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Lubrication Management & Technology July/August 2011 magazine...Achieving Efficiencies Through Practices & Products
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Page 1: LMT JulAug 2011
Page 2: LMT JulAug 2011

For more info, enter 61 at www.LMTfreeinfo.comFor more info, enter 61 at www.LMTfreeinfo.comFor more info, enter 61 at www.LMTfreeinfo.com

B A L L B E A R I N G S | R O L L E R B E A R I N G S | L I N E A R M O T I O N P R O D U C T S | T E C H N I C A L S E R V I C E S

When you think “Innovation”, you think about products designed to deliver optimum lubrication. We

think about NSK products such the EM series cylindrical roller bearings that provides improved grease

and oil flow in cage pockets. With a wear resistant machined brass cage, the EM series also delivers

30% higher load rating compared with conventional bearings and up to twice the bearing life. When

it comes to world class innovation to provide maximum lubrication and outperform in gearbox

applications, Think NSK.

www.nskamericas.com1.88ThinkNSK

Page 3: LMT JulAug 2011

contentsJULY/AUGUST 2011 • vOL 12, nO. 4 • www.LMTinfo.com

AchievinG efficiencieS ThROUGh PRAcTiceS & PRODUcTS

PROfeSSiOnAL DeveLOPMenT SeRieS

FeAtures

8 certifi cation Matters, Part iii: Gearbox Principles And Lubrication Learn the basics about these key components of all types of applications. Ray Thibault, Contributing Editor

18 elemental Analysis While you’ll want to make sure this ‘exciting’ methodology is part of your PdM toolkit, you’ll need to understand its limitations. Jane Alexander, Editor, with Ken Bannister and Ray Thibault

20 Tough Stuff Harsh environments and challenging processes ask a lot from a lubricant. Here, we look at some outstanding options for extreme and severe service.

22 The Anatomy Of A centralized Lubrication System: Dual Line Systems Off ering many hundreds of lube points from a single pump, these twin-line systems are well-suited for a range of industrial equipment. Ken Bannister, Contributing Editor

LAB SPOTLiGhT

PRODUcT ShOWcASe dePArtMeNts 6 from Our Perspective

25 Problem Solvers

29 classifi ed

29 Supplier index

30 Lube Starz

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DeLiveRinG The GOODS

JULY/AUGUST 2011 www.lmtinfo.com | 3

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

Achieving effi ciencies Through Practices & Products

Page 4: LMT JulAug 2011

July/August 2011 • Volume 12, No. 4

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. bANNister rAy 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]

Jill kAlethAReprint Manager

866-879-9144, ext. 168 [email protected]

editorial Office1300 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 offices. Arthur L. Rice, III, President/CEO. Circulation records are maintained at Lubrication Management & Technology, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Lubrication Management & Technology copyright 2011. No part of this publication may be reproduced or transmitted without written permission from the publisher. Annual subscription rates for nonqualified people: North America, $140; all others, $280 (air). No subscription agency is authorized by us to solicit or take orders for subscriptions. Postmaster: Please send address changes to Lubrication Management & Technology, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Please indicate position, title, company name, company address. For other circulation information call (630) 739-0900. Canadian Publications Agreement No. 40886011. Canada Post returns: IMEX, Station A, P.O. Box 54, Windsor, ON N9A 6J5, or email: [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 JULY/AUGUST 2011

AchievinG efficiencieS ThROUGh PRAcTiceS & PRODUcTS

For additional information, please contact Foster Printing Service,

the official reprint provider for Lubrication Management.

PMS 370 C

C: 60M: 0Y: 100K: 28

Reprints are a simple way to put information directly into

the hands of your target audience. Having been featured

in a well-respected publication

adds the credibility of a

third-party endorsement

to your message.

Custom reprint products of articles

and features from Lubrication Management

create powerful marketing tools that serve as

instantly credible endorsements.

CustoM REPRINts

use reprints to maximize your marketing

initiatives and strengthen your brand’s value.

RepRints aRe ideal foR:

n New Product Announcements

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n PR Materials & Media Kits

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n Customer & Prospect Communications

n Trade Shows/Promotional Events

n Conferences & Speaking Engagements

n Recruitment & Training Packages

Call 866.879.9144 or [email protected]

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DesigneD to Boost proDuctivity.Just like our luBricant solutions for general Manufacturing.At Shell Lubricants, we constantly seek to improve our products and services.When customers asked for an easier and simpler way to choose the rightlubricant for their operations, we acted. The result is an advanced industrialoil and grease range. Contact your local Shell Lubricants representative at 1-800-237-8645 to find out about our new and improved product portfolio designed to unlock your industrial production potential.

shell.us/lubricants

DesigneD to Meet cHallenges™

The term “Shell Lubricants” refers to the various Shell Group companies engaged in the lubricants business.© 2011 SOPUS Products. All rights reserved.

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Page 6: LMT JulAug 2011

FROM OUR PERSPECTIVE

Ken Bannister, Contributing Editor

On a recent trip to Paris, I reveled in the role of tourist. Among other points of interest, I visited the military academy/museum at the Place Invalides. There, I couldn’t help but

chuckle when my electronic “guide” referenced the graduation report for one of this college’s most celebrated alums—Napoleon Bonaparte. The report writer had evidently noted something to the effect that “given the right circumstances,” Napoleon would be able to “make something of himself.” What an understatement!

Although Napoleon was greatly disadvantaged due to his Corsican background, he was a master at recognizing opportunity. He used his savvy to open door after door for himself and, in just a few short years, became the legitimate Emperor of France.

Fast forward several centuries to a Planning and Scheduling workshop I conducted three weeks after trekking around Paris… My introduction of the work-order backlog management section was met with an all-too-familiar refrain. Like similar groups before them, these attendees voiced great frustration over their inability to get at equipment assets and perform the most basic of routine maintenance tasks. This time, however, my response to all the venting was different from past workshops, in that I could flavor it with this classic Napoleonesque admonition: “Ability is of little account without opportunity.”

The point of all this is that while we may know how to plan and schedule effectively, if we can’t get to the asset it is to no avail. Throughout the year, many non-controlled shutdown events will occur within a plant (i.e., operator-induced equipment/line shutdowns, safety shutdowns, audit inspec-tions, raw-material outages, etc.). There are also many short-term controlled shutdown events that occur on a daily basis (i.e., shift changes, product changeovers, break times, lunch times, manufac-turing-target-completion shutdowns, etc.). Both non-controlled and controlled events represent a huge maintenance opportunity and the chance to introduce an Opportunity Based Maintenance (OBM) strategy and program.

For example, at one mining client’s site, when production would not give up its underground scoop-tram vehicles for basic lubrication, we identified an opportunity to introduce a “pit-stop” maintenance service program to service the lubrica-tion needs of the vehicles during normal one-hour lunch periods—outside the drivers’ lunchroom. This “opportunity” resulted in handsome gains in both tram availability and productivity.

The fundamental difference between traditional scheduling and OBM lies not only in the duration of the event, but how the work scope is identified. OBM takes advantage of very small time windows. Therefore, the Planner/Scheduler must scope out proactive work tasks that can be scheduled immediately, require just one technician and have job-plan durations suitable for scheduling in incre-ments of 15 minutes, 30 minutes, 1 hour, on up to a maximum of 2 hours. The scope of work that can be included in an OBM approach will include:

n Manual lubricationn Oil/filter changen Equipment cleanupn Laser alignment n Utility-system leak checksn Calibrationn Wear checksn Oil-analysis samplingn Belt replacements

OBM program setup requires maintenance and production departments to develop a commu-nication strategy that will inform maintenance immediately when a non-controlled shutdown takes place—and to agree on an understanding about setting up pit-stop-styled maintenance tactics during short-term planned outages.

