Professional Documents
Culture Documents
Royalmfg.com
ML
July-August 2018
TABLE OF CONTENTS
HYDRAULICS 16 AS I SEE IT
Ghost Riders That Haunt Your Oil
5 Steps for More Effective Hydraulic Beware of those invisible particles not reported by most oil analysis labs. These
2
Troubleshooting contaminants, which often go unnoticed, need to be exposed and understood.
LUBRICANT SAMPLING 28
GREASES 32
LUBE-TIPS 42
8
BACK PAGE BASICS 50
"These
contaminants,
which go
unnoticed by
maintenance
staff and
unmeasured
and unreported
by oil analysis
labs, need to
be exposed and
understood."
The def inition of machine. No lubricant is indem- magazine. We’ve shown how the
a contaminant is nified from their effects or can damage can progress slowly or attack
any foreign “some- safely co-exist with contaminants. suddenly and destructively. Either
thing” that enters So too, there are no lubricants or way, contaminants are a serious
a lubricant during formulation, machines that can realistically be lubricant disease that merit vigilant
packaging, transport, storage or defined as contaminant-free. attention by lubricant analysts and
service. Contaminants compro- The hazards brought on by reliability professionals.
mise the lubricant’s integrity, various types of contaminants Solid conta minants (a lso
performance and ser vice life have been covered extensively in known as particles) come in wide-
as well as impart harm to the the pages of Machinery Lubrication ranging sizes, shapes, hardness and
This small-particle dominance is compounded mechanically in sliding frictional zones. Wear is only
further by filtration. Most machines with circulating controlled by the mitigating action of extreme-pressure
oil have filters. However, most filters remove parti- (EP) and anti-wear additives. However, these additives
cles based on size exclusion. This means they don’t do little to impede the abrasive damage caused by small
remove all particles but rather just certain particles particles, leading to polished and honed surfaces under
above specific micron sizes (based on the average pore common boundary conditions. The higher the popula-
size of the filter media). For simplicity, we can refer to tion of these small particles, the more wear damage that
this as the filter’s particle size cut-off. results. Of course, where there is wear there is excessive
Those particles larger than the filter’s size cut-off are friction, higher energy consumption and negative envi-
conveniently disposed of with each filter change. The ronmental consequences, all of which are not good.
particles smaller than the filter’s size cut-off stay with the
oil and in the machine. This results in a growing popula- Silt Lock
tion of small particles that are uncontrolled by filtration. Small particles are commonly referred to as silt-sized
Because of their extremely small size, they also are not particles or just silt. These particles can jam and pack into
prone to settling (Stoke’s law) but rather embed tightly narrow oil ways, glands and orifices. They can restrict oil
into the oil, held by viscosity, circulation and Brownian flow, leading to lubricant starvation, and impair mechan-
motion (like food dye in water). ical movement (e.g., in a servo valve), causing motion
To what size of particles are we referring? Well, impediment.
if the filter has a 10-micron cut-off, then all particles
Additive Tie-up
smaller than 10 microns are ghost riders. By total
weight, most of these particles may be submicron A high density of small particles exposes the oil
(i.e., less than 1 micron in size). These include organic to an extensive amount of surface area (the collec-
matter (soft, insoluble contaminants that can lead to tive outer-shell surfaces of all particles). Many of the
sludge and varnish) as well as inorganic hard particles lubricant’s additives are polar, meaning they are natu-
from environmental dust and wear debris. Remember, rally attracted to both machine and particle surfaces.
the human eye can see particles down to about 45 Examples include friction modifiers, dispersants, rust
microns. Therefore, we can confidently say that ghost inhibitors, metal deactivators, detergents, anti-wear
riders are only visible with the aid of microscopes and and extreme-pressure additives. When these additives
similar laboratory methods. hitch a ride on particles, they lose their functional
value to the oil and machine. The particles occupy
The Lurking Dangers of Small (tie up) this role instead. The scrubbing of additives by
Particles small particles is a common additive depletion mecha-
Don’t assume you’re completely safe if you have
a good filter, even if it is a high-capture-efficiency
3-micron filter. Yes, filters are important, and many metal deactivator detergent
deliver exceptional performance by mitigating the
exposure and risks of particle contamination. When
larger particles are quickly filtered from the oil, they
can’t damage machine surfaces and can’t be crushed
into small particles in the size range of our ghost
riders. For sure, good filtration is essential to contam-
ination control. antiwear
The concerns and risks associated with small particles additive
will vary depending on the type of lubricant and the type
of machine. The following is a brief listing of the dangers
and harm imposed on lubricants and machines from the
dispersant
abnormal presence of small ghost-rider particles: rust inhibitor
Polishing and Increased Figure 2. Many additives are attracted to par-
Mechanical Friction ticle surfaces and will adhere tightly. When the
Many machines are exposed to periodic or contin- particles later get removed by filters or settle to
uous boundary lubrication. This means that, due to slow sump floors the additives are stripped from the
speed and/or high unit loading, the lubricant is unable oil. Those particles that stay suspended in the
oil keep the additives occupied and unable to
to maintain an oil film. This results in surfaces that rub
perform their intended function.
MEMBRANE
MICROSCOPIC PARTICLE MICRO PORE BLOCK-
BASIC PATCH PATCH GRAVIMETRIC PATCH
PARTICLE PATCH IMAGING FILTERABILITY AGE PARTICLE
TEST FERROGRAPHY ANALYSIS COLORIMETRY
COUNT (PMPI) COUNT
(MPC)
Pending ASTM
SAE ARP 4285 ASTM D7684 ISO 4407 ISO 16232-6 16232 7&8 ISO 13357 BS 3406
Standard
Related Standards ASTM D4898
ASTM D7670 ASTM F312-08 ISO 21018
- 90
FTM 3012/3 FTM-3009 ISO 4405
Non-quantitative
Indication of Total No No No Yes No No No Yes
Solids
Submicron
No No No Yes No Yes No Yes
Particles
Quantification of
No No No Yes No Yes No No
Total Solids
Soft Insolubles
No No No Yes No No No Yes
Quantification
Wear Debris No Yes Yes Yes Yes Yes Yes No
Elemental
No No No No No No No No
Composition
Visual Indication
Yes Yes No Yes Yes No No Yes
of Solids
Availability of
Test Method
Yes Yes Limited Limited Limited Limited Limited Yes
(Commercial Labs
and Vendors)
Optical Particle
SEM/ RDE Sediment Blotter Spot Ferrous Density
ICP Spectroscopy Counting Ultracentrifuge
EDX Spectroscopy Content Test Tests
Methods
ISO
ASTM D5185 ASTM D6595 ASTM D2273 ASTM D7647 None None None
16232-8
Related Standards
ISO 11500
Non-quantita-
tive Indication of No No No Yes No Yes Yes No
Total Solids
Submicron
Yes Yes Yes Yes No Yes Yes No
Particles
Quantification of
No No No Limited No No Limited No
Total Solids
Soft Insolubles
No No No Yes No No Yes No
Quantification
Wear Debris Yes Yes Yes No Limited Limited No Yes
Elemental
Yes Yes Yes No Yes No No No
Composition
Visual Indication
Yes No No Yes Limited Yes Yes No
of Solids
Availability of
Limited Yes Yes Limited Yes Limited Limited Yes
Test Method
Royal has been a leader in serving the industrial lubricant industry for over
a century. We manufacture hundreds of different types of high performing
lubricants, for the toughest applications, in the most demanding industries.
We can help you find the lubricants that are a perfect fit for your operation.
BRAND
(
NEW LOOK)
SAME OLD CENTURY OF EXPERIENCE
CONTACT US TODAY & WE’LL FIND THE PERFECT FIT FOR YOUR REQUIREMENT
ROYALMFG.COM 9998 DOERR LANE 516 S. 25TH WEST AVE
INFO@ROYALMFG.COM SCHERTZ, TX (210) 651-7322 TULSA, OK (918) 584-2671
AS I SEE IT
nism. The more particles, the more lubricants have a greater tendency to quantify the soft insoluble particles
the depletion. This results in lost produce large, buoyant air bubbles and hard particles separately. Other
or impaired corrosion protection, (rapid air release). Conversely, highly tests in this table can also be effec-
oxidation stability, film strength, contaminated oils, including those tive, especially when combined with
dispersancy (soot control) and rich with organic solids, lead to additional testing methods. For
deposit control. the formation of small air bubbles, example, data from two or more
which impair buoyancy and result of the following tests can provide
Loss of Demulsibility
in slower air detrainment (Stoke’s a practical understanding of small
Many particles are emulsifying law effects). As has been discussed
agents. In other words, they inhibit particle contamination: ultracen-
previously in this magazine, there are
the natural settling of free water trifuge, MPC, blotter spot testing,
numerous negative consequences to
out of the moving oil and instead elemental spectroscopy and submi-
bubbly, aerated oil.
bind the water into a tight emulsion cron patch testing.
within the body of the oil. This Exposing Ghost Riders
allows the water to be carried into Through Oil Analysis Removing Ghost
frictional zones, leading to acceler- Many machines that hold large Riders from Your Oil
ated wear, and also exposes the polar volumes of circulating oil have and Machine
oil additive to microscopic water no scheduled oil change interval. Some types of depth filters have
globules, contributing to hydrolysis Instead, oil analysis is used to the ability to remove many particles
and depletion. Small rust particles alert the approaching end of the well into the submicron range. This
are particularly prone to forming remaining useful life (RUL). This is
oil-water emulsions. can impart significant control, partic-
referred to as a condition-based oil ularly if the filters are used throughout
Oxidation by Metal Catalysts change. This works very well if the the life of the oil. Often the effective-
Metal particles (especially iron tests conducted by the laboratory ness of these filters will vary depending
and copper) promote or catalyze fully assess all factors that define the
on the particle size and composition.
base oil oxidation. This condition is oil’s health and condition.
There are also charged-particle sepa-
more pronounced when the parti- For instance, if you only
rators of various types that can prove
cles are in the presence of abnormal monitor oxidation stability, the
premature depletion of corrosion effective. When all else fails, the most
levels of heat and water contamina- practical solution may simply be to
tion. Wear debris is the principal inhibitors might go unnoticed.
