CONTENTS

May - June 2010

Features machinerylubrication.com
Features in Detail
4 As I See It
Whats Hot? Current Trends in
Lubrication & Oil Analysis
Jim Fitch compiles a list of many of the most promising
and important trends in our industry today.

8 Viewpoint
You Have Gear Oil Questions.
Here are Some Answers.
Mark Barnes provides answers to your questions on
gearbox lubrication, and gear oils in general.

12 The Exponent
The Sound of a Train Not Running:
Act Now to Rewrite Your Plants History
Take action now to improve your OBE/OEE by executing
proven reliability strategies.

26 Hydraulics at Work
Battle Plans for the War Against
14 Cover Story Leaking Hydraulic Connections
Lubrication Superheroes! When you consider the true cost of oil leaks, surrender is
Area lubricators and an oil analyst team up to keep contamination on the run at the not an option. Be aware of all of the weapons available to you.
Packaging Corporation of America mill in Tomahawk, Wis. Editor-in-chief Paul V.
Arnold provides all of the details in this in-depth case study. 28 From the Field
Dont Miss Your Opportunities to
Improve with Lube Storage
28 32 Keep your lubricants clean, cool and properly identified
by following the best practices in this article.

32 Contamination Control
Rethinking Condition Monitoring
Strategies for Todays Turbine Oils
Modern turbine oils are formulated differently than
their cousins of the recent past. As a result, you shouldnt
monitor them with old-style analytical techniques.
54 40 Lubricant Selection
Synthetic Lubes, Contamination Control
and Oil Analysis Team Up
A comprehensive strategy has helped a co-generation
facility improve machine reliability.

60 Perspective
Screening vs. Testing: Know the Difference
When Monitoring Contaminants
Editorial Features Departments Jason Kopschinsky provides guidelines for used oil analysis.
2 Editors column 32 Contam. Control 24 Product News
4 As I See It 40 Lubricant Selection 36 Product Spotlight 62 Back Page Basics
8 Viewpoint 54 Get to Know ... 38 Product Supermarket Make Infrared a Heat-Seeking
12 The Exponent 58 Certification News 42 Bookstore Weapon in Your PdM Arsenal
26 Hydraulics at Work 60 Perspective 53 Crossword Puzzler IR is an indispensable technique for many temperature
28 From the Field 62 Back Page Basics 56 Web Preview measurement applications.

