing. It features a bacteriostatic agent to retard bacterial and fungus growth, and is extremely water resistant, even after frequent wash-downs. Polymer additives provide superior adhesive/cohesive strength to lower friction and protect against high shock loads. According to the manufacturer, the synthetic ingredients and anti-wear additives of this multi-temperature service product can increase equipment life.

Royal Purple, Inc.Porter, TX

Royal Purple’s Ultra-Performance®

Clear FDA Food Service Grease. . .

This product quickly lubricates, waterproofs and protects without attracting dirt or

other harmful contaminants, and can be used to eliminate sticking and binding and to stop squeaks. The formula withstands high pressure and is NSF H1 food grade certifi ed, yet doesn’t sacri-fi ce all the power and strength of an H2 formula. According to the manufacturer, this fl uid is ideal for releasing molded parts and for use on belts, linkages, pulleys, valves, slide conveyors, guide rails, tools, locks, doors, hinges and more. It is safe to use on all metal and non-metal surfaces, including rubber.

WD-40 CompanySan Diego, CA


Blue Works Industrial Grade Silicone from WD-40. . .


LUBE SHOWCASE

This polyol ester oven chain lubricant, one of many Inolex food grade offerings, is ideal for baking-chain temperatures up to 500 F. According to the manufacturer, the consistent lubricity

and fi lm strength of the Lexolube® line is remarkable and requires less re-application than many other lubricants available. When exposed to high temperatures over time, most lubricants gum up, smoke or leave stains on the machinery. Lexolube chain lubricants, on the other hand, provide clean lubrication and show minimal evaporation, which translates into enhanced performance. These non-toxic products do not require stirring before application. The FG line leads to less maintenance and downtime, and lower energy consumption.

Inolex Chemical CompanyPhiladelphia, PA

Clarion Food Machinery A/W Oils. . .

Inolex’s Lexolube® FG-350 H1 OCL…




A

Clean and clear, pure and simple, these food machinery oils are available in four ISO viscosity grades, and use an additive system designed specifi cally for lubricants for food-processing

equipment. Formulated with a high-purity white mineral oil and additive system, these lubricants are colorless, odorless, tasteless, non-staining and provide excellent wear, rust- and oxidation-protection. Clarion Food Machinery A/W Oils are NSF H1 approved and recommended for medium-pressure hydraulic systems in food processing, canning, bottling and airline lubrication.

Clarion LubricantsHouston, TXIdeal for the full spectrum

of hydraulic, gear and air-compressor applications,

Mobil SHC Cibus lubricants are designed to provide food and beverage processors with high performance and long service life, even in extreme operating conditions such as freezers and cookers. In addi-tion to being manufactured in equipment where cross-contamination is minimized, Mobil SHC Cibus Series lubri-cants are formulated to be nut-, wheat- and gluten-free and suitable under Kosher and Halal dietary law. Engineered with advanced synthetic base stocks, these oils, according to the manufacturer, have out-standing load-carrying prop-erties and low internal friction,which helps cut energy costs.

Mobil Industrial LubricantsFairfax. VA

Mobil SHC Cibus Series Oils For Food Machinery. . .


SOLUTION SPOTLIGHT

Employees at the 25 Five Rivers MetroParks facilities in the greater Dayton, OH area feel as though they’ve struck gold

—black gold, that is. The reason? They’ve been recycling used motor oil from service vehicles that maintain the system’s nearly 15,000 acres to generate heat for their offi ces and workshop.

According to Dave Spitler, assistant park manager, he was seeking a better way than wood-burning stoves to heat the operation’s buildings. “There was a big cost factor in man hours to have staff members cut and split wood for the stoves,” he says. The Clean Burn system has changed all that.

These daysUsed oil storage tanks now collect hundreds of gallons of recycled motor oil from the park’s 99 fl eet vehicles and 98 small motor-ized vehicles (including Gators and lawn mowers), as well as community contributions. After being refi ned, the oil is pushed through a fi lter and pre-heated. It’s then injected into the Clean Burn furnace and burned at 1800 F. The high temperatures create low emissions (less than 1% allowable by EPA standards) and generate enough heat to warm the park’s 2400-sq.-ft. offi ce and workshop facilities.

“I’ve sent oil recycle barrels to all MetroParks facilities to collect their used oil,” reports Spitler. “Each park saves money since they no longer have to pay anyone to properly dispose of the oil. We bring the full barrels to the central furnace area and replace them with empty barrels. This is a sensible solution that would be viable for other parks nationwide to adapt in order to save money and close the loop on recycling efforts.”