Condition-based oil changes depend perform an oil change. This is a more
source of metal particles in the oil.
on vigilance and the comprehensive logical choice for small sump machines
If this debris is not quickly filtered
assessment of all important factors compared to those holding thousands
out, these particles can be crushed
into smaller particles. The commi- and attributes of lubricant health and of gallons of oil. ML
nution of particles exposes a greater performance. Some labs do a good
job with this. Others cut corners. About the Author
nascent metal surface area to the
oil and its additives. Eventually, the Many common laboratory Jim Fitch has a wealth of “in
oxidation inhibitors are spent (fully methods have substantial blind the trenches” experience in lubri-
depleted), and the base oil reaches spots when it comes to quanti- cation, oil analysis, tribology
its breaking point, followed by a fying the actual concentration of and machinery failure investiga-
runaway state of oxidation. There small particles in oil. This is true tions. Over the past two decades,
is no way to remediate oxidation for particle counting, elemental he has presented hundreds of
other than a complete drain, flush spectroscopy, ferrous density, courses on these subjects. Jim
and oil change. analytical ferrog raphy and others.
has also published more than
Table 1 provides a list of various
High Air Hang Time 200 technical articles, papers and
oil analysis tests and the ability of
publications. He serves as a U.S.
All lubricants have significant these methods to quantify or even
levels of dissolved air (invisible to the roughly indicate the presence of delegate to the ISO tribology and
naked eye). Changes in oil pressure ghost-rider size particles in oil. oil analysis working group. Since
and temperature can cause the air One test stands out due to its 2002, he has been the director
to evolve from a dissolved state to a capability to report a single numer- and a board member of the Inter-
bubbly, entrained-air state (Henry’s ical value for total solids (hard and national Council for Machinery
law). Small particles aid the transi- soft). This test is gravimetric analysis. Lubrication. He is the CEO and a
tion by providing nucleation sites for It can be enhanced using solvents co-founder of Noria Corporation.
emerging air bubbles. Highly pure like toluene and hexane to isolate and Contact Jim at jfitch@noria.com.
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COVER STORY
3 CAUSES OF
UNRELIABLE
EQUIPMENT
AND HOW TO ELIMINATE THEM
By Dr. Nathan C. Wright
Reliability is all about getting out attempt to predict their failure, but this is only Improper Lubrication
in front of your equipment, under- 50 percent accurate. To achieve reliability, you
Improper lubrication drives mechanical
standing its failure modes and need to be proactive.
wear and corrosion, which leads to prema-
stopping them from happening. A Although equipment fails for a lot of
lot of elements cause equipment failure, and reasons, they all fall into one of three major ture failure of your lubricated assets. If your
because of this, about 90 percent of failures categories: improper lubrication, contamina- organization does nothing else to improve
happen randomly. You can try to prevent tion and incorrect installation. Of these three, reliability, you should address lubrication.
failure by changing your parts before they fail; lubrication, or better said, improper lubrication It offers the biggest bang for your buck and
this works 12-18 percent of the time. You can is the most prominent. can be implemented relatively cost effectively
Before After
For proper lubrication, you must store, handle and deliver the best lubricants to your equipment.
you need someone on your team who under- next is time, and the final one is quality. The own peril. Every case that I have seen where
stands this problem and is qualified to review middle of the triangle is traditionally risk. I the provider was also in charge of design
and eliminate it from happening. like to look at these projects with an eye on ended with substandard results. Providers will
the opportunity and not the risk. All projects offer free studies and other services which are
Developing a Lubrication Program
have associated risk and opportunity. Your job enticing to organizations that do not know
To proactively address the single most is to look at the risk and mitigate it to the best better and are budget-driven. If this is the
common cause of unreliability, you need to extent possible, or to look at the opportunity path you take, you should save your money.
develop a lubrication program. To start a lube and maximize it. Few providers have qualified representatives to
program, you must understand that there are My recommendation to all organizations accomplish what is needed. Without a quali-
several different substances that can be used is to never compromise on quality. For me, fied reliability leader in your organization who
to lubricate a surface. The most common are the decision on how to approach the project knows the difference, you will not achieve the
grease and oil. The selection of the proper comes down to cost and time. If cost is the desired results.
grease should be done with the utmost dili- determining factor in your organization, then
gence to address all equipment needs. Many The Goal
it will take more time. The reverse is also true:
manufacturers sell inferior grease, and the if you want results in a quicker timeframe, The goal of your lubrication program is
thickening agent and oil separate. This leads to then the costs will increase. The decision on to keep your equipment clean, cool and dry.
lubrication-based failures, because once the oil costs and time needs to be made by looking at For every 10 degrees C or 18 degrees F, you
separates, the grease loses its protective quality. the opportunity. Organizations that keep their increase or decrease the component life by 50
I have seen organizations use extension eye on the opportunity will gain an advantage percent. If you have the right program storing,
hoses to make grease points easily accessible. over their competitors. handling and delivering the best lubricants to
This can be a machine killer, depending on your equipment, you can do more with less just
your grease. You need to know the amount Partnerships by changing your lubricant suppliers.
of time the grease will sit in the line based on There are some distinct steps necessary
the frequency of application and the amount. to achieving a lubrication program that will Contamination
The wrong grease will allow the oil to leach deliver the desired results. You need to build Contamination can be segmented into
out of the thickening agent, and all you will a business case by determining the costs of the contamination of your lubricants and
be providing the lubricated asset with is the benchmarking your site, gathering data, and spare parts (specifically in their storage and
thickening agent, devoid of oil. What would designing and implementing the program. The handling), and the physical contamination of
appear to be a great idea to an uninformed first step you must take is to benchmark where the equipment, caused by poor housekeeping.
organization could be a self-inflicted wound. your organization is today. If you don't have Again, it is relatively cost-effective to get your
the internal resources to conduct this bench- teams to perform housekeeping and store your
Decision-making marking or time is an issue, collaborate with lubricants and spare parts correctly. However,
When making the decision to under- an outside subject-matter expert who has the it can be difficult to achieve if your leaders
take any project, you must understand what expertise to help you pull together all aspects lack the necessary skills to lead their teams.
constraints you have. The constraint can be of a lubrication program. Poor housekeeping is a direct representation
displayed as a triangle. A graphical represen- Organizations that make the mistake of of a lack of leadership, so addressing this
tation of this decision-making is shown on allowing their lubrication provider to do any problem should be focused on your leaders,
page 12. One leg of the triangle is cost, the of this work without verification do so at their not their teams.
are not protecting themselves from the reliability and design it into your equipment
effects of contamination, and their products first and foremost. Designing the equipment
are suffering from these unsafe processes. for reliability and maintainability will set up
Eighty percent of all contamination enters your organization for success. To remember
the process through entrances and exits. how to combat this portion of unreliability, I
Therefore, one of the first logical steps to think of it as having the right person with the
proactive reliability is the implementation of a right part at the right time. Improper instal-
STS
TIM
contamination control program for lubricants lation is made up of several parts; start your
CO
elimination of unreliability before the systems
E
and spare parts aimed at their entrance into
the building. enter your building.
Steps to Contamination Control Design for Reliability
Opportunity
Heat, moisture, air and particles rob equip- Designing for reliability is the most recent Quality
ment of life, but with rigid contamination term for engineering equipment for reliability.
control practices, fluids can last indefinitely. Ensuring that there are no hard-to-reach ment and materials costs. If you have little
This, in turn, prolongs the life of the equip- points that require the equipment to be shut variation in your plant equipment, you will
ment’s components and keeps the machine down to service will increase maintainability need to stock fewer parts, and your operators
running at the highest level of efficiency. and, as such, will achieve reliability right and technicians will need to have knowledge
Additionally, the costs to start a proactive out of the gate. It is during this phase that
of fewer systems. All these things result in
contamination control program are covered the importance of an experienced reliability
lowering the costs of operating and main-
by reliability cost savings. professional is clear. Without the experience
taining the equipment.
A contamination control program can be to know what failure modes or other issues
Demanding that all the equipment’s
employed in three steps. First, start by setting will arise with the equipment once it is
service points be accessible while the machine
target fluid cleanliness levels for all equipment. installed in your plant, you will spend a lot
is in operation will require fewer non-pro-
Second, select and install filtration equip- of money and lose a lot of productivity after
ductive hours to proactively maintain the
ment (or upgrade the existing filter rating) the fact when these failure modes and issues
equipment. If your return on investment is
and contamination prevention techniques to arise during production. Organizations fail
calculated by the equipment’s productivity,
achieve the cleanliness levels. Finally, monitor to recognize the importance of this phase in
then maximizing the hours it can run will
cleanliness at predetermined intervals to ensuring reliability and entrust it to young
engineers or senior engineers without the give you the best results.
achieve the desired levels.
experience to eliminate these issues before The final stage in designing for reliability
Contaminant Monitoring: The Cornerstone of they arise. is to conduct a factory acceptance test (FAT).
Contamination Control This can be made even worse by handing This refers to the functional test that is
For the same reason you do not drive a car this responsibility over to suppliers. Providing performed by vendors once they complete the
without a working fuel gauge, you shouldn’t the equipment manufacturers with your orga- assembly of the equipment. This test will verify
attempt proactive reliability without a moni- nization’s specifications will go a long way that the equipment meets the specifications
toring program. Monitoring will give you the toward setting up your facility for success. All and functionality agreed upon in the purchase
data you need to ensure that your machinery too often organizations are more focused on agreement. Before the equipment reaches the
is operating within contamination standards. the short-term cost of the equipment and pat plant, it is imperative that an organization put
Proactive reliability addresses much more themselves on the back for getting it cheaply. the equipment through its paces and recreate
systemic elements of a reliability program, This is another failed approach that is preva- all failure modes during this phase to work out
rather than inspecting the machine itself. This lent in all industries today. the bugs in the factory and not in the plant.
approach is more diligent and looks to manage One of the best arguments for establishing Spare parts management is another
the difficulties that can contribute to equip- these specifications is achieving standard- important element of incorrect installation.
ment wear and tear as opposed to the failure. ization throughout your facility. Requiring If the storeroom is run improperly (poor
Stopping contamination does not cost a lot manufacturers to build to your specifications inventory, stock-outs, etc.), the rest of the
of money, but it does take a lot of hard work. and not theirs will pay for itself hundreds reliability operation does not stand a chance.