If you have the ability, find the opportunity! As the comedian Milton Berle put it, “If opportunity doesn’t knock, build a door.” Good luck! LMT

[email protected]

Maintenance RocksWhen Opportunity Knocks

6 | LUBRICATION MANAGEMENT & TECHNOLOGY JULY/AUGUST 2011

Page 7: LMT JulAug 2011

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BRC-POW-M10-043ELubrication Mgmt “Barrel Art”Full PageBleed: 8.125” x 11”Trim: 7.875” x 10.75”Live: 7.125” x 10”This advertisement prepared by

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8 | LUBRICATION MANAGEMENT & TEChNOLOGy JULY/AUGUST 20118 | LUBRICATION MANAGEMENT & TEChNOLOGy JULY/AUGUST 2011

This article is the third in this ongoing series on the important

components of lubrication certifi cation examinations admin-

istered by the Society of Tribologists and Lubrication Eng-

ineers (STLE) and the International Council for Machinery

Lubrication (ICML). Please refer to pgs. 10-14, LMT January/Feb-

ruary 2011 for more information on STLE and ICML certifi cations.

A key component of all types of applications, gears are used to transmit speed and power (torque) from one revolving shaft to another. They can change speed, torque and direction of rotation. Their major advantages as drives include the fact that they don’t slip, they’re able to carry high loads and they are compact in size. Figure 1 shows the simplest type, the spur gear.

Ray ThibaultCLS, OMA I, OMA II,

MLT, MLT II, MLA II, MLA III

Contributing Editor

Gearbox Principles Gearbox Principles Gearbox Principles And LubricationAnd LubricationAnd Lubrication

Certification Matters:Part III

Fig. 1. The simplest gear is the spur type. In this unit, the smaller gear is the “pinion.” The large one is the “bull.”

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Page 9: LMT JulAug 2011

JULY/AUGUST 2011 www.LMTinfo.com | 9

PROFESSIONAL DEVELOPMENT SERIES

Referring to Fig. 1, note that the smaller gear in the spur unit is the pinion; the larger one is a bull gear (also known as a “driven gear”). Typically, gears are speed reducers. The amount of speed reduction is based on the teeth ratio of the pinion and bull gears. For example, if the pinion has 15 teeth and the bull (driven) gear has 75, the reduction ratio is 5:1. A pinion rotating 3000 rpm would result in the shaft of the driven gear to be 600 rpm. The rotation of the bull gear is opposite the rotation of the pinion. To have the same rotation between the pinion and bull gear, an idler gear—which has no effect on speed and torque—is inserted between the pinion and bull gear. Several terms are used to describe the mating action of gear teeth:

1. Pitch is the distance between a point on one tooth and the corresponding point on an adjacent tooth. It is the point on the tooth where rolling motion and the greatest force occur. Pitch circle is the circle formed by the point on each tooth at which meshing action is pure rolling.

2. Sliding motion that occurs above and below the pitch point, called respectively the addendum and dedendum of the tooth, can result in high wear.

3. The pure rolling at the pitch point results in an elastohydro-dynamic lubrication regime characterized by a small solid-like lubricant fi lm one micron or less in thickness. This small fi lm does not prevent asperities (rough surface edges) from coming in contact with the pitch point, and causes

initial pitting along the pitch line of the mating teeth. This is perfectly normal unless the pitting spreads destructively to the dedendum and eventually throughout the tooth.

4. Clearance is the distance between the top of one tooth and the base of the tooth in the other gear.

5. Backlash is the distance between the back of one tooth and the front of the next mating tooth.

Gear types and propertiesGears are classifi ed by shaft orientation. The most common type makes up the parallel shaft group, shown in Fig. 2.

Some confusion can exist between double helical and herring-bone gears: Most people consider them the same. In Fig. 2, though, notice that one of these gears has a strip in the middle and the other has continuous teeth. One defi nition holds that the double helical type has teeth slanting in opposite directions, while the teeth in the herringbone all slant in the same direction. Originally, that strip in the middle of the double helical was needed because of the manufacturing process. Eventually the process allowed all teeth to be continuous with no break in the middle. It should be noted that one of the major disadvantages of the helical gear is that it creates thrust along the shaft. This is eliminated by the use of herringbone (double helical) gears. Typical reduction ratios for parallel shaft gears do not exceed 10:1—and are more like 5:1. Table I summarizes the properties of parallel shaft gears.

Load carried on One tooth Multiple teeth Multiple teethTooth length Short Longer LongestSound Noisy Quieter QuietestBearing thrust No Yes NoMotion Rolling/sliding More sliding Most slidingLoad capacity Low Moderate HighSpeed Low Moderate HighCost Lowest Higher Highest

Table I. Properties of Parallel Shaft Gears

Spur Helical Herringbone

Fig. 2 The parallel shaft group is the most common gear type.

Spur Gear Helical Gear Double Helical Herringbone

Page 10: LMT JulAug 2011

10 | LUBRICATION MANAGEMENT & TEChNOLOGy JULY/AUGUST 2011

PROFESSIONAL DEVELOPMENT SERIES

As illustrated in Fig. 3, the next group of gears, which have shafts at right angles, are divided into intersecting and non-intersecting types.

Both bevel and spiral bevel gears have shafts that inter-sect at the centerline, whereas worm and hypoid gears have non-intersecting shafts with one below the centerline. The properties of right-angle shafts are illustrated in Table II.

It should be noted that hypoid gears are used primarily in automotive applications: They’ve replaced spiral bevel gears in differentials, which results in a much more compact arrange-ment since the shafts can pass each other. They also produce high torque.

Lubrication delivery systemsMost gears are lubricated by splashing oil from a sump onto the gear teeth and bearings. Achieving the right level/delivering the correct amount of lubricant is crucial. If the level is too low, you’ll fi nd yourself dealing with lubricant starvation, increased wear, inadequate heat dissipation and foaming. Too much lubricant, on the other hand, may lead to churning, resulting in higher operating temperatures, a decrease in effi ciency and greater foaming tendency. Typi-cally, for parallel shaft and bevel gears at normal speed

(1000 fpm- 4000 fpm), the oil level ranges from completely covering the bottom teeth up to three times the depth of the bottom teeth—the most common being twice the depth of the bottom teeth. At very low speeds (< 1000 fpm), the level of immersion can be 3-5 times the tooth depth. Lubrication of worm gears is different. Worm gears come in three designs, each with its own lubrication approach:

■Worm on top… the oil level is typically one-third of the wheel diameter.

■Worm on the bottom… the oil level is up to 50% of the worm, which is the center of the meshing zone.

■ Worm at the side… half the wheel is immersed to at least the worm height.

It’s best to adhere to what the OEM recommends for oil level during splash lubrication. The above levels are merely general guidelines.

Be aware that there is a speed limitation on the use of splash lubrication. Speed is measured in meter/second or feet/minute (fpm) and calculated by multiplying the

Table II. Properties of Right-Angle Shaft Gears

Gear Type Advantages Disadvantages

Bevel Gear Spiral Bevel Gear Worm Gear Hypoid Gear

Fig. 3. The right-angle shaft gear group is made up of intersecting and non-intersecting types.

Straight Bevel Economical Low load-carrying ability Low thrust Low speed Maximum reduction ratio 6:1

Spiral Bevel Increased load-carrying ability Axial thrust produced Maximum reduction ratio 6:1

Worm Smooth and quiet Low effi ciency High shock-loading capacity High thrust Reduction ratios as high as 100:1 Run hot (typically 90 F over ambient) Supporting shafts can pass each other High price per horsepower

Hypoid Compact Low effi ciency Moderate load-carrying capacity Run hot (typically 90 F over ambient) Reduction ratios as high as 100:1 Require strong EP additives Supporting shafts can pass each other Lower speed than spiral bevel