Machinery Lubrication www.machinerylubrication.com May - June 2010 1

EDITOR
PdM Poll Shows
Solid State, Buy-in Barriers,
PAUL V. ARNOLD
NORIA CORPORATION Fuzzy Future
A merican industrial plants have made significant progress in the
areas of predictive maintenance and condition monitoring,
however there is still plenty of room for improvement. That is the
main message that can be gleaned from the results of a recent
survey by Azima DLI, a provider of predictive machine and condition
monitoring and analysis services.
The study, conducted in January and February and released in
April, queried engineers and plant managers in the U.S. about the
methods their facilities employ to ensure the reliability and perform-
ance of critical production assets. The 162 respondents represented
predominantly large plants in a variety of industry segments.
The survey found that 64.8 percent of plants currently have a
machine condition monitoring / predictive maintenance program in
place. That figure didnt really surprise me and coincided with
personal findings from the large amount of interviews and site visits
that Ive conducted over the past decade. Two-thirds of facilities
pursuing CM/PdM is a much better state than when I started covering
the manufacturing and process industries in 1998. What did surprise
me, though, was that out of plants that currently do not have a
CM/PdM program, 84.2 percent said that they had no plans to
initiate one in 2010. That is living in the dark ages, my friends.
Outstanding technology tools and services are readily available and
are affordable to the vast majority of industrial companies, big or
small. Those facts are not news to Azima survey respondents who
currently have a CM/PdM program. The poll shows that these
advanced plants utilize four main tech tools in an effort to stay one
step ahead of downtime. A total of 84.8 percent said that vibration
analysis/monitoring is a primary component of their program. A total
of 75.24 percent said they actively utilize lubrication oil analysis. That
is followed by infrared thermography at 71.43 percent, and motor and
battery testing at 40.95 percent. Ultrasonic/ultrasound rounded out
the top five, but at less than 9 percent.
Buy-in and Barriers
Respondents from advanced plants felt pretty good about the
work that they have done in this area 75.7 percent stated that
they were currently satisfied with the results of their CM/PdM
program and 97.3 percent believed that the success of their
program directly impacts their companys bottom line. That last
point definitely deserves a pat on the back ... however, respondents
intimate that, more often than not, they have to supply their own
pat. Senior management is missing the boat on the value derived
2 May - June 2010 www.machinerylubrication.com
from lube oil analysis and other proactive methods. Only one in
three (35.1 percent) respondents believed that senior- and C-level
executives at their company would rank the CM/PdM program as
important to revenues and the overall productivity of the organiza-
tion. A total of 62.1 percent said their bosses find the program to
be somewhat important.
That sentiment on buy-in was echoed in a separate question on
the major barriers to CM/PdM program success. For those engineers
and plant managers who arent currently satisfied with their program,
25 percent placed the blame on the fact that the program was not
viewed as strategic by C-level executives. Thirty-two percent stated
that a lack of funding or budgetary support was standing in the way.
With this mixture of good and not-so-good news, perhaps it is
not surprising that 55.7 percent of respondents dont exactly know
what solutions and tools are needed to maintain an effective
CM/PdM program.
Gain a Clearer Picture
Are you among the many who are seeking help or direction in
this area?
Are you wondering whats new and whats on the horizon for
condition monitoring and predictive maintenance?
Are you in need of advice in order to expand, update or overhaul
your CM/PdM toolkit (or your CM/PdM program)?
Are you looking for ways to get more returns from your program?
Are you looking for the means to obtain buy-in and get upper
management to see the true importance of your efforts?
If you answered yes to any of these questions, look no further
than Noria Corporations RELIABLE PLANT 2010 conference and
exhibition. This outstanding event, held August 31-September 2 at
the Nashville Convention Center in Nashville, Tenn., offers you the
opportunity to expand your CM/PdM knowledge through educa-
tional sessions (particularly in the Lubrication Excellence and
Reliability World tracks) and through open dialogue with suppliers
of vibration analysis, lubrication and oil analysis, infrared thermog-
raphy, and ultrasound products and services (most notably on the
50,000-plus-square-foot expo floor).
Information on exhibitors, educational sessions and registration
is accessible on the RELIABLE PLANT 2010 Web site,
http://conference.reliableplant.com. Stay on the cutting edge by
attending this years conference and exhibition.
- Paul V. Arnold, editor-in-chief
Machinery Lubrication
AS I SEE IT
Whats Hot? Current Trends
in Lubrication & Oil Analysis
JIM FITCH