I know hard and work are dirty words, but of times over, absorbing any increased costs The level of service in an organization’s store-
doing the right thing is rarely easy. associated with the requirement. Equipment room is a solid indication of the effectiveness
manufacturers use the cheapest materials of its reliability efforts. Having the right
Incorrect Installation they can get away with in their construction parts is key to the elimination of improper
Improper installation starts with your to increase their profit margins. If you do not installation. Without the right parts at the
equipment design. Those charged with the demand quality, you will not receive it. By right time, reliability is not possible. What is
design of your equipment need to understand standardizing, you will reduce your develop- the impact of not having the right parts? The
DESICCANT BREATHER
Prevent particulates and
remove moisture from
the headspace of your
equipment with a desiccant
breather
FLUID HANDLING
Filter, store and transfer
fluids the clean way
delay caused by trying to expedite parts to the Combining resources from the organiza- and design. If any one of these is not present,
plant increases downtime and costs. If this tion and the storeroom partner to focus on the the person sitting on the stool must try to
delay is beyond acceptable time restraints, goal of cleansing the inventory is part of inven- balance while also trying to produce. If you
then it becomes necessary to use an alterna- tory accuracy. This includes providing overall have three sturdy legs, the person/organization
tive part. This increases downtime and costs coordination in fulfillment of the expectations. has the foundation to perform at its peak in
as well. Also, it requires additional repairs to Improper installation can be compared to this area. Which organization do you want to
remove the alternative parts and install the a milking stool — it has three legs that keep it work for and what type of leader do you want
correct parts once they arrive. Now you incur from falling. The three legs are training, stores to be? ML
more downtime, costs and wasted reliability
resources, which distracts the team that could
be working proactively to address other issues.
Of course, downtime is a loss of production Products
You Can
and finished product. This impacts customers www.klsummit.com
and their confidence in the organization.
The Storeroom as Partner
The main ingredient for success from
Trust
the storeroom is to continuously monitor
the needs of reliability and to adapt and
partner with it. To manage this relation-
ship, the storeroom must be deliberate in its
communications. Reliability must know what
assistance it will receive and in what fashion
to count on the storeroom.
From a reliability standpoint, there is an
expectation of parts availability. Most of the
time this expectation can be met. However,
when it comes to certain parts, this expecta-
tion is not realistic due to costs. Reliability
management and the storeroom need to
communicate to operations in these situations
to manage their expectations. Setting store-
room expectations after analyzing the failure
modes and their impact on downtime is the
most effective way to ensure reliability.
The best time to decide which parts
are to be stocked is when the equipment is
new and before it is placed into service. The
original equipment manufacturer, the part
suppliers and the reliability leaders should
work together to determine necessary spares.
Once the equipment has generated historical
data, reliability can adjust inventory levels Quality Lubricants + Great Service
and increase or decrease the stock on hand. Whether it’s fixing an issue or finding the right
In larger organizations, a parts inventory product for your application, we want to put our
planner can enhance the determination of years of expertise to work for your business.
stocking levels, re-order points and replen- Summit Quality + Summit Service = Results.
ishment trigger levels.
Let us know how we can best support you.
Having an inventory that reflects and
supports the current operation is one of the
most important steps you can take to improve To see all our products visit
www.klsummit.com
cost, work efficiency and reliability. The objec-
tive is to have the right parts in the right place Klüber Lubrication NA LP
at the right time. 800.749.5823 // info@klsummit.com
RELIABLE PLANT 2019
HYDRAULICS
A blown fuse on a solenoid-operated valve resulted in unnecessary Reading a hydraulic schematic can
downtime at a plant in Arkansas. identify a problem before the first
part is replaced.
a loose wire was found in the cabinet. The intermittent mean that the valve will not work in the system.
stopping of the motor was a volume problem. When the Several years ago, a positioning problem was identi-
power supply voltage dropped below the acceptable level, fied on an oriented strand-board press in Georgia. The
the pump was de-stroked to a zero flow output. position of the platen was controlled at four different
points with linear-displacement transducers. The pressure
2. Gather Information in the ram that controlled one of the corner rams was
Once you’ve identified the type of problem, the next fluctuating excessively. After 11 hours, it was determined
step is to gather information. More than likely when you that the replacement position-control valve had one letter
arrive at the problematic hydraulic system, some things different than the original valve. Once the correct valve
have already been done. Have any pressure or electrical was installed, the press operated normally.
adjustments been made? Have any hydraulic components Visual checks must be made during this process
been changed out? If so, do the new components have the to assess the oil level, filter condition, leakage, pump
exact part number as the components that were replaced? coupling condition, etc. Also, ask for the latest oil anal-
One number or letter difference in the part number may ysis report to verify the oil’s cleanliness level.
I was recently called to troubleshoot an issue at an
automotive plant where five pumps had been changed
START YOUR in 24 hours. When I arrived, I asked if anything had
been done prior to the repeated failure of the pumps.
FREE SUBSCRIPTION The supervisor said that a hose failed in the system and
www.machinerylubrication.com that the reservoir was refilled with fluid during the shift
change. Shortly after that, the issues with the pumps
started. After inspecting the system, I did not see a
breather cap on the reservoir. Apparently, when the
first-shift oiler refilled the tank, he did so by removing
the breather cap. Once filling was completed, the
second-shift oiler installed a pipe plug on the threads
where the breather was originally mounted. Now there
was no place for air to enter the reservoir, which resulted
in the failure of the pumps.
Machine operators can provide some of the best
information as to what is occurring. While main-
tenance workers may only show up when a machine
Vibration Thermography Oil Analysis Wear Particle Motor Testing Ultrasound Lubrication Alignment Balancing
Don’t Starve
Your Equipment
TRAINING MATTERS Machinery Lubrication I
It’s important for your team to maintain precise oil levels for all types Pittsburgh, PA September 18 – 20, 2018
of equipment. When your equipment runs low on fluids, it leads to Denver, CO August 28 – 30, 2018
friction, causing wear, damage and ultimately, failure. Don’t let your
equipment become starved for oil when it needs it most. Learn how Machinery Lubrication II
to stave off oil starvation with Noria training. New Orleans, LA November 13 – 15 2018
The outcome of the investigation improper commissioning, improper nical specifications? Are fasteners
led to the U.S. Navy implementing routine maintenance, and mainte- tightened using a torque wrench or
a new program to address submarine nance workmanship. the strength of the rebuilder? How
safety. This program was known as Considering the causes of the is the pump tested before being put
“SubSafe.” The SubSafe program high probability of failure for new back into stock or service?
required detailed written procedures or recently overhauled equipment, If you were to ask a group of
and checklists to be developed and it was determined that more main- craftspeople these questions, you
followed to the letter by all personnel tenance was not the answer. The likely would get a wide range of
engaged in maintenance of specified solution was related to controlling answers, and two people would not
components of all systems affecting the variation in activities. These have the same process for rebuilding
submarine safety. To date, the Navy activities included such things as and commissioning a pump. This
has not lost a submarine due to a design reviews, supplier quality variation makes it virtually impossible
maintenance mistake under the and certification programs, and to establish a root cause of a prema-
SubSafe program. This shows the the development of procedures for ture failure or poor performance of a
impact that a robust procedure-based operating and maintaining equip- rebuilt pump. A procedure based on
maintenance program can have on ment. There was a conscious effort the experience of the staff can capture
reliability and safety. to move away from relying upon the collective knowledge and put it
Later in the 1960s, there was a on-the-job training, intuition, etc., into a repeatable and consistent
focus on improving the reliability toward the use of detailed, technical method, eliminating this variation.
of commercial aircraft. This study, procedures. As a result of these Secondly, procedure-based
which was published by Nowlan changes, along with the move to maintenance minimizes the odds
and Heap, brought to light that most condition-based maintenance from of an individual making a mistake.
failures were not induced by time time-based maintenance, world- There are various types of factors
or wear but were either random or wide aircraft incident rates have that can contribute to an error, and
triggered by improper maintenance fallen from nearly 40 incidents per it is important to understand these
or installation. Looking at the six
1 million takeoffs in the early 1960s factors to ensure that procedures are
failure patterns, it was observed that
to just one or two incidents per 1 written to address them.
failure pattern six, which experi-
million takeoffs in 2016. For example, anthropometric
ences a high level of infant mortality
factors are those related to the size
followed by a random, consistent Importance of or strength of the person performing
failure rate, was more prevalent at
68 percent. This indicates that the
Procedures the activity. These are primarily
Procedure-based maintenance addressed through a redesign or tools
highest probability of failure is when
serves to address two key issues when and not with procedures.
the equipment is new or just over-
hauled. So, what led to the spike in performing maintenance activities. Human sensory factors are those
the probability of failure? The causes First, it reduces the variation that concerned with the ease in which
could be related to design, manufac- occurs when many craftspeople are people can see, hear, feel and even
turing defects, installation defects, conducting the same work. Consider smell what is going on around them.
how many ways there are to rebuild These are also mainly addressed by
a pump. How does the disassembly redesigning or with tools and not
happen? Does the disassembly occur through procedures.
with a precision torch and hammer, Physiological factors refer to
or does it take place with the proper environmental stresses, such as
tools? Does the rebuild happen in a high or low temperatures, excess
clean room or in a dirty shop which noise, humidity, etc. Once again,
can contribute to contamination? these cannot be addressed through
Are the parts inspected according to procedures.
a standard or left to the experience Psychological factors are related
of the rebuilder? Is there a standard to the causes of which mistakes
list of parts that are replaced, or is are made. Psychological errors are
it left to the inspection? Is a thread- divided into two types: unintended
locking component used during errors, which occur when someone
reassembly? Are the clearances does a task incorrectly, and intended
checked based on experience or tech- errors, which happen when someone
“Well-written procedures
deliberately sets out to do something,
but what they do is inappropriate.
The intended error can be either a
eliminate misinterpretation
mistake or violation. A mistake is
a misapplication of a good rule, an
application of a bad rule or an inap-
as absolute truth. Instead, it means opinions on the sequence, specifi- procedures include the following:
reviewing, evaluating and either cations, etc. Once this is sorted out, •
• Use short sentences. The
using the feedback or providing the procedure should be written in recommended maximum limit
explanations as to why the feed- a way so it can be followed by all is 20 words in a procedural
back will not be used. This type of craftspeople, including non-native sentence and 25 words in a
approach will help guarantee that English speakers. Thankfully, with descriptive sentence.
feedback is provided. English being the universal language
•
• Restrict noun clusters to less
As more maintenance tasks are of aviation, we can continue to learn
than three nouns.
converted to procedures, develop from the aviation industry. This
and use a single template. This will industry has developed simplified, • • Restrict paragraphs to less than
foster consistency across an orga- technical English. six sentences.
nization, making procedure-based Simplified, technical English • • Avoid slang or jargon.
maintenance easier to put in place is a controlled version of English
and sustain. that is designed to help the users • • Avoid the passive voice.