Page 11: LMT JulAug 2011

COT Water Removal & Filtration Skids · servo valve stiction · DFE Rated Filter Element Upgrades · wind turbine gearbox lube oil varnish · SVR Soluble Varnish Removal · gas turbines · NSD Non-Sparking Filter Elements · low ISO codes · Steel Mills · water in lube oil · VUD Vacuum Dehydrator · paper mills · coal mill gearbox failures · Filter Carts · FSL Gearbox Fil-tration · compressor lube oil · COT Water Removal & Filtration Skids · servo valve stiction · DFE Rated Filter Element Up-grades · wind turbine gearbox contamination · Dedicated Gearbox Filtration · plastic injection molding · AW hydraulic Oil Varnish Removal · sawmill hydraulic failures · Hy-Pro Total System Cleanliness · rolling mill bearing failures · VUD Vacuum Dehydrator · diesel fuel contamination · COD Off-Line Diesel Purifiers · cooling tower gearboxes · FPL Filter Panel · boiler feed pump · DFN Duplex Filters · phosphate ester acid & gels · ICB Element Technology · drilling rigs · Hy-Pro Extends Oil Life · refinery rotating equipment · Hy-Pro Contamination Solutions Equipment · roll-off cleanliness requirements · DFE Rated Filter Element Upgrades & FSL Skids · reservoir contamination · Hy-Dry Desiccant Breathers · hydraulic, lube oil & diesel reliability · Hy-Pro · lube oil varnish · SVR Soluble Varnish · gas turbines · NSD Non-Sparking Filter Elements · low ISO codes · Steel Mills · water in lube oil · VUD Vacuum Dehydrator · paper mills · Filter Carts · coal mill gearbox failures · FSL Gearbox Filtration · compressor lube oil · COT Water Removal & Filtration Skids · servo valve stiction · DFE Rated Filter Element Upgrades · wind turbine gearbox contamination · Dedicated Gearbox Filtration · plastic injection molding · AW hydraulic Oil Varnish Removal · sawmill hydraulic failures · Hy-Pro Total System Cleanliness · rolling mill bearing fail-ures · VUD Vacuum Dehydrator · diesel fuel contamination · COD Off-Line Diesel Purifiers · cooling tower gearboxes · FPL Filter Panel · boiler feed pump · DFN Duplex Filters · phosphate ester acid & gels · ICB Element Technology · drilling rigs · Hy-Pro Extends Oil Life · refinery rotating equipment · Hy-Pro Contamination Solutions Equipment · roll-off cleanliness requirements · DFE Rated Filter Element Upgrades & FSL Skids · reservoir contamination · Hy-Dry Desiccant Breathers · hydraulic, lube oil & diesel reliability · Hy-Pro · lube oil varnish · SVR Soluble Varnish · gas turbines · NSD Non-Sparking Filter Elements · low ISO codes · Steel Mills · water in lube oil · VUD Vacuum Dehydrator · paper mills · VUD Vacuum De-hydrator · Filter Carts · DFE Rated Filter Element Upgrades · coal mill gearbox failures · FSL Gearbox Filtration · compres-sor lube oil · VUD Vacuum Dehydrator · servo valve stiction · DFE Rated Filter Element Upgrades · wind turbine gearbox contamination · Dedicated Gearbox Filtration · plastic injection molding · AW hydraulic Oil Varnish Removal · sawmill hydraulic failures · Hy-Pro Total System Cleanliness · rolling mill bearing failures · VUD Vacuum Dehydrator · diesel fuel contamination · COD Off-Line Diesel Purifiers · cooling tower gearboxes · FPL Filter Panel · boiler feed pump · DFN Duplex Filters · phosphate ester acid & gels · ICB Element Technology · drilling rigs · Hy-Pro Extends Oil Life · refinery rotating equipment · Hy-Pro Contamination Solutions Equipment · roll-off cleanliness requirements · DFE Rated Filter Element Upgrades & FSL Skids · reservoir contamination · Hy-Dry Desiccant Breathers · hydraulic, lube oil & diesel reliability · Hy-Pro · lube oil varnish · SVR Soluble Varnish · gas turbines · NSD Non-Sparking Filter Elements · low ISO codes · Steel Mills · water in lube oil · paper mills · Filter Carts · coal mill gearbox failures · FSL Gearbox Filtration · compressor lube oil · COT Water Removal & Filtration Skids · servo valve stiction · DFE Rated Filter Element Upgrades · wind turbine gearbox contamination · Dedicated Gearbox Filtration · plastic injection molding · AW hydraulic Oil Varnish Removal · sawmill hydraulic failures · Hy-Pro Total System Cleanliness · rolling mill bearing failures · VUD Vacuum Dehydrator · diesel fuel contamination · COD Off-Line Diesel Purifiers · cooling tower gearboxes · FPL Filter Panel · boiler feed pump · DFN Duplex Filters · phosphate ester acid & geaaaaaaaaaaaaaaaa ls · ICB Element Technology · Hy-Pro Extends Oil Life · refinery ro-tating equipment · Hy-Pro Contamination Solutions Equipment · roll-off cleanliness requirements · DFE Rated Filter Ele-ment Upgrades & FSL Skids · reservoir contamination · Hy-Dry Desiccant Breathers · hydraulic, lube oil & diesel reliability · Hy-Pro · lube oil varnish · SVR Soluble Varnish · gas turbines · NSD Non-Sparking Filter Elements · low ISO codes · Steel Mills · water in lube oil · VUD Vacuum Dehydrator · paper mills · Filter Carts · coal mill gearbox failures · FSL Gearbox Filtration · compressor lube oil · COT Water Removal & Filtr · Lower ISO Codes · DFE Rated Filter Element Upgrades · wind turbine gearbox contamination · Dedicated Gearbox Filtration · plastic injection molding · AW hydraulic Oil Varnish Removal · sawmill hydraulic failures · Hy-Pro Total System Cleanliness · rolling mill bearing failures · VUD Vacuum Dehy-drator · diesel fuel contamination · COD Off-Line Diesel Purifiers · cooling tower gearboxes · FPL Filter Panel · boiler feed pump · DFN Duplex Filters · phosphate ester acid & gels · ICB Element Technology · drilling rigs · Hy-Pro Extends Oil Life · refinery rotating equipment · Hy-Pro Contamination Solutions Equipment · roll-off cleanliness requirements · DFE Rated codes · Steel Mills · SVR Soluble Varnish Removal · VUD Vacuum Dehydrator · paper mills · Filter Carts · coal mill gearbox failures · FSL Gearbox Filtration · compressor lube oil · COT Water Removal & Filtration Skids · servo valve stiction · DFE Rated Filter · wind turbine gearbox contamination · Dedicated Gearbox Filtration · plastic injection molding · AW hy

Removal · sawmill hydraulic failures · Hy-Pro Total System Cleanliness · rolling mill bearing failures · VUD Vacuum Dehydrator · diesel fuel contamination · COD Off-Line Diesel Purifiers · cooling tower gearboxes · FPL Filter Panel · boiler feed

ICB Element Technology · drilling rigs · Hy-Pro Extends Oil Life · refinery rotating equipment · Hy-Pro Contamination Solutions Equipment · roll-off cleanliness requirements · DFE Rated

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DFN Duplex Filters · phosphate ester acid & gels · ICB Element Technology · drilling rigs · Hy-Pro Extends Oil Life · refinery rotating equipment · Hy-Pro Contamination Solutions Equipment · roll-off cleanliness

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Page 12: LMT JulAug 2011

12 | LUBRICATION MANAGEMENT & TEChNOLOGy JULY/AUGUST 2011

PROFESSIONAL DEVELOPMENT SERIES

circumference of the gear (π x diameter). For example, a 12” diameter gear, running at 1000 rpm, will have a speed of 3140 fpm (3.14 x 1 ft x 1000 rpm). With no design changes, a splash-lubrication system can usually operate up to 4000 fpm. By installing baffl e plates and oil pockets, the speed can reach 11,000 fpm. At higher speeds, a pressure-circulation system is used. The two major types are dry sump(where the oil is stored outside the gearbox), or wet sump(where the oil is in the gearbox). In a pressure-circulation system, oil is sprayed directly at the teeth contact points.

Lubricant selectionThe most important property for an oil used to lubricate enclosed gears is correct viscosity. The major variable in viscosity selection is the speed of the gears expressed in pitch line velocity, which is defi ned as speed of the gear in rpm times the circular pitch diameter in inches. The American Gear Manufacturers Association (AGMA) publishes viscosity recom-mendations based on pitch line velocity. Robert Errichello, a world-renowned expert on gear failure analysis, has developed the following simplifi ed formula for determining the correct viscosity to use on enclosed gears:

Table III notes the most common viscosities and gear oil types for enclosed gearboxes.