About Clean BurnAccording to the manufacturer, there are 80,000 Clean Burn functional furnaces and boilers located across the globe. They burn millions of gallons of used oil each year on-site, at the point of generation.

Clean Burn is an ENERGY STAR® partner. The company holds numerous industry certifi cations and works with the U.S. government, the Environmental Protection Agency and various associations to help coordinate the establish-ment of standards and regulations related to heat recovery and recycling efforts involving used motor oils.

Clean Burn, Inc.Leola, PA


Prior to installing the Clean Burn system, the Five Rivers Metroparks operation had hired contractors to haul away and dispose of used oil. This process not only posed considerable risk for spills and/or contamination of the environment, it also required signifi cant amounts of fossil fuels for transporting the waste oil.

Economical And Ecological Solution For Used Oil

at the 25 Five Rivers s facilities in the greater H area feel as though they’ve struck gold hat is. The reason? They’ve been recycling used

i hi l h i i h ’ lPrior to installing the Clean Burn system, the Five Ri M k i h d hi d

Before Clean Burn


PROBLEM SOLVERSPROBLEM SOLVERS




Near-Laboratory-Quality Viscosity Measurements Made Easy

T he SimpleVIS™ system from Cannon Instrument is a specialized semi-automated

viscometer that provides quick, reliable kinematic viscosity results with a touch of a fi nger. According to the company, this portable unit is ideal for any site that needs near-laboratory-quality viscosity measurements. Everything to get started is included; the user provides only sample and solvent. Capable of delivering direct kinematic viscosity measurement, with no need to correlate dynamic viscosity data, the product incorporates a modifi ed cross-arm style tube that works with both transparent and opaque oils.

Cannon Instrument Co.State College, PA

Mobile Monitoring Of Aging-Oil Conditions

The Oil Condition Monitor (or OCM 01) from Internormen

is a mobile diagnostic system for determining the aging condition of oil in hydraulic and lubrication systems by measuring solid contam-ination, water saturation, temperature, viscosity and relative dielectricity. The system is applicable for both pressure and suction lines and can also be employed when working with foamed oils in gears.

InternormenAltlussheim, Germany

Upgraded Electronic Lubrication Meters

Lincoln’s Model 980, 981 and 982 Elec-tronic Lube Meters

for vehicle mainte-nance, lube-truck and other industrial appli-cations feature large, easy-to-read, six-digit digital displays with two-decimal-point precision. The pres-sure rating has been increased from older models to 1500 psi, and fl ow capability has been improved to 8 gpm. The meters have a resettable and non-resettable totalizer that displays dispense quantities in pints, quarts, gallons or liters. Each unit has a long-life, fi eld-replaceable, top-load battery, a ½”- ball-bearing swivel and a locking trigger with built-in trigger guard.

LincolnSt. Louis, MO

New Synthetic To Protect Wire Rope

Lubrication Engineers’ new Wirelife™ Almasol® Syn Coating Lubricant is an

extremely tacky, nonasphaltic synthetic with exceptionally high fi lm strength. Suitable for extreme environments and conditions, it provides robust outer-surface protection for wire rope and cable used in mining, construction and marine opera-tions. It reduces wear by minimizing wire-to-wire contact with the rope. Typical applications for this product include standing and running lines, draglines, cranes, derricks, hoists and drilling rigs.

Lubrication EngineersFort Worth, TX


PROBLEM SOLVERS




Reduced-Odor, Multi-Tasking, Semi-Synthetic Metalworking Fluid

Master Chemical is offering TRIM® SC520, a semi-synthetic metal-

working fl uid that incorpo-rates a proven EP-additive package to control built-up edge and improve tool life. The manufacturer notes that it performs well in multi-metal, multi-operational job shops, and has the wetting and cooling characteristics necessary for excellent machining results on high-speed milling and turning operations. It controls chip welding on soft, gummy materials like aluminum, and rejects tramp oils rapidly. This fl uid is compatible with a wide range of mate-rials, including aluminum alloys, cast iron, steels and copper, as well as most plastics and composites.