One caution when using of English-language maintenance • • Be as specific as possible.
craftspeople to write procedures is documentation understand what
to first train them on the process. • • Use articles such as “a/an” and
they read. Technical writing can be
Procedures need to be specific and complex and difficult to understand, “the” wherever possible.
actionable without any unnecessary even for native English speakers. •
• Use simple verb tenses (past,
information. Another approach Simplified, technical English makes present and future).
is to have a craftsperson write procedures easy to understand and
• • Write sequential steps as sepa-
the procedure and then have it follow, eliminating language issues
rate sentences.
edited by a technical writer. Both and reducing premature and main-
approaches have their pros and tenance-induced failures. • • Put commands first in warnings
cons, so be sure to choose the right Simplified, technical English and cautions, with the exception
one for your organization. provides a set of writing rules and a of certain conditions.
dictionary of controlled vocabulary. • • Use the word “that” after subor-
Writing Usable The rules cover grammar and style. dinate clauses that use verbs
Procedures The dictionary specifies the words such as “make sure” and “show.”
Writing procedures is not an easy that can be used and those that can’t.
task. Many people have different For the words selected, there is only •
• Introduce a list item with a
one word for one meaning, and one dash (hyphen).
part of speech for one word. • • Use graphics where needed to
Some of the benefits of simpli- clarify meaning. A picture is
fied, technical English include worth a thousand words.
reducing ambiguity, enhancing
the clarity of technical writing, •
• Use the word "warning" to
improving comprehension for people protect against harm to
whose first language is not English, personnel but the word
and increasing equipment reliability "caution" to protect against
by lowering the probability of defects equipment damage.
being introduced during mainte- Once the procedure is written,
nance and assembly. review and delete any information
The simplified, technical English that is not relevant (i.e., instead of
specification is not easy to learn, but synthetic lubricating oil, use only
training and software are available. oil). Well-written procedures should
Even without becoming an expert, help to eliminate any misinter-
you can still make your procedures pretation and drive clarity to the
more readable and drive reliability. craftsperson performing the activity.
Begin with some basic writing Here is an example of how the
guidelines and by reviewing the wording of a procedural step could
procedures before they are issued. be open to interpretation. The task
Some of the best practices for writing “replace the filter” could mean either
to put back the filter that you took This method enables organizations to the more likely the change will be
out or to install a new filter. plan and manage the change being adopted and sustained.
Now you can see how one person implemented as well as bring people Procedure-based maintenance has
might perform a task and how along with the change. Each step the opportunity to drive significant
another would perform it differently. in the framework provides specific improvements in safety, reliability
Once the task is clear, a technical actions that should be taken, such and operations. But before an organi-
specification should be added so the as awareness of the need for change, zation can jump into procedure-based
task can be performed to a standard, desire to participate and support the maintenance, there must be a plan for
such as “Tighten to 15 foot-pounds.” change, knowledge of how to change,
how it will be implemented, who will
The result of making the task clear ability to implement required skills
write the procedures, to what stan-
and adding a specification would be, and behaviors, and reinforcement to
dard the procedures will be written
“Install a new filter and tighten to sustain the change.
and how the staff will be trained on
15 foot-pounds.” This task is simple, The whole purpose of using a
the new procedures.
clear, easy to understand and can be framework like ADKAR is to iden-
tify any concerns associated with With procedure-based mainte-
performed in a consistent and repeat-
the change, address those concerns, nance having been adopted by the
able manner.
express how the change will benefit U.S. Navy, aviation and nuclear
If an organization decides not to
follow simplified, technical English, the staff, provide the knowledge and power industries, the results have
there at least should be a standard training, and finally demonstrate been proven. If these types of orga-
in place for writing procedures that the change is not a flavor of nizations are using procedure-based
so everyone is doing it the same the month. The more time spent maintenance, what is preventing
way. Although it may sound crazy planning and managing the change, your organization from using it? ML
to have a procedure for writing a
procedure, it is vital for consistency
and repeatability.
LUBRICANT SAMPLING
A ducted-fan UAV
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The new PowerShield MONITORING SYSTEM FLUID The new LaserNet 200
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motor oils from Cham- The new Dynapar Houghton Interna- Comprehensive Particle
pion are specially designed OnSite Condition tional’s new HOCUT Analyzer Series from
to reduce the potential of engine Monitoring System is 8640 metal-removal Spectro Scientific was developed
failure during hard break-ins. engineered to enable remote fluid is intended for multi- for extensive analysis of particles
Offered in 10W-40 and 20W-50 monitoring of virtually any metal machining and grinding in lubricating and hydraulic
viscosities, the break-in oils asset, including turbines, fans, applications. Formulated to fluids. The new series increases
contain high levels of zinc thio- pumps, gearboxes, etc. The improve operational efficiency, the particle counting range
phosphates in combination with wireless system combines 24/7 part quality and surface finish, up to 10 million particles per
Champion's Thermal Viscosity condition monitoring with the biostable fluid features milliliter without dilution and
Stabilizer (TVS) to extend oil cloud-based analytic software built-in detergency, dispers- incorporates a new set of ferrous
film capacity for proper ring for multi-stakeholder access. ibility, emulsion stability and particle measurements to give
seating. The new lubricants are The hardware consists of a low foaming characteristics for users insight into the progress
also formulated with polymer central hub that aggregates consistent lubrication and heat of machine wear. The analyzer
thickeners to allow the use of data from four separate wired transfer performance. In field employs laser-imaging technology
a thinner viscosity base oil for sensors. Each sensor measures tests, HOCUT 8640 provided and dual magnetometers to char-
easier cold starting and reduced vibration along three axes proven performance on a broad acterize ferrous particles larger
friction. Dispersants and other as well as temperature. The range of metals, including high than 25 microns as well as total
additives are included to help system can also connect to and low carbon steel, stainless ferrous particles. Users can now
keep the engine clean. an encoder, integrating speed and alloyed steel, cast nodular process very dirty engine and
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Champion troubleshooting. aluminum, powdered metal, and ment such as mining excavators.
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AND GREASE PUMP STATION NOZZLES The new LX-1403
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intended for applications where Filtration can be configured as where liquid application is needed greasing process. It features
high output and fast lubrication a single-drum dispensing and in a broad area. The nozzles an ergonomic thumb-lever
cycles are needed to lubricate filtering station or multiple produce a fine mist of atomized design that firmly latches onto a
equipment while it’s working. units bolted together for liquid that can be easily adjusted to grease fitting, enabling hands-
The single-line parallel pump is a complete lube room and meet the needs of the application. free greasing. The heavy-duty
able to fire hundreds of injectors multi-fluid dispensing, recir- Commonly used with water, coupler locks on and creates a
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The unique pump design also Up to 15 standard stations provide liquid flows from 10.8 to no damage to the seal even after
allows for reduced venting times. can be connected, with each 150 gallons per hour and can spray hundreds of uses. The device can
Available in a variety of configu- station self-contained. The in all directions as well as up to 13 fit on all SAE and metric grease
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factory-installed pressure gauge, on-demand dispensing. The are available in a variety of sizes, with manual, battery-powered
adjustable pressure relief and smart system also locks out shapes and connections. and air-operated grease guns as
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GREASES
Grease Sampling
Methods Matter
700
600
R2 = 0.7386
500
Iron Wear (ppm)
400
300
R2 = 0.0173
200
100
0
0 50 100 150 200 250 300 350 400 450
Cycles
“We shoved cable ties into the the sampling challenge had resulted methods of sampling and characterize
housing and wiped them off on the in the previous month of my career the movement of the grease in the
mouth of your oil sample bottles.” producing very little actionable data valve while in operation. Sampling
Over the next hour, we both for my company. tools and methods were developed
came to the realization that the Several years later, I was afforded that were incorporated into a new
sampling method was at the heart the opportunity to participate in a ASTM standard for in-service grease
of the problem. It was likely that the research project for the Electric sampling (ASTM D7718).
grease that was adhering to the cable Power Research Institute (EPRI). Additionally, the test stand
ties was “opportunity grease,” the EPRI member utilities had identified was used to create a known higher
material closest to the access plug. a need to better understand greases wear condition to see if this could
As we began to understand how and how they worked in power plant be detected by the grease sampling
the grease moved in the housing, equipment. From this, the Nuclear and analysis process. After the motor
it became clear that the samples I Maintenance Application Center to the gearbox was deliberately
analyzed were in many cases grease (NMAC) of EPRI assembled the misaligned, the result was a clear
that was not currently active in the funding for the “Effective Grease change in the measured wear content
lubrication of the valve gears. A few Practices” research project and of the grease obtained by the new
of the “dirty dozen” turned out to guideline. Among a number of areas recommended sampling method, as
be valves that had failed in the past of investigation was a focus on the seen in Figure 2.
but had since been rebuilt and were challenges and best practices for A few years later, while
operating very well. What we had motor-operated valve (MOV) grease attending an MOV conference, I
discovered was old particulate from sampling and analysis. overheard some engineers discussing
the previous damage that was not This gave me the opportunity the lubrication of MOV valve stems.
completely cleared from the housing to determine where my prior efforts Their concern was with short-
and ended up on the cable tie. to sample MOV grease had gone stroking valves and the challenge
We learned a lot through this wrong and share those findings with in ensuring that an effective coating
failed project about the valve the industry. Nick Camilli of EPRI of grease was being delivered to the
grease and how it functioned in the provided the insight and leadership valve stem and stem nut when it
gearbox, but we learned very little that resulted in the construction of was impossible to move the stem
about the condition of the valves. I an MOV test stand (Figure 1). This to expose most of the threads. Why
found that my failure to first address test stand allowed us to try various was the application of grease so crit-
ical in this application? Because the MOVs are tested by the story of how his team had overcome the challenges
measuring the force of the motor through power signal of sealing out the atmosphere to produce the world’s
analysis. By looking at the power signature of the motor, largest vacuum chamber for simulating the conditions
the closing force of the valve was inferred. This is only of space, we came upon a design solution for fixing the
valid when the coefficient of friction for the stem and leaking fixture to relubricate the valve stem. The result
stem nut interface is properly accounted for. If a stem is was a new way to lubricate valve stems in critical appli-
not fully lubricated, and the friction is higher than the cations like the MOV by taking a completely different
calculations assume, then the force (and thus the power experience and applying what had been learned. Not
signature) normally sufficient to fully seat the valve is only had we developed a way to relubricate the valve
suddenly inadequate. stem, but in the process had created a new sample of the
Knowing the challenge at hand, I returned to the lab grease that had been in service, offering the potential
to try out some solutions for relubricating the stem. Our for new condition data from the grease.
first efforts failed, as we were unable to design a fixture It took a long and painful experience in analyzing
that could be connected to the valve stem and deliver hundreds of meaningless samples to help me realize the
the high pressure of new grease required to displace importance of lubricant sampling. The best analysts at the
the old and provide a new, reliable layer of lubricant. top laboratories in the world cannot produce meaningful
It was at a picnic where I got the chance to discuss this results from samples that have been taken incorrectly. It
problem with my uncle. Roy Leitz had a long career is essential that we focus not only on the task of gener-
as a welder and pipefitter. He was also used to solving ating analysis data but also in ensuring that the data will
difficult problems. One such challenge he had was in have value. This can only be achieved with accurate and
sealing the high-vacuum valves of NASA’s space simula- representative samples from motor-operated valves and all
tion vacuum chamber in Sandusky, Ohio. As he told me other critical grease-lubricated machines. ML
schaefferoil.com
314.865.4100
Rounded square
44
for creating better lube routes.