Keep in mind that Table III is only a summary of the most common viscosity grades for enclosed gears: It incorporates the old AGMA system, which has been changed. New tables no longer include the AGMA number. Many gearboxes still refl ect the old system where viscosity grades were also expressed as a single digit number. Referring to Table III, we see the outdated AGMA number for ISO 220 gear oil is 5. To purchase the most up-to-date AGMA Classifi cation System chart, go to www.AGMA.org. Once the correct vis-cosity has been determined, the oil type must be selected. Options include rust and oxidation (R&O) inhibited lubricants, synthetics, extreme pressure (EP) products and compounded oils. Table IV lists the types of oils used on enclosed reducer gearboxes.

Table IV refl ects general guidelines only: There are many exceptions. The following are additional comments on oil selection for reducer gearboxes:

■ The most common viscosity grade for both parallel shaft and right-angle intersecting gears is ISO 220 EP. When in doubt about using EP oil, go with it.

■ Worm gears experience high sliding, and the ring gear is typically bronze. EP additives are not recommended because of the additive attack on the yellow metal at high temperatures.

◆ Although new EP additives are less aggressive, in some cases such additives are not activated by the yellow metal and steel contact and serve no purpose in the formulation.

◆ Traditionally, worm gears were lubricated with oils compounded with synthetic animal fat to provide protection during the severe sliding that occurs.

V1 = pitchline velocity of the lowest speed pinion in feet/minute (fpm)

fpm = 0.262 x speed (pinion rpm) x pinion diameter (inches)

Ambient temperature adjustments: 95 F increase ISO grade by one 122 F increase ISO grade by two

Viscosity40

= 7000√ V

1

Table III. AGMA Gear Oil Viscosity Classifi cation System

Spur, Helical, 150-320 EP Herringbone PAO, PAG

Bevel, 150-320 EP Spiral Bevel PAO, PAG

Worm 460-1000 Compounded PAO PAG

Hypoid 460 EP

Table IV. The Most Common Gear Oils for Enclosed Reducer Gearboxes

32 32 S 046 46 S 168 68 EP 68 S 2100 100 EP 100 S 3150 150 EP 150 S 4220 220 EP 220 S 5320 320 EP 320 S 6460 460 Comp 460 EP 460 S 7680 680 Comp 680 EP 680 S 81000 1000 Comp 1000 EP 1000 S 9

R&O Compounded Extreme

Pressure (EP) Synthetic AGMA #

Gear Type ISO Viscosity Range Oil Type

Source: American Gear Manufacturers Association (AGMA)

Page 13: LMT JulAug 2011

JULY/AUGUST 2011 www.LMTinfo.com | 13

PROFESSIONAL DEVELOPMENT SERIES

◆ PAOs have been success-fully used in worm gears by providing protection during severe sliding without the use of EP additives. They also lower the temperature of the box and are completely compatible withmineral oils.

◆ PAGs are the lubricants of choice on new gearboxes as they provide the best effi ciency. They’re also used in small, sealed-for-life worm gearboxes. If changing from another type of oil to a PAG, follow proper fl ushing procedures. PAGs are incompatible with mineral oils and PAOs.

■ Although hypoid gears are used mainly in automotive applications, they do have a few industrial uses. The severe sliding that occurs in these types of gears calls for very aggressive EP additives in high concentrations. Typical EP indus-trial oils will not provide the neces-sary protection for hypoid gears.

This information is just a start: More details on gear oils can be obtained from product data sheets.

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Correct viscosity is the most important property of

an oil used in the lubrication of enclosed gears.

NOTE: While a product data sheet provides useful informa-tion, the true test of a gear oil is how it works in the system. Adhere to OEM guidelines and consult with your lube supplier for further information.

Page 14: LMT JulAug 2011

14 | LUBRICATION MANAGEMENT & TEChNOLOGy JULY/AUGUST 2011

PROFESSIONAL DEVELOPMENT SERIES

Gear failure modesThe major factors affecting gear life are load, environment, temperature and speed. Wear modes are summarized as follows:

1. Adhesive wear is caused by an inadequate lubricant film under severe boundary-lubrication conditions. This situation may require the use of higher-viscosity oil with an EP additive.

2. Abrasive wear is caused by hard particles in the oil gouging the gear teeth. The degree of wear is related to hardness and amount of particles present. Some have the misconception that gear oils don’t need a high cleanliness standard. That is incorrect: Gear oils should be kept as clean as possible. Very clean oil in a gearbox would be 17/15/13.

3. Surface fatigue is material failure caused by repeated surface and sub-surface stresses beyond the endurance limit of the metal that result in surface pitting.

◆ Initial pitting occurs at the pitchline where the lubri-cant film is very thin, resulting in asperity removal creating a smoother surface. This is perfectly normal and should be no cause for concern.

◆ Normal pitting occurs in the root part of the tooth (dedendum) and usually stabilizes. It occurs primarily when gear loads are close to the maximum and should be watched closely.

◆ Destructive pitting starts at the pitchline and progresses until the tooth is destroyed and is caused by surface overload conditions. This can be seen in Fig. 4.

4. Plastic flow is the deformation of gear teeth due to severe overload—this condition is NOT lubrication-related. It can be caused by unhardened teeth subjected to heavy loads (particularly shock-loading) causing surface mate-rial to be squeezed out at the tips of the teeth, shown in Fig. 5. (The ridging on the side of the tooth indicates plastic flow.)

5. Tooth breakage is primarily caused by severe surface over-load, but also could result from severe surface fatigue that significantly weakens the tooth.

Fig. 4. Destructive pitting is caused by surface overload conditions.

Fig. 5. Ridging on the side of a deformed gear tooth indicates a condition known as plastic flow, which is caused by severe over-load. (This is NOT a lubrication-related condition.)

ConclusionGears are an integral part of many manufacturing processes: A failure of a gear can have an enormous impact on produc-tion. These components must be lubricated properly and maintained to achieve long life. Oil analysis is an important predictive tool in monitoring gear wear. (This topic will be discussed in a later installment of our series.)

Coming upThe next installment in this series discusses the Basic Prin-ciples of Fluid Power. Look for it in the September/October issue of LMT.

Ray Thibault is based in Cypress (Houston), TX. An STLE-Certified Lubrication Specialist and Oil Monitoring Analyst, he conducts extensive training for operations around the world. Telephone: (281) 257-1526; email: [email protected].

Hypoid gears call for very aggressive

EP additives in high concentrations.

Typical EP industrial oils won’t work for them.

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The New Gearmotor Gold Standard

©2011 Baldor Electric Company

• Energy Efficient

• Unmatched Quality

• Superior Reliability

• Quickest Delivery Available

The new Baldor•Dodge® Quantis® Gold gearmotor combines the Baldor•Reliance® premium efficient Super-E® motor with the superior Quantis gearbox, making the Quantis Gold the most energy efficient, coolest running gearmotor in the world.

Available as in-line helical or right angle helical bevel c-face units, 1/2 to 10 Hp, the Quantis Gold raises gearmotor energy efficiency, quality and reliability to a new gold standard.

dodge-pt.com baldor.com 479-646-4711

For more information on EISA, scan with a QR reader app on your smartphone.

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©

IT TAKES ONE TO KNOW ONE...

The Innovators Of

Are Proud To Sponsor The Maintenance & Reliability

Innovator Of The Year Award

The innovators of INPRO/SEAL

will provide individual iPads and cases to the

Grand Prize winner and 3 Innovation Category winners.

WHAT ABOUT YOUR INNOVATION?All entries have a shot at the Grand Prize and three Category* Awards to be announced in early 2012. Deadline for submissions is December 31, 2011. Four more monthly winners will be announced through the end of the year. Don’t Procrastinate. . . Innovate!Enter now. For complete details and submission forms, go to www.ReliablityInnovator.com

There’s more than just bragging rights at stake...

Presented By Applied Technology Publications

As Grand Prize Winner, You Could Win An Expense-Paid Trip To MARTS 2012 and more,

including special prizes from the Innovators of Inpro/Seal, Royal Purple and Scalewatcher!

More About Our Monthly Winner For June...Reader Dale Westrick made it into the June winner’s circle with his development of an innovative spray-system nozzle assembly for applications ranging from the washing of dairy-cases to the cleaning of industrial tanks. Westrick notes that this innovation can reduce maintenance for cleaning of nozzles and improve cleaning processes without the need to shut down equipment. If used with cooling-tower sprays, he says it could reduce the amount of regular cleaning.