NORIA CORPORATION
T he dynamics of the lubrication field today is advancing at an
intensity and pace that has not been seen since the early days of
the industrial revolution, around the time of the invention of the
steam engine. In many respects, the roots of lubrication still are
solidly tied to the products and methods that were spawned during
that era. We see this in the types of lubricants that are used and the
products, tools and approaches with which they are employed.
Still, evolutionary and perhaps revolutionary change is afoot.
Since I first started writing my column in Machinery Lubrication
magazine, and previously in Practicing Oil Analysis magazine, Ive
tried to bring to light industry trends that should be important to
both suppliers and users alike. These relate to not only whats new
and different but equally to what is being phased out and poten-
tially heading toward obsolescence. Many of these aspiring
methods and ideas were later validated by their continued growth
of interest and usage. As is often the case, it is easy to see that some
of the trends today are really reincarnations of ideas and concepts
that first emerged in the past but were years ahead of their time.
Staying abreast with landscape-changing industry movements
can define the difference between success and failure in a world
characterized by punishing competition and unforgiving economic
conditions. With this as the backdrop, Im going to compile a list
of many of the most promising trends in our industry today. I will
stay away from what is simply in vogue and flavor-of-the-month
concepts. Instead, the trends I want to emphasize are those that
meet one or more of the following criteria:
they have staying power;
they are value-based (reduce costs and/or increase productivity);
they are new problem-solvers (overcome previously unresolved
problems);
they are better problem-solvers (provide measurable improve-
ments over prior methods)
Trends in Lubricant Selection and Use
Correct viscosity: More precise selection of viscosity is getting
renewed attention. Viscosity affects a number of important factors,
including energy consumption, wear and tolerance to contamination.
This relates to not only the ISO viscosity grade, but also to the viscosity
4 May - June 2010 www.machinerylubrication.com
index. Getting in the general ballpark on viscosity seems to be no
longer acceptable, and for good reason.
Not selecting lubricants solely on film strength: Todays lubricants
need a range of performance qualities, so choosing a lubricant that
delivers the complete package is the greater priority. This includes
(depending on lubricant type) such features as dispersancy, foam
suppression, moisture-handling ability, corrosion protection, oxida-
tive stability, viscosity index and, of course, good lubricity.
Judicious use of premium and synthetic lubricants: The rage to
switch to premium and synthetic lubricants as a silver bullet for
every problem is winding down. We are now more aware of the true
strength of these lubricants and their appropriate application. They
can indeed solve a plethora of problems, but not all problems.
Precision lubrication means correctly matching these lubricants to
the applications to which they are best applied.
Energy-conserving and environmentally friendly lubricants: In the
past 10 years, huge strides have been made in this area, but even
then, it seems weve barely scratched the surface. Brace yourself as
the pace of change in this area greatly picks up steam.
Replacing grease with oil in mission-critical applications: The
debate continues on the grease vs. oil front. From my vantage
point, the balance of power is tilting toward oil in a range of relia-
bility-critical industrial applications.
Dumping economy formulations: Buying lubricants from the lowest
bidder is rarely a recipe for achieving machine reliability at the lowest
possible cost. Its time to stop pretending to save money by buying
cheap, commodity-grade lubricants to save a quick buck at the expense
of tomorrows need for reliability. Through greater awareness and
education, large user organizations are finally getting the message.
Additive reconstruction: You wouldnt discard a new car the first
time it ran out of windshield wiper fluid. Despite cries of resistance
from some industry players, when done using sound practices,
many depleting lube oil additives are candidates for a booster shot,
as more and more users are discovering.
Halting Contaminant Invasion
Headspace management: Many contaminants enter a lubricant
by means of the headspace above the tank or sump oil level. Novel
Machinery Lubrication
new methods have been introduced in recent
years to restrict their ingression.
Smart filter carts: Filter carts can do much
more than clean new or used oils. Many are
instrumented with computers and oil analysis
sensors, enabling them to perform a number of
smart tasks while unattended.
Dryer and cleaner targets: Aggressive setting of
target dryness and cleanliness levels is more than
just a fad. Its proved to be an active and depend-
able means to boost and sustain machine
reliability.
More focus on a lubricants air-handling ability:
In the past, entrained air and surface foam werent