Quick Filter
Check Tip for Reducing Bearing Failures
When checking differen- If you are experiencing premature anti-friction bearing failures, you should not only look at your lubrication
practices but also your installation practices. When induction bearing heaters are used, the inner race heats faster
tial filter clogging indicators,
than the outer race. This causes a thermal differential between the inner and outer race of the bearing, which will
be sure that the pilot holes in
reduce the bearing’s internal clearance. If this differential is allowed to climb high enough, all internal clearance
the filter body (the ones that
in the bearing can be eliminated and damage to the balls and races can occur.
feed the indicator with oil
pressure) are clear of debris.
This will help ensure you are
receiving the correct signal.
Smart Valve Labeling
A good way to make sure valves are put in the proper
operating position after maintenance is to affix perma-
nent tags on the valves indicating their normal operating
position. Wording such as, “This valve normally open for
operation,” is very helpful. A pre-startup checklist will add
another layer of protection.
Did You Know?
Additional tips can be
found in our Lube-Tips
email newsletter. To receive Advice for Oil Reservoir Baffles
the Lube-Tips newsletter,
subscribe now at and Settling Zones
Baffles are used to prevent fluid just returned to the
MachineryLubrication.com. tank from passing directly back to the pump inlet. For
a number of reasons, a longer transit path is considered
beneficial, as it encourages better heat conduction from the
Have Some Tips? fluid, better contamination and air separation, and better
If you have a tip to share, mixing with the bulk fluid. This is usually accomplished
email it to by separating the inlet and outlet by as long of a flow path
editor@noria.com. as feasible. ML
you would expect to see advancing shearing down of the viscosity index
signs of wear inside the machine. improver additive. Over time this
Therefore, you need to know the additive is cut into smaller pieces
minimum operating viscosity to set and loses its impact in the oil. You
an alarm and limit on that value. then see a drop off in the high-
Most oil labs test industrial temperature viscosity. This generally
fluids at 40 and 100 degrees C. By is measured or monitored by reading
using these two parameters, you
the viscosity at two temperatures.
can calculate the viscosity index
While there isn't a set level for
and extrapolate the viscosity at
whatever in-service temperature the viscosity index across the board, you
higher at the operating tempera- compressor is operating. can determine the required viscosity
tures, providing a safeguard in case You should take the approach index for your machine and then
something were to happen in terms of setting both upper and lower set limits based on how much the
of higher operating temperatures limits on viscosity, cautionary limits viscosity will drop at a given oper-
or contaminants lowering the oil's at plus or minus 5 percent, and ating temperature. Remember, with
viscosity. Reducing the operating critical limits at plus or minus 10 viscosity, in most cases it is better to
temperatures with coolers or other percent. Viscosity index could be err on the side of caution and have
means, or raising the ISO grade included as well, as there are many too much rather than not enough. ML
can also help you achieve a measure reasons viscosity index could change
of safety. throughout the life of the oil. If you have a question for
If the viscosity index were to Perhaps the most common one of Noria’s experts, email it
drop below 108 in this example, way viscosity index changes is by to editor@noria.com.
standardized the way samples were the top, especially having a strong • • Lubrication management
being taken while verifying that director and program manager by •
• Oil analysis methods and
everyone was using clean sample you, made the team really shine.”
strategies
bottles and that everything was
labelled properly. Gill Award Criteria • • Use of information technology
The number of like oils was also Designed to motivate compa- • • Continuous improvement
consolidated, resulting in a drastic nies to improve machine reliability
reduction in shop-stocked oils. In and maintenance quality through Both the Augustus H. Gill and
addition, compatibility testing was the application of oil analysis, the John R. Battle awards are open to
implemented to ensure proper lubri- Augustus H. Gill Award has specific organizations worldwide indepen-
cant selection. dent of any involvement with ICML.
criteria for potential recipients.
Although still a work in prog- To avoid bias, ICML has chosen a
These include:
ress, the oil analysis program has policy by which it does not nominate
• • Commitment to education
been a huge success. As more equip- companies. Instead, nominations
ment arrives at the Kennedy Space • Maintenance culture and
• must come from the companies
Center for the Space Launch System management support directly via an application.
program, the oil analysis program will •
• Performance measurements If you know of any organizations
need to expand to accommodate the used that deserve to be recognized for their
space and fire- suppression system machinery lubrication or oil analysis
required to store oils and greases. • • Proactive/predictive maintenance programs, encourage them to apply
“We knew that this was going to • • Use of standardized procedures for an ICML award. To submit a
be a journey,” Hollis added. “Being nomination for one of ICML’s recog-
• • Technology integration
able to essentially preach the gospel nition of excellence awards, visit
from the bottom all the way to • • Contamination control www.lubecouncil.org. ML
CERTIFICATION NEWS
Ahmed Magdy Mosbah, MLA II Compañia Minera Chungar Fuchs Egypt Kiel Warwick, MLT I
Christopher Lopez Perez, MLA II Oscar Ccaccya Anca, MLA II Mohamed Jamal Abd-El-Sadek, Tyler Bergene, MLT I
Mark Smyth, MLA I MLA II
Taha Paracha, MLA I Confipetrol Andina Jordan Bromine Co.
Dustin Rojas Casas, MLA II Georgia-Pacific Salameh Alabed, MLA I
Aecom Maintenance William Ever Siesquen Inga, Brandon Creasey, MLT I
Contractors Kellogg
MLA II Chester Collins, MLT I
Zahid Javed, MLT I Robert Gillis, MLT I
David Wray, MLT I
Continental Building Tom Peeters, MLT I
George Minnick, MLT I
Aecon Products
Justin Sayers, MLT I
Jacob Lovik, MLT I Koch Industries
Joey Mullins, MLT II Joseph Crawley, MLT I Chris Pickering, MLT I
Alberta Pacific Forest Dow Chemical Logan Rhoads, MLT I Derek Dronberger, MLT I
Industries Randy Howard, MLT I Don Rice, MLT I
Kyle Grantham, MLT I
Ross Whieldon, MLT I Robert Brooks, MLT I Eric Sharpshair, MLT I
Egyptian Maintenance Co. Robert Hudson, MLT I Jason Rees, MLT I
Ardent Mills Mohamed Gamal Shaaban Ashry Steven Haupt, MLT I Mitchel Bruss, MLT I
Kyle Weber, MLT I
Need to take Atlantic Power
Gheith, MLA I Glencore
Jeff Lilko, MLA I
Komatsu
Entergy Anthony Vilar Roque, MLA I
an exam? Jason Tyrrell, MLA I Aaron Davis, MLA I Goodyear Jose Luis Malaga Alarco, MLA II
Charles Clayton, MLA I
ICML regularly holds Berry Global
Dean Kelley, MLA I
Favio Rodriguez Tejeda, MLA II Lube-Tech & Partners
exam sessions throughout Matthew Hagen, MLT I Brooke Jaunich, MLT I
Phillip Harrison, MLT I Derek Duplessis, MLA I Hellenic Petroleum
Daryl Andersen, MLT I
the United States and the Douglas Deloach, MLA I Ioannis Binikos, MLA I
Boise Cascade Honore Templet, MLA I Ioannis Spyrou, MLA I Lubrication Engineers
world. Upcoming dates Brandon Poag-Crozier, MLT I Jacob Loving, MLA I Konstantinos Pagonis, MLA I Alan Lich, MLT I
and locations for ICML James Coyle, MLA I Marcus Vichert, MLA I Dan Gentry, MLT I
British University in Egypt
exams can be found at Sherif Elsoudy, MLA I
James D’Antono, MLA I Theofanis Stavrou, MLA I Patrick Schwindaman, MLT I
Jarrett Morris, MLA I Vassileios Bouras, MLA I Thomas Bjellos, MLT I
www.lubecouncil.org. Jonathan Odonnell, MLT I
Bureau Veritas Hormel Foods Corp. Lubrimor
Justin Alsdorf, MLA I
Andres Avelino Caceres Lara, Carl Benttine, MLT I
Kyle Temple, MLA I Alejandro Jose Moreno, MLA I
MLT I Connor Moore, MLT I
Mannanseh Price, MLA I
Dominique Dawson, MLT I Mehtanex
C&W Services Melissa Franco, MLA I
Philip (Eugene) Begley, MLA I Jordan Riemann, MLT I Mohamed Hafez Metwally, MLA II
Andrew Ashenfelter, MLT I
Ryan Peters, MLA I Kayum Ayinde, MLT I
Brian Beam, MLT I Michelin
ICML Certifications Donald Lindly II, MLT I Stephen Maciasz, MLA I Kevin Kendrick, MLT I
Nicholas Bjerke, MLT I
Jonathan Schofield, MLT & MLT II
Kenneth Hinsley, MLT I Thomas Collins, MLT I
Rodney Bogle, MLT I Vance Kirk, MLA I Opeyemi Ajaiyeoba, MLT I Mosaic Co.