Announcing Our Monthly Winner For July... Our July winner is a team from Sandia National Laboratories (Sandia), led by facilities manager Mike Quinlan. Working with Doc Palmer as a third-party resource, Quinlan and his team innovated their way to more effi cient creation of weekly schedules for Sandia’s maintenance planners. Read more about about this monthly winner in the August issue.

Categories include innovative devices gizmos and gadgets; innovative processes and procedures; and

innovative use of outside resources.*Categories include innovative devices gizmos and gadgets; innovative processes and procedures; and innovative use of outside resources.

Inventor of the original Bearing Isolator, Inpro/Seal has been delivering innovative sealing solutions and superior customer service for more than 30 years. Now part of Waukesha Bearings and Dover Corp., Inpro/Seal is stronger and more innovative than ever and continues to invest in technology and product development. This brand built its reputation on the outstanding performance of the original Bearing Isolator, which increases the reliability of rotating equipment and provides cost savings by improving mean-time-between-repair (MTBR). Plus, Inpro/Seal offers same- or next-day shipments, even on new designs. But Bearing Isolators were just the start. In response to customer needs, Inpro/Seal now offers the Air Mizer®, for sealing a variety of product-handling equipment; the Current Diverter Ring™ (CDR®), which protects motor bearings and coupled equip-ment by diverting damaging electrical currents to ground; and the Motor Grounding Seal (MGS®) that combines CDR technology with the complete protection of a Bearing Isolator to safeguard bear-ings from electrical currents and contamination.

Inpro/SealRock Island, IL

www.inpro-seal.com

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16 | LUBRICATION MANAGEMENT & TECHNOLOGY JULY/AUGUST 2011

Page 17: LMT JulAug 2011

...AN INNOVATOR, THAT IS!

The Innovators Of The Innovators Of

Are Proud To Sponsor The Maintenance & Reliability

Innovator Of The Year Award

Are Proud To Sponsor The Maintenance & Reliability

Innovator Of The Year Award

The innovators of ROYAL PURPLE

will provide individual cases of Royal Purple products to the

Grand Prize winner and 3 Innovation Category winners.

The innovators of SCALEWATCHER

will provide individual water treatment units to the

Grand Prize winner and 3 Innovation Category winners.

Categories include innovative devices gizmos and gadgets; innovative processes and procedures; and

innovative use of outside resources.

Categories include innovative devices gizmos and gadgets; innovative processes and procedures; and

innovative use of outside resources.

Lubricant performance can vary greatly between competing mineral-based and synthetic products. According to the innovators of Royal Purple, since quality differences can signifi cantly impact the cost of operating and maintaining equipment, your lube purchases can’t be effectively managed as a commodity: Lubricant excellence is paramount. The company notes that benefi ts attainable across a broad population of rotating equipment from up-grading to Royal Purple lubricants include, among other things, energy savings greater than 3%, and a reduction in the need for equipment repair by at least 30%. Although Royal Purple products may cost more per gallon, an operation’s annual cost for lubricants changes little, due to greatly extend-ed drain intervals and the elimination of oil chang-es associated with equipment repairs. Initiatives to reduce maintenance and improve equipment reliability often are time- and people-intensive. Royal Purple offers substantial improvements and savings simply through replacement of a product you already buy and use. It doesn’t get any easier than this.

Scalewatcher™ is a no-maintenance environmen-tally friendly descaler that does not change water composition. Scales and stains disappear gradu-ally and completely, without further action required, guaranteed. The Scalewatcher products work by way of magnetic and electric fi elds and a continu-ously changing frequency. The process forces dis-solved minerals such as calcium and magnesium to crystallize before mineral ions (the cause of hard scale) can settle on surfaces. This stops or reduces new buildup of hard scale, and because the water is better able to dissolve minerals, existing hard-scale layers are softened and eventually disappear. The Scalewatcher technol-ogy has been used by more than 250,000 satisfi ed customers worldwide. These products prevent corrosion in pipework; prevent settlement of zebra mussels in plants using sea or river water for cool-ing; reduce bacterial counts in cooling systems; cut water and energy bills; extend the life of water-using equipment (especially boilers); can be installed without plant shutdown; are mainte-nance-free; and last 20+ years.

Royal PurplePorter, TX

www.royal-purple-industrial.com

Scalewatcher North America, Inc.Oxford, PA

www.scalewatcher.com

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Page 18: LMT JulAug 2011

18 | LUBRICATION MANAGEMENT & TECHNOLOGY JULY/AUGUST 2011

LAB SPOTLIGHT

Elemental Analysis

An element, in the simplest of

terms, can be defi ned as a pure,

naturally occurring chemical

substance made up of a single

unique type of atom. Elements in an

oil can come from additives added to

the virgin base stock, as well as from

contaminants, wear metals or cool-

ants that have found their way into the

lubricant over its life cycle. Analyzing

used oil for these known elements

can help determine if the lubricant is

still fi t for use or requires change. Has

the original additive package been

depleted? Has the lubricant become

contaminated and to what extent?

Have wear metals begun showing up

and are they a problem?

Make sure this ‘exciting’ methodology is part of

your predictive maintenance toolkit.

Referencing used oil against a virgin oil sample can pinpoint which elements should and should not be present. Combined with an under-standing of the industry and service for which the oil is designed (i.e., gearbox, internal combustion engine, hydraulic system, cooling system, etc.), this type of analysis can help detect where the unwanted elements may have originated and, in turn, predict impending mechanical failure.

Elemental analysis is done through emission spectrometry. Today, the most commonly performed procedure of this type is atomic emission spectroscopy (AES). This test has been around for approximately 60 years. Originally a tool of the railroad industry for monitoring wear metals in diesel-engine oils, it’s now used on all types of equipment—and is a major component of comprehensive oil-analysis programs.

MethodologyIn AES, the electrons in metal particles are excited into a higher energy state. As they revert to a lower energy state, they release light energy—which is inversely proportional to the wavelength and dependent on the atomic structure of the metal. Each metal will release energy at a specifi c, identifi able wavelength. The intensity of the light that’s measured relates to the concentration of the metal present in the oil sample and is reported in parts per million (ppm). Based on the spectrum produced by the excited particles (see Fig. 1), and the method used to excite them, up to 75 metallic elements in a lubricant can be identifi ed.

Inductively Coupled Plasma (ICP) and Rotating Disc Electrode (RDE) are the two methods used to excite the metal particles. In ICP, the elements are vaporized and excited by injecting a sample diluted with solvent into high-temperature argon plasma. The RDE method utilizes a high-energy electrode spark on a carbon wheel that rotates in the oil sample to excite the metallic elements.

Jane Alexander, Editorwith

Ken Bannister and Ray Thibault

© M

IAM

IAM

IA @

SXC.

HU

Page 19: LMT JulAug 2011

JULY/AUGUST 2011 www.LMTinfo.com | 19

LAB SPOTLIGHT

ParametersElemental analysis (i.e., AES) is a powerful test, but not perfect. One of its major drawbacks involves the size limita-tion of the metallic elements that can be detected.

With RDE, the particle sizes detected are no larger than 8-10 microns. The ICP method detects metals no larger than 3-5 microns. Softer metals are easier to excite and can be detected at a higher size range than hard metals. Interest-ingly, while many labs are moving from RDE to ICP, both methods have advantages.

RDE…■ Detects larger particle sizes.■ Detects up to 25 metallic elements.■ No sample dilution is required.

ICP…■ Detects up to 75 metallic elements.■ Is more accurate at smaller size ranges and used for quality

control of additive concentrations in fi nished lubricants.■ Newer, automated ICPs run samples faster.

Figure 2 depicts how elemental analysis data is typically documented in an oil-analysis report. It’s segregated into three major groups: Wear, Contaminants and Additives.