Master Chemical Corp.Perrysburg, OH

Extended-Life Cordless Grease Guns

The M12TM Cordless Grease Gun from Milwaukee Elec-

tric Tool is part of the company’s LITHIUM-ION system. Capable of delivering 8000 psi max operating pressure for heavy-duty applications, it dispenses up to seven grease cartridges per battery charge. The unit comes standard with a high-capacity LITHIUM-ION battery that, the manufacturer notes, can double the performance of the user’s other M12TM tools. Additional features include a lightweight, ergonomic handle design, onboard hose storage and shoulder strap loop.

Milwaukee Electric Tool Corp.Brookfi eld, WI

Self-Lubricating Composite Reduces Blow-Mold Maintenance

Kohlox™, a self-lubricating thermo composite material

designed for blow-mold parts, was created to reduce weekly main-tenance on the molds. The material’s low coef-fi cient of friction helps blow-mold parts move freely without the use of lubrication, eliminating the need for mold re-greasing. New grease-free parts include wear rings for mold bottoms and female studs. Patented by Sidel, this technology is available as an option for most new molds and can be adapted to several existing molds for all types of the manufacturer’s blow molders.

SidelNorcross, GA

i l hi h d

f

Bearing Isolator Brand Under New Ownership

Waukesha Bearings, an operating company of Dover Corporation, has acquired Inpro/Seal Company, the leading designer and manufacturer of bearing

isolator technologies, effective December 30, 2009. The acquisition adds adjacent product lines to Waukesha’s already strong bearing solutions for oil & gas and power generation markets. To date, nearly 4 million Inpro/Seal Bearing Isolators have been installed in rotating equip-ment throughout the world.

Waukesha Bearing Corp.Pewaukee, WI

B i I l B d

For rate information on advertising in the Information Highway Section Contact your Sales Rep or KATHY JAROS at: Phone: (847) 382-8100 x117 / Fax: (847) 304-8603 / e-mail: [email protected]

INFORMATION HIGHWAY

NSK Corporation offers over 100,000 different types of bearings, linear motion and automotive component prod-ucts and ensures maximum uptime with industry-specifi c solutions and comprehensive services that ensure bear-ings are being installed and maintained properly. Learn more about NSK’s Asset Improvement Program and world-class components at www.us.nsk.com.

For more info, enter 76 at www.LMTfreeinfo.comwww.us.nsk.com

Baker Instrument Co. manufactures high-voltage test equipment for the safeguard of electric motors. Its surge and hipot testers verify insulation integrity by fi nding weaknesses in turn-to-turn, phase-to-phase and coil-to-coil insulation systems within the motor.

For more info, enter 74 at www.LMTfreeinfo.comwww.bakerinst.com

Alignment Supplies, Inc. offers a variety of laser alignment and measurement systems. With Easy-Laser measurement products we can offer a solu-tion for your application and alignment needs.

For more info, enter 79 at www.LMTfreeinfo.comwww.alignmentsupplies.com/

IMI Sensors manufactures ICP®, 4-20 mA and high tem-perature vibration sensors and transmitters, smart vibration switches, bearing fault detectors, reciprocating machinery protectors, signal conditioning and accessories for predic-tive maintenance, equipment protection, condition moni-toring and machinery vibration analysis. Sensors monitor bearings, gears, motors, spindles, reciprocating compres-sors and other rotating machinery in harsh environments.

For more info, enter 78 at www.LMTfreeinfo.com www.imi-sensors.com


Web Spotlight: LUBRICATION MANAGEMENT & TECHNOLOGY

For more info, enter 72 at www.LMTfreeinfo.comwww.MT-online.com

LUDECA, INC. - Preventive, Predictive and Cor-rective Maintenance Solutions including laser shaft alignment, pulley alignment, bore alignment, straightness and fl atness measurement, monitor-ing of thermal growth, online condition monitoring, vibration analysis and balancing equipment as well as software, services and training.For more info, enter 73 at www.LMTfreeinfo.com

www.ludeca.com

For more info, enter 71 at www.LMTfreeinfo.comwww.LMTinfo.com

Hy-Pro Filtration is a total solutions provider for hydraulic and lubrication fl uid contamination chal-lenges. The range of products includes DFE rated fi lter elements, fi lter assemblies, mobile fi lter carts, vacuum dehydration units, breathers, coalesce skids and fl uid analysis equipment. For more info, enter 77 at www.LMTfreeinfo.com

www.fi lterelement.com

The goal of MT-online.com is quite simple: to help plants and facilities leverage their increasingly pre-cious time and resources and achieve world-class status via state-of-the-art asset management strat-egies, technologies and methodologies..