LLA I Shane Burgher, MLT I
EPROM
Sherveen Masghati, MLT I Angel Suarez, MLT I
Terry McCarthy, MLT I Cody Alvarez, MLT I
L aboratory Lubricant Cargill Amir Basyouni, MLA II Zachary Fadness, MLT I Dale Thompson, MLT I
A nalyst Level I Cody Dreaden, MLT I Joe Diaz, MLT I
ExxonMobil Hudbay
Louis Kitt, MLT I Joseph Farabaugh, MLT I
Jonathan Urbach, MLT I Erick Jorge Pachas Quispe, MLA II
MLA I Catalyst Paper Paul Griffin, MLT I
Kelly Byrd, MLT I
M achine Lubricant I-care Deutschland
Clayton Bujotzek, MLT I MVS Acmei Technologies
Finning Leon Cornelius Pollmeier, MLT I
A nalyst Level I Cenovus Energy Sheldon Esau, MLA I
Bijay Kumar Singh, MLA II
Imerys
Shawn Oles, MLT I & MLA I Noria Corp.
MLA II Cia Minera Ares
First Quantum Minerals
Ben Ngoshe, MLA I
Robin Davis, MLT I
Devin Jarrett, MLT II
M achine Lubricant Besh Muleya, MLA I Industrial Oils Unlimited OG&E Energy Corp.
Carlos Salazar Franco, MLA II
A nalyst Level II Bright Malumbwa, MLA I Dillon Evans, MLT I & MLA I
Keith Massar, MLA I
Circor Reliability Services/ Chama Chilumba, MLA I Kenneth Stinson, MLA I
COT-Puritech & LSC Orange County Sanitation
MLA III Cole Jolly, MLA II
Gerald Zambika, MLA I
Maxmillan Shamakumba, MLA I
Ingredion District
Carl Carlton, MLT I
M achine Lubricant Darryl Kinsey, MLA II Michael Simukoko, MLA I Rodney Hendricks, MLT I
Brian Tafolla, MLT I
A nalyst Level III Dean Ingram, MLA II Misheck Koni, MLA I Brian Terrell, MLT I
Harold Lloyd, MLA II Ron Haboush, MLT I
Moses Mukanda, MLA I Cory Mayne, MLT I
Keith Spoonmore, MLA II Pavious Mulenga, MLA I International Paper Gilbert Padilla, MLT I
MLT I Kendall Tompkins, MLA II Wasa Kampamba, MLA I Donald Godin, MLT II Jesse Freeman, MLT I
M achine Lubrication Levi Sanders, MLA II Robert Brandt, MLT I
Peter Mattes, MLA II Flint Hills Resources Intertek Santiago Escobar, MLT I
Technician Level I Robert Kent, MLA II Dan Gerten, MLA I Rahul Venkiteswaran, MLA II Trung Tan Nguyen, MLA I
Jonathan Leland, MLT I Victor Gonzalez, MLT I
Compañía de Galletas Noel Jennie-O Turkey Store
MLT II Carlos Andres García Osorio, Fluid Life Corp. Adam Krych, MLT I Osceola Foods
M achine Lubrication MLA I Rob Shepherd, MLA I AJ Walsh Brenizer, MLT I Andrew Smith, MLT I
Technician Level II
CERTIFICATION NEWS
How Hub
Assemblies Work
The majority of hub assemblies
utilize a rolling-element bearing on
the spindle to allow the wheel to rotate
freely. These typically are tapered
element bearings to help support loads
in multiple directions. They are often
installed in pairs on steering wheels.
For wheels that don’t steer, known
periodically to enable maximum life Lubricant Selection
of the assembly. This raises the ques- Oils have been employed in
as drive or idle wheels, you may find
traditional ball bearings. Although tion as to which lubricant should be many hub assemblies with good
these bearings can reduce the amount used to lubricate, protect and ensure results. When using an oil bath to
of friction between the moving parts, the bearing will provide trouble-free lubricate the wheel ends, there is
the bearings must be lubricated service for an extended period of time. generally less drag on the bearings
when compared to grease lubrication. designations are considered inactive For wheel ends that share a sump
The oil is applied either directly to the and usually are not recommended with the rest of the axle assembly,
hub via a fill port or supplied inter- in these applications. Breaking the you may need to pull the level plug
nally from the differential utilizing mold is the MT-1 designation, which from the differential or gear assembly
a piping mechanism. In both cases, is frequently employed in non-syn- to verify that the oil is at the appro-
maintaining the correct oil level and chronized manual transmissions. priate operating level. Ideally, you
selecting the appropriate oil are key to These oils are more specialized, should check these levels when the
preserving the bearing and ensuring and care should be taken to prevent vehicle is on level ground, as the
that the hub functions properly. accidentally mixing these with slope of the surface could impact the
Bearings that share oil from other fluids. oil level and give you a false reading.
the differential will commonly In order for a lubricant to meet Remember, having too high of an oil
be lubricated with gear oil. Even these specifications, there must be a level can be just as dangerous and
hubs that are splash lubricated in healthy dose of additives to fortify destructive as having an oil level that
their own individual bath may be the base oil. The most common is too low.
lubricated with an approved gear additives in these types of fluids
oil. While most people may be are antioxidants, viscosity index Grease Lubrication
familiar with gear oils, the ones improvers and extreme-pressure The vast majority of wheel ends
used in automotive applications (EP) additives. Some EP additives are grease lubricated. Unlike oil,
are slightly different than those contain active sulfur phosphorus, grease does a better job of staying
for industrial applications, which which can be corrosive to softer in place within the bearing and
have their own designations and metals, so always check your equip- housing. It also can resist breaking
viscosity grade systems. Gear oils ment manual before selecting and down while in service better than a
for these applications should meet using any oil for your particular traditional oil. The downside is that
the specifications of the American application. grease can be difficult to replace,
Petroleum Institute (API). For drive In addition to the oil designa- and overgreasing is common in
wheel ends, where the oil is shared tion, you must also choose the proper many applications.
between the hub and the axle, this oil viscosity to replace or refill the Passenger-car wheel bearings are
becomes very important, as the oil system. The viscosity will be denoted typically grease lubricated and sealed
will be lubricating a gear set as well by the SAE viscosity grade and typi- for life, which means the lubricant
as a bearing set. cally will be listed in the same place can’t be replaced. Not only must
Be sure to consult the original as the oil designation. Many auto- the in-service grease provide the
equipment manufacturer’s recom- motive applications utilize a 75W-90 same lubricating properties as oil,
mendations to see which gear oil viscosity oil in these applications, but but it also must be able to resist the
designation is preferred. The most it is not uncommon to find some temperatures present in the wheel
current and widely used is GL-5. viscosities higher than SAE 140. end to avoid excessive bleeding
This designation is employed with The higher viscosities are often used of oil from the thickener. This is
most hypoid gear sets and has stan- for higher loads and higher torque very important in applications that
dard performance levels listed in the applications or for those experiencing require frequent braking, as the fric-
ASTM D7450 specification. Much higher temperatures. tion in the brakes is often transferred
of this specification is dedicated into the wheel bearings.
to testing the lubricant’s ability to Oil Levels When selecting a grease for a
reduce wear on gear components. When using oil to lubricate wheel bearing, start by considering
Other tested parameters include a wheel end, the oil level will be the recommended lubricant or the
61%
foam stability, rust protection, and critical to the system’s health and grease that is already in use within
thermal and oxidative stability. overall performance. If the wheel the bearing. Greases are known
The full range of gear oil desig- end has its own individual reser- to have compatibility issues when
nations span from GL-1 through voir, there likely will be a sight glass different types are mixed. This risk
GL-6. The only active designations which can be used to monitor the is greatly minimized if you can fully
are GL-4 and GL-5. GL-4 is utilized oil level. Depending on the type of replace the grease charge by cleaning of lubrication professionals
consider wheel-end
in many manual transmissions and wheel end, the oil level can vary, so out all remnants of the old lubricant. lubrication during normal
transaxles. These tend to be used be sure to check the sight glass for Some research into the grease’s maintenance of their vehicles,
more at lower speeds and loads the “full” mark and not simply look thickener and base oil can shed light according to a recent survey
when compared to GL-5. The other for signs of oil in the glass. on whether the new grease will be at MachineryLubrication.com
able to mix with the in-service tests. Additional testing for corro- malfunction. Also, if lubricant is
grease. When in doubt or if there sion protection, water resistance, no longer present, the bearing may
are compatibility concerns, try to leakage, high-temperature life, heat up and cause a fire. The wheel
perform as thorough of a grease wear protection and elastomer could even become unattached
changeout as possible. compatibility is performed for GB and result in damage or harm to
Automotive greases have and GC greases. The GC greases other motorists.
performance specifications that are tested for extreme-pressure Therefore, wheel ends should be
are similar to the gear designations performance as well. properly maintained for the perfor-
of oils. These specifications, which During installation, grease is mance of the vehicle as well as the
were originally classified by NLGI, often packed into these bearings safety of the public. Their lubrica-
follow a testing protocol outlined by hand. Not only should grease tion doesn’t need to be mysterious
by ASTM International. The clas- be packed into the bearing, but and can often be performed during
sifications for automotive greases some grease should be applied to normal maintenance of your vehicle.
fall into two categories: chassis the housing and on the wheel end’s If you take your vehicle to a repair
and wheel bearings. Some greases inside surfaces where the bearing shop, be sure the principles outlined
that pass both testing protocols sits. This will help prevent corrosion. here are followed so you will be set
may bear the dual-service mark. The housing should also have some for your next road trip. ML
Chassis greases are classified as grease in the cavity surrounding
References
“LA” for light duty and “LB” for the bearing, but it should not be
severe duty. Wheel bearing greases ASTM D7450-13 Standard Specifica-
filled. This space in the cavity will
have three classifications: GA, GB tion for Performance of Rear Axle Gear
permit grease to be spun out of the
Lubricants Intended for API Category
and GC. Like the chassis classi- bearing as well as provide room for
GL-5 Service, ASTM International 2018
fications, the main difference is thermal expansion of the lubricant.
Annual Book of ASTM Standards
how robust the grease is and how If the cavity is completely filled,
ASTM D4950-14 Standard Classifi-
severe the driving conditions are. grease churning and excessive heat
cation and Specification for Automotive
They range from mild duty (GA), will result.
Service Greases, ASTM International
to moderate duty (GB) and severe Certain wheel ends have
2018 Annual Book of ASTM Standards
duty (GC). The regreasing frequen- grease fittings that enable peri-
Fitch, J.C., Scott, R., & Leugner, L.
cies follow the same pattern, with odic regreasing of the bearing. If
(2012). “The Practical Handbook of
more frequent relubrication for regreasing these with a grease gun,
Machinery Lubrication - Fourth Edition.”