ConclusionElemental analysis—in the form of atomic emission spectros-copy—is a valuable predictive maintenance tool. Keep in mind, however, that it does have critical limitations (espe-cially with regard to the size of particles it can pinpoint). While AES can identify early rubbing wear, it is unable to fi nd large particles that lead to catastrophic failure. The lesson? Don’t depend solely on elemental analysis for particle detection. That said, in the September/October issue, we’ll examine Ferrography Testing. LMT

This article is based on material from Ken Bannister’s best-selling book, Lubrication for Industry (Industrial Press), and Ray Thibault’s article “Introduction to the Use of Atomic Emission Spectroscopy as a Predictive Maintenance Tool” (pgs 30-35, Lubrication & Fluid Power [now LMT], September/October 2006).

Fe

Cr

Al

Cu

Pb

Sn

Fig. 2. Elemental analysis data as produced in a typical oil-analysis report

Fe

Cr

Al

Cu

Pb

Sn

Fig. 1. Excitation of metal particles in an oil sample results in a spectrum that can be used to identify up to 75 elements.

Iron

Fe

Chromium

Cr

Nickel

Ni

Aluminum

Al

Copper

Cu

Lead

Pb

Tin

Sn

Silver

Ag

Silicon

Si

Sodium

Na

Potassium

K

Molybdenum

Mo

Boron

B

Magnesium

Mg

Calcium

Ca

Barium

Ba

Phosphorus

P

Zinc

Zn

Wear Contaminants Additives

Page 20: LMT JulAug 2011

20 | LUBRICATION MANAGEMENT & TECHNOLOGY JULY/AUGUST 2011

PRODUCT SHOWCASE

For more info, enter 33 at www.LMTfreeinfo.comFor more info, enter 31 at www.LMTfreeinfo.com

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Shell Omala S2 G Oil

Shell Omala S2 G oil is formulated for extra protec-tion and performance of industrial gears. It offers the type of corrosion protection and water separa-

tion capabilities that help keep equipment working effi ciently in severe service. Applications include lubrica-tion of enclosed industrial spur and bevel gearboxes in extreme-pressure and highly loaded systems and of bear-ings and other components in circulating and splash-lubricated systems.

Shell LubricantsHouston, TX

Dupont Tefl on Severe Service Grease

Tefl on™ Severe Service Grease from DuPont™ is a multi-functional industrial-grade grease suited for most heavy-duty and industrial applications. DuPont

notes the product’s new thickener technology, Overbased Calcium Sulfonate, offers water washout and mechanical stability properties that surpass lithium complex greases. A high dropping point ensures superior retention in high-temperature applications and provides rust and corrosion protection, especially in salt-water and high-moisture environments.

DuPontWilmington, DE

Tough Stuff Extreme & Severe ServiceLUBRICANTS

Hydrex Extreme From Petro-Canada

Petro-Canada’s Hydrex Extreme is a premium-quality, high-performance hydraulic fl uid designed for use in both mobile and industrial equipment. Starting with

a patented HT process that produces 99.9% pure base oils, the product is specially formulated to deliver enhanced oxidation and shear stability and anti-wear protection. According to the manufacturer, Hydrex Extreme helps reduce sludge buildup and harmful varnish deposits and is inherently biodegradable.

Petro-Canada Lubricants, Inc.Mississauga, ON

Royal Purple Open Gear Guard XP

Open Gear Guard XP is designed to lubricate open gears and chains subjected to heavy loads in dusty or dirty environments. A thixotrophic lubricant blended with a

solvent carrier, it’s easily applied by spraying or brushing and can effectively lubricate at temperatures up to 400 F. Once applied, the carrier fi lm evaporates, leaving a dry, wax-like lubricating fi lm that minimizes collection of dust and other contaminants. The fi lm consists of calcium carbonate and calcium sulfate, both naturally occurring minerals.

Royal Purple, Inc.Porter, TX

Page 21: LMT JulAug 2011

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Mobil Glygoyle Series Lubricants

Mobil Glygoyle Series lubricants are fully synthetic gear, bearing and compressor oils developed for

use under operating conditions beyond the capabilities of other synthetic and mineral-based products. Low pour points of these PAGs ensure excellent low-temperature fl uidity while their formulation provides EP/antiwear protection for critical equipment components, micropitting protection for sensitive gear systems and protec-tion against rust and corrosion.

ExxonMobil Corp.Fairfax, VA

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CRC Extreme Duty Food Grade Grease

CRC Extreme Duty Food Grade Grease is a high-performance product for use where incidental contact with food is possible. It excels where resistance to water washout and broad operating temperatures are required. Formulated without

heavy metals or undesirable additives, it withstands extreme pressures and corrosion, including salt spray, and retains mechanical stability even in the presence of water.

CRC IndustriesWarminster, PA

Bel-Ray 1030 Grease

Bel-Ray’s 1030 Grease is a heavy-duty, non-melting, silicone-based product designed for harsh chemical environments. The manufacturer notes that this grease has excellent extreme-pressure, antiwear, thermal-stability and waterproof

properties, as well as a useful temperature range from -40 F to 400 F (-40 C to 204 C). The properties of its base materials protect against moisture and corrosion while exhibiting little change throughout the recommended temperature range.

Bel-Ray Co., Inc. Farmingdale, NJ For more info, enter 35 at www.LMTfreeinfo.com

PRODUCT SHOWCASE

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22 | LUBRICATION MANAGEMENT & TECHNOLOGY JULY/AUGUST 2011

DELIVERING THE GOODS

First introduced by the Farval Lubrication

company, the Dual Line centralized delivery

system (also known as a Twin-Line Parallel)

was designed to accurately displace and move

oil or grease over great distances from a single

pumping station to as few as 20 lubrication points

and up to many hundreds of points. The system’s

heavy-duty construction and use of small-bore

piping and tubing made it an ideal choice for

automated lubrication in medium- and large-sized

industrial equipment typically found in the steel,

mining, pulp and paper, power-generation and

petrochemical industries.

The Dual Line lubrication system bears many similarities to the Positive Displacement Injector (PDI) or Single Line Parallel system, in that each metering valve—or point—can be set independently or easily adjusted during operation. This unique feature also enables additional injectors (lube points) to be added into the system at a later date, without the need to re-engineer the entire system.

How the System WorksAs its name suggests, the Dual Line system employs two main lubrication lines that run in parallel from the pump to the last lubrication point through a series of lubrication delivery valves. Once the pump is activated, line pressure is built up on the pressure or delivery supply line to fi re the lubrication point injectors while simultaneously venting the second return line back through a reversing valve to the reservoir.

Dual Line injectors differ from Single Line injectors in that they do not use a spring arrangement to fi re and load

The Anatomy Of A Centralized Lubrication System

Dual Line Systems

Ken BannisterContributing Editor

Dropsa’s DM-XOVER sub-base gives customers with existing traditional dual line delivery systems the option to easily switch over to a modular design concept and take advantage of numerous benefi ts that modularity offers, including reduced risk of contamination and less downtime. There’s no need to change pipe-work or fi ttings. This drop-in upgrade is supplied with the divider valves preassembled onto the sub-base plate along with a bracket to secure the base.

Ken Bannister

Dropsa’s DM-XOVER sub-base Dropsa’s DM-XOVER sub-base gives customers with existing traditional dual line delivery systems the option to easily switch over to a modular design concept and take advantage of numerous benefi ts that modularity offers, including reduced risk of contamination and less downtime. There’s no need to change pipe-work or fi ttings. This drop-in upgrade is supplied with the divider valves preassembled onto the sub-base plate along with a

Page 23: LMT JulAug 2011

JULY/AUGUST 2011 www.LMTinfo.com | 23

the injector. Instead, they employ a dual-acting hydraulic spool valve set up to feed two separate lubrication points (one per each pressure cycle).

Once an end-of-line pressure switch signals that a preset line pressure has been reached and all injectors have fi red, the system has completed one pressure cycle—or a one-half lubrication cycle. The reversing valve is then actuated to its changeover position to allow the previous venting line to become the new primary pressure line and the process is repeated to complete one full-lubrication cycle.

These systems can operate in manual mode with a pull-handle pump, as well as in full automatic mode.

Pros & ConsBecause Dual Line systems can be used with oil and grease, their engineering is not demanding—and can easily accom-modate the addition or reduction of system points after they’ve been installed.

As with Single Line systems, the adjustable injectors are easily tampered with and can lead to an over- or under-lubrication condition unless they are access-controlled.