much more than a casual concern. Todays users
are proactively responding to aeration and foam
issues before irreparable harm is done.
Addressing contaminant exclusion first:
Restoring a contaminated lubricant to a clean and
dry state after the fact can be costly. Keeping lubri-
cants clean and dry by proactive contaminant
exclusion is a much more economical alternative.
Far greater attention and resources are applied to
controlling ingression than simply achieving
contamination control by filtration alone.
Varnish management: Varnish problems have
reached nearly chronic levels in certain applications
in recent years. In response, a flurry of new products
and services has been rolled out to keep varnish in
check. More such products are likely on the way.
Whats New in Oil Analysis
Multiple technologies in condition-based
maintenance (CBM): Reliability is a collaborative
effort. Tools should work together and not in
isolation to achieve reliability. Oil analysis is
increasingly being teamed with vibration analysis,
infrared thermography and other technologies to
enhance the CBM toolbox.
Particle counting of opaque fluids (like engine
oil): Fluid cleanliness is as important in machines
lubricated with opaque fluids as it is for those
that use turbine oils and hydraulic fluids. After
all, if its important, you measure it. Particle
counts of engine oils are currently being
performed successfully by labs that have recog-
nized this need.
On-site oil analysis in an instant-information
world: Despite frequent claims to the contrary,
many oil analysis labs cant seem to achieve quick
turnarounds on oil analysis data. This fact
continues to spawn growth in on-site labs for
those who want to know now.
Live zone sampling: Pulling samples from
sump bottoms and large reservoirs is being
phased out. Such defective practices cripple the
potential value of oil analysis. Modern programs
place primary and secondary sampling ports in
active live zones.
The database in your filter: The filter is the
recipient of a vast amount of root cause and
symptomatic information relating to your
machine and oil. Get on the bandwagon and start
inspecting and analyzing it.
Reporting the RUL: Monitoring the remaining
useful life (RUL) of a lubricant is one of the
primary objectives of oil analysis. For instance,
tracking the progressive depletion of additives
provides a relatively good estimate of RUL. This is
a great metric to have on an oil analysis report.
Standardized test methods: Through the
committee work of ASTM D02.96, the number of
new standardized test methods for in-service
lubricant testing is at an all-time high. It is a
welcome change that is long overdue.
Grease sampling and analysis: Despite its
inherent challenges, new methods have been
introduced to simplify the sampling of grease for
analysis by labs the same way that oil has been
done for years.
Online sensors and real-time monitoring: The
growth in this category of oil analysis has picked
up sharply in recent years. There are now online
sensors for nearly every data parameter.
Suppliers Get New Attention
Buying more than lubrication: Users are
becoming much more sophisticated and analytical
in selecting lube brands and distributors. The
emphasis is less on cost and performance and more
on a broader range of capabilities and lubrication
deliverables, including quality, service, support,
contamination control and other important factors
within the framework of lubrication excellence.
Chain-of-custody quality control: Many big-
brand lube marketers are taking aim at quality at
each link within the chain of custody. Included are
additive and base oil suppliers, blend plants,
distributors, transport companies and jobbers.
Cleanliness and dryness now are being included in
the definition of quality.
Packaging, Storage,
Handling
Lubricant expiration dates: Lubricants are not
like a fine wine that gets better over time (not
even in storage). The use of visible expiration date
markings on lube package labels is finally
becoming widespread.
Graphical lubricant tagging: The risk of acci-
dental use of the wrong lube in a machine is totally
unnecessary. Modern tagging methods for lubes
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MACHINERY LUBRICATION
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 AS I SEE IT
include the use of naming system, shape coding and color coding
that make cross-contamination of lubricants nearly infallible.
Good housekeeping: Well-designed and well-kept lube rooms set
the stage for lubrication excellence. So, too, is the banishment of
outdated tools such as funnels, unclean top-up containers, transfer
systems, etc.
People and Metrics
The death of the oiler: Pride in ones profession is good for the
employee and good for the employer. Lubrication shouldnt be
treated as a mindless task. An oiler is an oil can, not a living,
thinking person. On the other hand, a lube technician is an indi-
vidual who is trained, has the tools he needs, is empowered, works
from the neck up and is paid well.
Working the metric: People respond to measurement (what gets
measured gets done). There are all kinds of potential metrics,
including those that are lagging and leading (what just happened,