GA to less frequent with GC. be sure to apply grease slowly and
Pirro, D.M. & Wessol, A.A. (2001).
Most greases employed in automo- stop if abnormal back-pressure is
“Lubrication Fundamentals - Second
tive applications tend to hold the experienced. Keep in mind that a
Edition, Revised and Expanded.”
dual-service mark, which includes grease gun can generate enough
LB and GC. pressure to blow out seals and create About the Author
The GA-GC wheel bearing an opening that will allow contam- Wes Cash is the director of
classifications have similar testing inants to enter and oil to bleed out. technical services for Noria Corpora-
performed per the specification, tion. He serves as a senior technical
but the protocol varies based on Key Considerations consultant for Lubrication Program
the classification. All wheel bearing When lubricated correctly, Development projects and as a senior
classifications are subjected to wheel ends should meet or exceed instructor for Noria’s Oil Analysis
consistency, dropping point and their estimated design life. The key II and Machinery Lubrication I
low-temperature performance items to consider include main- and II training courses. Wes holds
tests. They also all have the same taining the oil level, regreasing at a Machine Lubrication Technician
criteria for consistency, which puts the proper frequency, using the (MLT) Level II certification and a
them in the NLGI consistency right specification for oils and Machine Lubricant Analyst (MLA)
range of 1-3. The most common greases, and routinely monitoring Level III certification through the
grease consistency is NLGI 2. For the wheel assembly for any signs of International Council for Machinery
the other two tests, the acceptance leakage. If the seals are leaking and Lubrication (ICML). Contact Wes at
limits change according to the the lubricant is allowed to be flung wcash@noria.com to learn how Noria
classification, with GC requiring out of the housing, it may reach can help you choose the right lubri-
higher values in most of the other the brakes, which could lead to a cants for your application.
. 4X S
Stronger - Made of
high
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. 360° View - no
obstructions for
easy viewing of
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Proactive Monitoring
Made Easy.
The ultimate 2-in-1 accessory, the Bowl serves as both a sight glass and BS&W bowl. Made of impact-resistant
Tritan™, the Bowl is stronger than other drain port sight glasses, crystal clear and chemically resistant. The distinctive
contour design allows for immediate visual inspection of the oil, along with early detection of potential contamination
problems. The Bowl’s rare earth magnetic drain plug also protects machinery by attracting and drawing wear particles
to the bottom, proactively preventing machine failure and enabling a thorough drain of contaminants.
Whether you are entry-level or a seasoned professional, Machinery Lubrication 4. Encounter new vendors and
is the place for you. Join lubrication and reliability professionals from services: Keep our industry
industries such as petrochemical, power generation, pulp and paper, food thriving by staying current
processing, manufacturing, fleet and off-highway. Start driving change in your with the latest technologies
facility and join us in Houston for Machinery Lubrication 2018. and information.
Wednesday, Nov. 7
7:00 a.m. – 5:00 p.m........................................Onsite Registration WHY ATTEND?
7:30 a.m. – 8:00 a.m................................... Continental Breakfast Machinery Lubrication 2018 covers every facet of the
8:00 a.m. – 8:50 a.m............................................Opening Keynote lubrication and oil analysis industry. In Houston, you
9:00 a.m. – 9:35 a.m......................................... Learning Sessions will hear how industry leaders, such as Simmons Feed,
9:35 a.m. – 10:40 a.m..........................Coffee Break in Exhibit Hall Aleris and Owens Corning, put their facilities on the path
10:40 a.m. – 11:15 a.m........................................ Learning Sessions to excellence. Realize immediate bottom-line results by
obtaining real-world information and processes that you
11:25 a.m. – 12:00 p.m....................................... Learning Sessions
can put into practice as soon as you return home.
12:00 p.m. – 1:30 p.m.............................................................Lunch
1:30 p.m. – 2:05 p.m.......................................... Learning Sessions
2:15 p.m. – 2:50 p.m.......................................... Learning Sessions
WHO ATTENDS?
2:50 p.m. – 3:50 p.m................ Refreshment Break in Exhibit Hall As a machinery lubrication and oil analysis professional,
3:50 p.m. – 4:25 p.m......................................... Learning Sessions you value best practices to ensure bottom-line results.
Whether you’re entry-level or a seasoned professional,
4:35 p.m. – 5:10 p.m.......................................... Learning Sessions
you’ll benefit from the comprehensive schedule of
5:10 p.m. – 6:30 p.m.............Networking Reception in Exhibit Hall learning sessions, case studies and colleague interaction.
___________________________________________________________ Make plans now to attend Machinery Lubrication 2018 to
_9:00 a.m. – 6:30 p.m..........................................Exhibition Hours network with and gather information from the following
attendees:
Thursday, Nov. 8 CBM Professionals Mechanical Engineers
7:30 a.m. – 4:00 p.m........................................Onsite Registration
Engineers & Engineering Operations Managers
7:30 a.m. – 8:00 a.m............Continental Breakfast in Exhibit Hall Managers
8:00 a.m. – 8:35 a.m......................................... Learning Sessions PdM Analysts and Specialists
Facility Managers
8:45 a.m. – 9:20 a.m......................................... Learning Sessions Plant Managers & Engineers
9:20 a.m. – 9:55 a.m...........................Coffee Break in Exhibit Hall Hydraulic Specialists
Quality Managers
9:55 a.m. – 10:30 a.m........................................ Learning Sessions Lab Managers
Reliability Coordinators
10:40 a.m. – 11:15 a.m........................................ Learning Sessions Lube Analysts
11:25 a.m. – 12:00 p.m....................................... Learning Sessions Reliability Engineers
Lubricant Industry
12:00 p.m. – 1:30 p.m.............................................................Lunch Professionals Reliability Team Leaders
1:30 p.m. – 2:05 p.m.......................................... Learning Sessions Lubrication Technicians Reliability Technicians
2:15 p.m. – 2:50 p.m.......................................... Learning Sessions & Specialists Safety Managers & Directors
3:00 p.m. – 3:35 p.m......................................... Learning Sessions Machinery Engineers Senior Reliability Engineers
3:35 p.m. – 4:15 p.m................. Refreshment Break in Exhibit Hall
Maintenance Engineers TPM Coordinators & Facilitators
4:15 p.m. – 4:50 p.m.......................................... Learning Sessions & Managers
5:00 p.m..................................................Giveaways in Exhibit Hall … and more
Maintenance Planners
___________________________________________________________
9:00 a.m. – 5:00 p.m...........................................Exhibition Hours Managers of Maintenance
and Reliability
OPENING KEYNOTE
10 GAMECHANGERS
SHAPING THE FUTURE
OF LUBRICATION AND
THE LUBRICANTS
INDUSTRY
Jim Fitch
Wednesday, Nov. 7
8:00 – 8:50 a.m.
Lubrication is going through
transformational change powered
by both internal and external forces.
These include Industry 4.0, the
technology clusters of condition-
based maintenance, the industrial
internet of things, standardization
of asset management systems,
globalization and low-wage
economies, environmental
protection, energy conservation, risk
and reliability management, value-
chain alignment, etc.
= Case Studies
_________________________________________________________________________________________________________________________________________________
Case Study: How a Proper Lubrication Program all your maintenance efforts on installation, alignment
Can Cut Downtime by 50 Percent and balancing but get lubrication wrong. Learn the best
Tim Newman - Maintenance Manager, and William Hada practices for centrifugal pump lubrication, including how
- Director of Maintenance Services, Simmons Feed to select the right lubricant, additives and viscosity, as
Ingredients well as other factors that affect a pump’s operation. By
understanding these key issues, you can increase the
This case-study presentation will explain how the lifespan of your centrifugal pumps.
Simmons Feed Ingredients plant in Southwest City,
Missouri, was able to reduce equipment breakdowns by
How to Cost Justify a Lubrication Program
more than 50 percent and achieve an annual cost savings
Thomas Kurtz - Director of Business Development, Noria
of nearly $1 million once the organization decided to put
Corporation
more of an emphasis on lubrication. Attendees not only
will hear how the plant made a complete transformation in Plain common sense says that lubrication programs
its lubricant storage and handling practices but also see need support from plant and corporate-level managers
how it changed its culture through employee training and to succeed. Is a lack of support from management
certification, allowing the company to focus on predictive restraining your lubrication initiatives? In this session,
and proactive maintenance rather than just reactive work. you’ll learn how to confidently cost justify, explain and
defend your lubrication project. You’ll also learn how
Steps for Successful Change: Leading Your Team to calculate lubrication program ROI, stop lubrication
into the Future program budgets from getting slashed, and help
Chris Christenson - Director of Education, Noria Corporation management understand the impact of an effective
lubrication program on maintenance and reliability.