A pressure-line failure is easily detected through a time-out switch located at the end of line. No secondary-line failure device is available. Users must perform system line integrity checks as part of their PM programs. LMT

For more details on centralized lubrication systems, see Ken Bannister’s book, Lubrication For Industry, published by Industrial Press, or contact him directly. Telephone: (519) 469-9173; email: [email protected].

For more info, enter 65 at www.LMTfreeinfo.comFor more info, enter 03 at www.LMTfreeinfo.com

Founded in 1946 in Milan, Italy, Dropsa is one of the world’s leading producers of centralized lubrication systems and components. According to Dropsa, as it has for more than 60 years, it continues to innovate in the fi eld of lubrication technology and now offers a wide range of products in the areas of Total Loss Oil, Grease Lubrication, Re-circulating Oil and Air/Oil Lubrication. All of them are backed by a production program catering to “the most diverse lubrication applications, from small machine tools to transfer lines, printing presses, paper machines, steel mills and practically all other sectors of industry.”

Based in Sterling Heights, MI, Dropsa USA coordinates the company’s network of distributors and specialist part-ners in the United States. In addition to maintaining an experienced team to support customers, this facility houses a full-product training center for customers and distributors.

Delivering innovation and high-performance solutions...

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JULY/AUGUST 2011 www.LMTinfo.com | 25

PROBLEM SOLVERS

Attention-Grabbing, Cut-Resistant Safety Gloves

Youngstown Glove’s Titan XT™ lined with Kevlar® product is highly visible, cut-resistant and durable. Foam padding and TPR knuckles across the top of

the hand protect users from smashes, pinches and cuts due to heavy machinery, power tools and broken glass. The company says the palms on these colorful products exceed Level 3 on the ANSI/ISEA 105-2005 Mechanical ratings for cut resistance.

Youngstown Glove Co.Agoura Hills, CA

Advanced-Pattern-Recognition Condition Monitoring

General Physics has integrated advanced pattern recognition

(APR) technology into the Version 10 of its EtaPRO™ Performance and Condition Moni-toring System to track equipment health para-meters such as shaft vibration and bearing temperatures. The product provides early warning of impending equip-ment failure by continuously comparing current values to detailed empirical models of “normal” data.

General Physics Corp.Amherst, NY

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26 | LUBRICATION MANAGEMENT & TECHNOLOGY JULY/AUGUST 2011

PROBLEM SOLVERS

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Expanded Line Of Oil-Soluble PAG Synthetic Base Fluids

Dow Chemical has added three new ISO viscosity grades to its existing line of UCON™ Oil Soluble Polyalkylene Glycol (OSP) Base Fluids. ISO viscosity

grades 320, 460 and 680 now complement the existing ISO viscosity grades 32, 46, 68, 150 and 220. The fl uids are used as primary base oils, co-base oils and as addi-tives in automotive and industrial lubricants. They allow formulators to incorporate the advantages of a PAG synthetic base fl uid in combination with mineral, synthetic hydrocarbon or other oils.

The Dow Chemical Co.Midland, MI

Portable Grease Test Kit

SKF’s Grease Test Kit is a portable, user-friendly option for performing bearing grease condition assessments in the fi eld. It lets

users who have had no special training collect samples and evaluate for grease consistency, oil-bleeding character-istics and contamina-tion, without harmful chemicals. The kit is equipped with instruc-tions, tools for sam-pling and testing and guidelines to interpret results. Only 0.5 grams of grease is required to perform all three tests.

SKFLansdale, PA

Non-Electric, Liquid Drum Vacuum

Exair’s compressed air-powered Reversible Drum Vac™ offers an effective way to clean up liquids, including coolants, hydraulic oils, spills, sludge, tramp oil and waste-

water. With no moving parts, it provides maintenance-free operation. This system includes a 110-gal. drum with bolt ring and lid, shut-off valve, drum dolly, 10’ vacuum hose, ABS Spill Recovery Kit, aluminum wand, 11” and 24” crevice tools, skimmer tool, 20’ compressed air hose and tool holder.

Exair Corp. Cincinnati, OH

Page 27: LMT JulAug 2011

JULY/AUGUST 2011 www.LMTinfo.com | 27

PROBLEM SOLVERS

For more info, enter 41 at www.LMTfreeinfo.comFor more info, enter 40 at www.LMTfreeinfo.com

The Experts are in Toronto

this Fall

IMEC is organized by:

International Maintenance Excellence Conference

October 5 to 7

International Maintenance Excellence Conference October 5 to 7 October 5 to 7

Intrinsically Safe, Mercury-Free Thermometer

Fluke’s 1551A “Stik” thermometer offers accur-acy, durabili-ty and safety,

and they do it all with no mercury. This ATEX- and IECEx-certified unit can be used in environments where potentially explosive gases are present. According to Fluke, the instrument is capable of repeatable accuracy of +0.09 F (± 0.05 C) over itsfull range from -58 F to 320 F (-50 C to 160 C).

Fluke Corp.Everett, WA

Electric Heating For Asphalt Pumps

Electric heat is now available on Viking’s Universal Seal series cast iron asphalt pumps. A patent-pending design uses heat cartridges in

the head crescent to quickly melt asphalt throughout the casing. Two heat cartridges on the bracket fl ange behind the rotor ensure suffi cient heating in the shaft bushing and stuffi ngbox. A temperature-control system incorporates a thermocouple and thermowell adapter for mounting in the bracket port and a controller that powers all heat cartridges on the pump. Viking says electric heating can offer a number of advantages over steam, hot oil and electric heat tracing, including lower installation costs, reduced environmental and energy costs, simplifi ed service and improved safety.

Viking PumpA Unit of IDEX Corp.Cedar Falls, IA

The 2011 International Maintenance Excellence Conference IMEC October 5 to 7 in Toronto, Canada

Expand your knowledge in unexpected ways by joining maintenance and asset-management professionals from around the world at the seventh-annual International Maintenance Excellence Conference. IMEC’s two days of keynote presentations and one day of in-depth workshops are presented with academic and industrial perspectives that deliver well-rounded interpretations of modern issues.

Hosted by Dr. Andrew Jardine of the University of Toronto’s Centre for Maintenance Optimization & Reliability Engineering and co-produced with Maintenance Technology magazine, IMEC 2011 takes place at the University’s convenient, full-service conference venue located in the heart of beautiful downtown Toronto.

Don’t miss this unique, multi-dimensional learning opportunity for maintenance professionals everywhere!

Learn more about IMEC at www.imec.caor contact Bill Kiesel at [email protected] / 847-382-8100, ext. 116

For more info, enter 72 at www.LMTfreeinfo.com

Page 28: LMT JulAug 2011

28 | LUBRICATION MANAGEMENT & TECHNOLOGY JULY/AUGUST 2011

PROBLEM SOLVERS

For more info, enter 43 at www.LMTfreeinfo.comFor more info, enter 42 at www.LMTfreeinfo.com

For more information on this “expert in a box” approach to successful lubrication programs, contact ENGTECH Industries

at 519.469.9173 or email [email protected]* Amortized over one year

Tap into your Liquid Gold for less than $20 per day!*

Tap into your Liquid Gold for Tap into your Liquid Gold for less than $20 per day!*

Whether you’re looking to increase asset utilization and maintainability, reduce contamination, downtime, energy consumption and/or your

carbon footprint, or simply cut your maintenance and operating costs, you’re ready for a 7-Step Best Practice lubrication program!

7-Step Best Practice Lubrication ProgramProfessional Self-Directed Implementation ToolKit

For more info, enter 73 at www.LMTfreeinfo.com

Electric Utility Vehicle For Moving Maintenance Teams

The rugged Polaris Ranger EV LSV can be an effi cient means

of moving maintenance teams around an opera-tion. Both electric andstreet-legal, this mid-sizeutility vehicle boasts atop speed of 25 mph, all-wheel-drive and a full 10” of ground clearance. Polaris says that with its 11.7 kWh maximum-power battery pack and three-mode system (High, Low and Max), this side-by-side has the longest range in its class (up to 50 miles). Offered as a transportation solution for industries of all types, it can be charged by plugging into a 110V AC outlet.