NEW LOOK! LMTinfo.com, the newly redesigned Website of LUBRICATION MANAGEMENT & TECHNOLOGY, serves the business and technical information needs of engineers, managers, and technicians who design, troubleshoot, and maintain lubrication and fl uid power systems and buy and specify lubricants and fl uids. It features information on best practices for managing these systems and the industrial machinery and mobile equipment that utilize them. LMTinfo.com is the one-stop shop for all real-world lubrication professionals, now offering full article archives, enhanced training pages, a comprehensive events calendar and business directory, and more!

The Maintenance & Reliability Technology Summit is the #1 learning venue and source of practical solutions for anyone concerned with the reliability, maintenance and the overall capacity assurance of critical equip-ment systems in a plant or facility. Mark your calen-dars! MARTS 2010 is taking place April 27-30, 2010 at the Hyatt Regency O’Hare in Rosemont, IL.For more info, enter 75 at www.LMTfreeinfo.com

www.MARTSConference.com

REGISTRATIONNOW OPEN!

IndexADVERTISER WEBSITE CIRCLE # PAGE #

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.

JANUARY/FEBRUARY 2010 • Volume 11, No. 1


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 105Barrington, IL 60010

PH 847-382-8100 FX 847-304-8603

www.LMTinfo.com

SALES STAFF

ATP Lists ....................................... www.atplists.com ......................................... 67 ..............UM5

Engtech Industries Inc. ................ www.engtechindustries.com ....................... 66 ..............UM4

Hy-Pro Filtration ......................... www.hyprofi ltration.com............................ 65 ................... 13

Inolex Chemical Company ......... www.inolex.com ........................................... 62 ..................... 4

Inpro/Seal Co. ............................... www.inpro-seal.com/cdr ............................. 81 ..................BC

MARTS ......................................... www.MARTSconference.com .................... 23,27 ........68,70

NSK Corporation ........................ www.thinknsk.com ...................................... 61 ..................... 2

Nuts, Bolts and Thingamajigs..... www.nutsandboltsfoundation.org ............. 63 ..................... 7

Royal Purple ................................. www.royal-purple-industrial.com ............. 80 ................... 39

Scalewatcher ................................. www.scalewatcher.com ................................ 69 ................... 25

WD-40 .......................................... www.wd40.com ............................................ 64 ......... Insert, 9

IA, MT, NE, ND, SD, WY, AB, MB, SK


847-382-8100 x106; Fax 847-304-8603ARTHUR L. RICE

[email protected]

Classifi ed Advertising/Electronic Sales:1300 South Grove Avenue, Suite 105

Barrington, IL 60010847-382-8100 x117; Fax 847-304-8603

KATHY [email protected]

AR, AZ, NV, NM, OK, UT 1300 South Grove Avenue, Suite 105

Barrington, IL 60010847-382-8100 x116; Fax 847-304-8603

BILL [email protected]

IL, IN, KS, LA, MI, MN, MO, OR, TX, WA,WI, BC


847-382-8100 x108; Fax 847-304-8603TOM MADDING

[email protected]

CT, ME, MA, NH, NY, RI, VT, ON, QC P.O. Box 1059

Osterville, MA 02655508-428-3331; Fax 508-428-2545

VINCENT [email protected]

AL, CA, CO, DE, FL, GA, MD, MS, NC, NJ, SC, PA, VA, WV, DC

1750 Holmes DriveWest Chester, PA 19382

610-793-3093; Fax 610-793-3094JIM HANLEY

[email protected]

OH, KY, TN135 N. Rocky River Road

Berea, OH 44017440-463-0907; Fax 440-891-1254

JOHN [email protected]


http://www.LMTfreeinfo.com

For more information on Royal Purple, visit royal-purple-industrial.com today.

“...we extended drain intervalsfrom every 15 days to everythree months AND reduced

engine repairs and replacements.”

Luis GarzaKingfisher 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 ofOwnership’ today by calling 866-447-5173 . . .

For more information on Royal Purple, visit royal-purple-industrial.com today.


http://www.royal-purple-industrial.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:

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.

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.

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.

ROBUST

RELIABLE

REALISTIC

For more information visit www.inpro-seal.com/CDR or contact800-447-0524 for your Inpro/Seal Representative.


http://www.inpro-seal.com/CDR

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