One of the biggest hurdles when trying to implement
a lubrication program is that people naturally choose How to Calculate Grease Quantity and Frequency for
the path of least resistance or effort. This principle can
Bearings
be a powerful influence. At times, it will inspire those
Bennett Fitch - Senior Technical Consultant, Noria
involved to create innovative solutions that unleash great
Corporation
efficiencies. However, it can also be a force that holds your
team in old habits, ruining attempts by leadership to move One of the most fundamental roles of a lubrication
to new processes. This presentation will offer examples of technician is to ensure that all grease points are
the challenges leaders face when implementing change as relubricated when necessary. As fundamental as this
well as some of the key steps that you can take to convert task may be, knowing exactly how much grease to apply
resistance into a successful project implementation. and how often to regrease is not as straightforward as
it might seem. This presentation will provide answers
Boosting Centrifugal Pump Reliability Through Lubrication to these common questions as well as offer advice on
which feedback mechanisms can reduce the influence
Best Practices
of unknown variables. Attendees will walk away with the
Terry Harris - President, Reliable Process Solutions
knowledge to finally be able to remove the uncertainty
Centrifugal pumps are among the most prevalent types from these fundamental lubrication practices.
of industrial equipment, with many facilities employing
hundreds or even thousands of these machines. KPIs and Metrics for Lubrication Program Success
Frequently, redundant backup pumps are kept on hand, Alejandro Meza - Senior Technical Consultant, Noria
which can lead to a lack of concern about emergency Corporation
breakdowns. However, significant costs can still be
incurred if a pump fails. This presentation will explain Key performance indicators (KPIs) are essential for
why a pump failure is unavoidable if you concentrate measuring the progress of any project or initiative. A
successful lubrication program implementation is no items that are essential for any organization involved
exception. This presentation will discuss the importance in food processing. Attendees may be shocked to learn
of measuring relevant parameters for a comprehensive how far the FSMA reaches and what all it encompasses.
lube program in a facility or fleet, from lubricant selection Discover what this act means for your organization and
to storage, handling, application and disposal. Attendees lubrication program.
will learn critical KPIs that can be implemented across any
lubrication management system to monitor the success of Error-proof Your Lubrication Program with Visual
their programs. Lubrication Best Practices
Bennett Fitch - Senior Technical Consultant, Noria
Basic Lubrication: What Every Lubrication Professional Corporation
Should Know In the world of reliability-centered maintenance, every
Wes Cash - Director of Technical Services, Noria opportunity to prevent a mistake from an unintentional
Corporation error should be considered. Many practices surrounding
Lubrication is the cornerstone of any reliability program, the requirements for machinery lubrication are often
yet few truly understand what all lubrication entails. It challenging to get right. Even when correct procedures
doesn’t have to be a foreign language to you any longer. are understood, human error can still be a factor. This
In this session, Noria’s Wes Cash will explain the basics of can lead to unnecessary and inadvertent mistakes, which
lubrication along with the key terms that will further your contribute to catastrophic failures and downtime. This
understanding and ability to help drive your lube program session aims to help error-proof your lubrication program
to success. by reviewing the many visual and often simple-to-
implement proactive opportunities at your plant.
Food Processing Lubrication: 7 Critical Items for Success
Loren Green - Senior Technical Consultant, Noria Using Single-Point Lessons for Improving Lubrication Task
Corporation Training
The lack of knowledge regarding the Food Safety Chris Christenson - Director of Education, Noria Corporation
Modernization Act (FSMA) and ISO 21469 is truly Training is an investment in your team. Its ultimate goal
astounding, especially considering that violations of is often to align your efforts in order to make a positive
this important legislation not only can lead to fines but impact on your lubrication program. But what is required
also jail time for those involved and the boardroom-level to ensure that your training is retained? How can you verify
leadership. This presentation will outline seven critical that new knowledge is converted into applicable skills? In
Attendees will leave this session with thought-provoking
ideas for how they can better monitor their machines and
have real-time data relating to the current condition of
those critical assets.
The Power of Correlating Lubrication, Vibration and Infrared your lubricants and equipment not only can enhance
Analysis Results the reliability of your plant but can also significantly
Matt Adams - Technical Consultant, Noria Corporation improve the environmental sustainability of your
operation. This presentation will review several case
Although each individual predictive maintenance studies illustrating the increasingly important role that
(PdM) technology can function properly alone, these oil condition monitoring plays in improving an operation’s
tools truly flourish when working in unison. Utilizing sustainability efforts.
lubrication, vibration or infrared as a second and third
form of verification can often help identify and resolve
equipment reliability issues. This session will investigate When and Why to Choose Synthetic Lubricants: Making the
several common component failures and how each Financial and Reliability Case
technology has a role to play in the detection process. Alejandro Meza - Senior Technical Consultant, Noria
Attendees will acquire a better understanding of several Corporation
PdM technologies and how they must work together to Synthetic lubricants offer the opportunity to solve many
minimize equipment downtime. of the challenges related to lubrication. The benefits
can be estimated in terms of energy savings, extended
Using Oil Condition Monitoring to Improve Environmental lubricant life, enhanced machine performance and life, and
Sustainability ultimately cost reduction. This presentation will provide an
Greg Livingstone - Executive Vice President, Fluitec overview of common synthetics, including their properties,
performance and the value that can be achieved through
Monitoring and trending the health of your lubricants is their use, so you can determine whether these lubricants
an essential part of a predictive maintenance program. are the right solution for your application.
Taking appropriate actions based on the condition of
I know the you will continue to experience unplanned downtime due
to lubrication issues.
decided to go.”
immediate and measurable. The crown jewel of any
lubrication excellence program is often a world-class lube
room. This case-study presentation will detail the lube
– Mark Hogrefe, Maintenance Manager, room transformation at the Owens Corning composites
PolyOne Corporation plant in Aiken, South Carolina, including the processes,
lessons learned and benefits of having world-class
practices on display. Hear how an upgraded lube room led
to measurable gains on the company’s bottom line.
So You Want a World-class Lube Room?
Prepare to Justify, Educate and Communicate How to Inspect and Analyze New Oil Deliveries
David Williams - Manager of AOS Asset Reliability North Loren Green - Senior Technical Consultant, Noria
America, and Glenn Delaney - Corporate Reliability Manager, Corporation
Aleris While numerous organizations test lubricants upon
The transformation to a world-class lubrication room receipt, many others do not, which is unfortunate and even
is a journey that requires engagement of the entire dangerous. Several studies have shown that, on average,
workforce as well as management to be successful. This 3.6 percent of lubricants on the market are mislabeled or
case-study presentation will explain how the Aleris plant off-specification. Therefore, at the very least, you should
in Clayton, New Jersey, was able to achieve buy-in from be checking the viscosity of your incoming lubricants.
both management and maintenance teams to achieve This presentation will outline what else you should be
a world-class lube room. Attendees will hear how the looking for and why, as well as the proper procedures for
facility transformed a 40-plus-year-old culture of various receiving and accepting new lubricant deliveries, including
satellite storage areas and poor handling practices into a the required testing, decontamination, stock rotation and
state-of-the-art operation. In addition, you will learn how storage methods.
the facility sold the business case for capital expense,
educated its workforce to change the culture and Understanding Oil Filter Ratings and Why They Matter
developed processes to sustain the results. Eric Krause - Technical Specialist, Pall Corp.
Although anyone who uses an oil filter on a regular basis
Garbage in, Garbage out: How Lubricant Storage should understand the difference between beta values
Can Make or Break Your Lube Program and micron ratings, confusion often exists over what
Alan Knight - Senior Reliability Leader, Mueller Co. these numbers mean. This presentation will explain filter
More and more maintenance professionals are waking ratings and discuss why beta values truly matter. It will
up to the fact that lubrication issues are a crucial factor also provide important information on the applicable
in rotating equipment failures. Some reports estimate test methods and presentation of the results. Attendees
that as many as 40 percent of all bearing failures in these will hear about the various filter rating methods and why
assets can be attributed to lubrication-related issues. higher beta ratings can equal better reliability.
This case-study presentation will detail how Mueller
Co. had implemented a dedicated oil program but was
overlooking a foundational element – storage conditions.
Attendees will learn that regardless of the brand of
lubricants you use, if this single factor is overlooked, your
lube program will not produce the results you desire, and
EXHIBITION
EXHIBIT HALL
117 Refreshments/ 418 Tuesday, Nov. 6 | 4:30 – 6:30 p.m.
Reception Area Wednesday, Nov. 7 | 9 a.m. – 6:30 p.m.
Thursday, Nov. 8 | 9 a.m. – 5 p.m.
Machinery Lubrication 2018
113 114 213 314 413 414 showcases advanced technologies
and products in an interactive
event that drives lasting business
111 112 211 212 311 312 411 412
connections. The Machinery
Lubrication 2018 audience is high-
110 209 210 309 310 409 level and solutions-driven, and they
visit the exhibition hall to gain the
107 108 207 208 307 308 407 408 insight needed to excel in lubrication
and oil analysis.
105 106 205 206 305 306 405 406 Meet face-to-face with a diverse
group of industry leaders at
104 203 204 303 304 403 Machinery Lubrication 2018.
important to keep
>> Open to all Machinery Lubrication 2018 attendees
and exhibitors
HOST HOTEL 2. Check out Minute Maid Park, home to the Houston
Machinery Lubrication 2018 will be held at the Astros.
Houston Marriott Westchase in Houston, Texas. 3. Enjoy Discovery Green, an urban oasis where you
Noria has made arrangements for attendees to can listen to local musicians or explore local
receive a $155 discounted room rate. You can take craftsmen at monthly markets.
advantage of these discounted rates by booking
your room(s) directly with the Houston Marriott 4. View African, Byzantine and Native American art
Westchase using the group code ML18 at the time at the Menil Collection.
of your reservation. Availability is limited, so you
are encouraged to make reservations early. 5. Visit the Art Car Museum (aka “Garage Mahal”)
where you can see the Roachster up close and
Houston Marriott Westchase personal.
2900 Briarpark Dr.
Houston, TX 77042 6. Witness 250,000 bats emerge at dusk under the
1-800-452-5110 Waugh Drive Bridge along the Buffalo Bayou.
Register online at Call (M-F, 8-5 p.m. CDT) Fax your registration form to:
Conference.MachineryLubrication.com 918-392-5038 918-746-0925
WHAT’S INCLUDED?
Full-Conference Registration Includes:
>> Admission to all conference sessions
>> Conference proceedings
>> Opening general session and keynote address
>> Exhibition hall access
>> Daily meals and refreshments
>> Networking receptions
Register online at Call (M-F, 8-5 p.m. CST) Fax your registration form to:
Conference.MachineryLubrication.com 918-392-5038 918-746-0925
Zip/Postal Code ______________ Country _____________________ ____ (Qty.) 3-9 Full-Conference Registrations... $695 each
Card # _________________________________________ Exp. _________ ____ (Qty.) 1:00 p.m. - 4:30 p.m.
Turn Your Lube Room into a Cost-Savings Machine
Name on Card _________________________________________________
Registrations canceled before Oct. 5, 2018, will receive a full refund. Cancellations made after Oct. 5, 2018, are subject to a $75
administrative fee. Cancellations after Oct. 23, 2018, are not eligible for refunds. However, you may send a colleague in your place. If
you are unable to send a colleague, the entire registration fee will be forfeited.
1328 E. 43rd Ct. | Tulsa, OK 74105
Noria.com | 800-597-5460
HIGHLIGHTS:
>> 10,000-square-foot Exhibit Hall
>> 45+ Learning Sessions
>> 7+ Networking Events
>> 4 Pre-conference Workshops
>> Plus much more!
DRIVE CHANGE IN
YOUR FACILITY.
Attend and Learn How To:
>> Significantly Reduce Maintenance Costs
>> Get Out of the Cycle of Recurring Failures
>> Prevent Costly Reliability Problems
>> Detect Early Stage Equipment Failures
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