Polaris Industries, Inc. Medina, MN

Explosion-Proof Motors For Hazardous Duty

The XP100 (1-300 hp) motors from Siemens Industry are UL® and CSA listed for gas and dust ignition-proof environments and suitable for Division 1, Class

I, Groups C & D, Class II, Groups F & G, hazardous area classifi cations. Their electrical design meets or exceeds the requirements of the Energy Independence & Security Act of 2007.

Siemens Industry, Inc.Atlanta, GA

Page 29: LMT JulAug 2011

MARCH/APRIL 2011 www.LMTinfo.com | 29

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.

JULY/AUGUST 2011 • Volume 12, No. 4

Submissions Policy: Lubrication Management &Technology gladly welcomes submissions. By sending us your submission, unless otherwise negoti-ated 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

Baldor Electric Company .........................www.baldor.com .............................. 67 ................... 15Bel-Ray Company .....................................www.belray.com ............................... 64 ..................... 7Des-Case Corporation .............................www.descase.com ............................ 66 ................... 13Dropsa USA Inc ........................................www.dropsa.com ............................. 69 ................... 23Engtech Industries Inc. .............................www.engtechindustries.com........... 73 ................... 28FosteReprints .............................................www.fostereprints.com ................... 62 ..................... 4Hy-Pro Filtration ......................................www.hyprofi ltration.com ............... 65 ................... 11IMEC ..........................................................www.imec.ca ..................................... 72 ................... 27LubeStarz ...................................................www.lmtinfo.com/lubestarz ........... 77 ................... 30NEC Avio Infrared Technologies/SOLTEC ....www.NECAvioinfrared.com........... 70 ................... 25NSK Corporation .....................................www.nskamericas.com .................... 61 ..................... 2Royal Purple ..............................................www.royal-purple-industrial.com .... 75 ................... 32Shell ............................................................www.shell.us/lubricants .................. 63 ..................... 5SMRP .........................................................www.smrp.org/conference.com ..... 68 ................... 21Strategic Work Systems, Inc. ....................www.swspitcrew.com ...................... 71 ................... 26Turbomachinery Lab ................................http://turbolab.tamu.edu ................ 76 ................... 24U.S. Tsubaki Power Transmission, LLC ..longlifelambda.com ......................... 74 ................... 31

ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS

SALES STAFF

CLASSIFIED

For rate information on advertising in the Classifi ed Section Contact your Sales Rep or

JERRY PRESTON: Phone: (480) 396-9585 e-mail: [email protected]

Specializing InMachinery Health Personnel

PM & PdM Field Service • Mgt • Sales • Hrly

Nationwide • Confi dential • All Fees Company Paid

TOLL FREE 877-386-1091www.lineal.com [email protected]

Ellen Sandkam www.atplists.com847-382-8100 x110 / 800-223-3423 x110 [email protected] / [email protected]

ATP List

Services

ATP Services

Customized, Targeted Lists For Your Marketing Needs

JULY/AUGUST 2011 www.LMTinfo.com | 29

www.meltric.com • 800.433.7642

� Disconnect Switch Rated

� Simplifies NFPA 70Ecompliance

SafetyShutter

OFFButton

AR, KS, LA, MO, NM, OK, TX5930 Royal Lane, Suite E #201

Dallas, TX 75230972-816-6745; Fax 972-767-4442

GERRY [email protected]

CLASSIFIED ADVERTISING3629 N. Sonoran Heights

Mesa, AZ 85207480-396-9585

JERRY [email protected]

AZ, CA, CO, ID, MT, NV, OR, UT, WA, WY, AB, BC, MB, SK

3629 N. Sonoran HeightsMesa, AZ 85207

480-396-9585 JERRY PRESTON

[email protected]

IL, IN, IA, MI, MN, NE, ND, SD, WI1300 South Grove Avenue, Suite 105

Barrington, IL 60010847-382-8100 x108; Fax 847-304-8603

TOM [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, DC, DE, FL, GA, MD, MS, NC, NJ, PA, SC, VA, WV 1750 Holmes Drive

West Chester, PA 19382610-793-3093; Fax 610-793-3094

JIM [email protected]

OH, KY, TN135 N. Rocky River Road

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

JOHN [email protected]

Page 30: LMT JulAug 2011

WE’RE BUILDING A TEAM...

We love to learn about LMT readers, including what they do in the fi eld of lubrication (and what they like about their jobs)! Here’s what our July/August Lube Star told us:

30 | LUBRICATION MANAGEMENT & TECHNOLOGY JULY/AUGUST 2011

Meet Our

Company InfoContact Info Herewww.websitehere.com

Follow the instructions for submitting your own application and photo and you might fi nd your work-related profi le in a future LMT issue. We look forward to hearing from you soon!

Company InfoContact Info Herewww.websitehere.com

LubeStarz

LubeStarz

©

WE’RE BUILDING A TEAM...

We love to learn about LMT readers, including what they do in the fi eld

about their jobs)! Here’s what our

Meet OurLubeStarz

LubeStarz

©

Our caps are off to all hardworking Lube Starz, who’ll receive their own baseball caps for making the team. Up for the game? Go to www.lmtinfo.com/lubestarzor www.lubestarz.com to tell us about yourself!

Mark L. Graham, CLS, CLGS, OMA

Title: Technical Services Manager, LubricantsO’Rourke Petroleum Products, based in Houston, TX

Background: Mark has spent a total of 25 years in the maintenance/lubrication arena (14 of them with O’Rourke, including three years in his current role). After graduating from college, this native of Bandera, TX, coached football and baseball in the public schools for awhile before moving into the solvent and chemical business.

Why He Became A Lubrication Professional: Mark’s former employer also carried lubricants in its line. He eventually found himself drawn to that side of the business and began pursuing both on-the-job and formal training in it. Today, he holds certifi cations as a CLGS (from NLGI) and as both a CLS and OMA (from STLE). Over the years, he says he’s been very fortunate “to work with and learn from some of the fi nest individuals in our business.” Mark gives props to John Wagner (of Shell Oil) and Bob Portwood (of Pacer Lubricants) for being tremendous resources in building his lube knowledge and skills. “With all their fi eld experience,” he explains, “they had seen most every-thing that would or could go wrong. I could not have asked for better mentors.”

What He Likes Most About His Work: Mark takes great pride in his work with O’Rourke Petroleum Products (founded in 1932). As a Shell Alliance Distributor, the company is committed to providing the best products and services in the industry—and Dennis O’Rourke (Owner & CEO), Mushahid Khan (President & COO) and Tony Garcia (GM) expect their organization to provide nothing less than the fi nest technical support for its customers 24/7/365. As far as his specifi c duties are concerned, Mark tells us every day is different. That’s what makes his work so enjoyable, he says. “It pleases me a great deal to help people solve their lubrication problems and extend the life of their equipment. Advancing technologies in this industry create a stimulating environment and fuel a continuous learning process for me. I look at it as a win-win all the way around.”

For more info, enter 77 at www.LMTfreeinfo.com

Page 31: LMT JulAug 2011

C H O O S I N G C H A I N S H O U L D N ’ T B E R I S K Y B U S I N E S S

Give Tsubaki Lube-Free LAMBDA® Roller Chain a Try.Never take chances with your operation. Get the original and longest-lasting lube-free roller chain working for you. Tsubaki LAMBDA® is your sure bet for long-term operation without additional lubrication. And now you can hit the jackpot with our winning proposal.

L U B E - F R E E • M A I N T E N A N C E - F R E E • H A S S L E - F R E E • W O R R Y - F R E E

You can’t lose with our RISK FREE TRIAL

For complete details on our RISK FREE TRIAL OFFER go to: LongLifeLambda.com

© 2011 U.S. Tsubaki Power Transmission, LLC. All Rights Reserved.

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

Page 32: LMT JulAug 2011

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 lowermaintenance costs are labor intensive and involve painfulcultural changes. Numerous progressive companies haveexperienced significant cost savings simply by upgradinglubricants. You can learn how by reading the special report‘Lowest Total Cost of Ownership’. This special reportincludes extensive case studies that document real-worldsavings 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.

For more info, enter 75 at www.LMTfreeinfo.com


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