whats going to happen). Good metrics need to provide conspic-
uous reporting of program performance relative to goals. They
need to include overall lubrication effectiveness (OLE) and preven-
tive maintenance (PM) compliance. Leading organizations are way
ahead on this front.
The Power of an Educated and
Certified Workforce
Thousands are now certified: The International Council for
Machinery Lubrication (ICML) has certified thousands of lubrica-
tion and oil analysis professionals through ISO-compliant
standardized testing. Dont be left behind.
Multilingualism: Reliability and condition monitoring specialists
are adding new technologies to their bag of tricks. Attainment of
multiple certifications (in oil analysis, vibration and thermography)
by individuals is increasingly more common.
Training on demand: Training on demand is knowledge on
demand is best practice on demand. New and more common use
of knowledge management systems on corporate intranet servers is
making this possible.
PMs, Methods and Tools
Accessorizing machines for lubrication excellence: Most machines
arent ready for modern lube methods. They lack the basic accessories
for live-zone sampling, contamination control, quality inspections,
condition-based maintenance and correct relubrication. Most OEMs
fail to include these items in the original bill of material. As a result, one
of the first steps of lubrication excellence is to select the correct acces-
sory items and retrofit them to the machine.
Not just any procedure: Procedure-based maintenance needs to
deploy the rights of lubrication (i.e., the right lubricant, the right
procedure, the right location, the right frequency, the right tools,
etc.). Doing lubrication and doing lubrication right are two
entirely different concepts and have different reliability outcomes.
Lubrication and the computer age: Many organizations only
now are leveraging the power of the computer and the Internet to
increase maintenance productivity and optimize reliability. Others
6 May - June 2010 www.machinerylubrication.com
still are lagging way behind. The opportunities are enormous and
include automated delivery of work plans, dynamic routing, tools
management, workforce and skills management, and material
management.
One-minute daily inspections: Daily critical lube inspections
often can be more effective than even the most sophisticated oil
analysis program performed monthly. After all, you cant catch a
fish unless your hook is in the water. Learn the modern skills of
doing these daily inspections.
Bottom sediment and water: Nearly all of the things that you
dont want in your oil are heavier than your oil. These include wear
particles, sludge, water, antifreeze and dirt. Put BS&W on your
inspection route.
Site glass oil analysis: Checking oil color, foam, aeration and
water on a daily basis is a smart idea, as many have found out. Put
this on your inspection route, too.
Optimizing relubrication frequency: Many users are revisiting
past decisions relating to regreasing and oil drain intervals. This
includes proactively improving the use of lubricants to extend
service life as well as relubricating on condition or at least at inter-
vals more closely relating to actual need. Its time to optimize your
relube practices.
Souped-up grease guns: Todays grease guns can be instru-
mented for more precise lubrication and include options such as
volume meters, sonic pickups and back-pressure gages. The grease
gun is still alive and well in the world of lubrication.
Be a Trend-Setter
The advancement of new technology and the urgent need to
enhance plant reliability are altering the face of lubrication today.
These are exciting times for those of us who have been patiently
waiting for radical change in our field. For users, the opportunity to
transform fleet or plant equipment to lubrication excellence is
enormous. Start with education. Follow that by benchmarking your
program to best practices. Next, begin the systematic process of
transformation. Plenty of help is available for those who dont want
to go it alone. Stay ahead of the curve and reap the benefits.
About the Author
Jim Fitch has a wealth of in the trenches experience in lubrication, oil
analysis, tribology and machinery failure investigations. Over the past two
decades, he has presented hundreds of lectures on these subjects. Jim has
published more than 200 technical articles, papers and publications. He
serves as a U.S. delegate to the ISO tribology and oil analysis working group.
Since 2002, he has been director and board member of the International
Council for Machinery Lubrication. He is the CEO and a co-founder of Noria
Corporation. Contact Jim at jfitch@noria.com.
SEE WHATS NEW
IN LUBRICATION
Identify, test and compare products hands
on. Hear case studies and ask questions.
The Lubrication Excellence conference
is one of 3 co-located events at Reliable Plant
2010 in Nashville, TN. See page 43 or visit
conference.reliableplant.com for details.
Machinery Lubrication
VIEWPOINT
You Have Gear Oil Questions.
Here are Some Answers.
MARK BARNES
NORIA CORPORATION
O f all the lubricated components out there, there are few more
pervasive than gearboxes. From high-speed gearing in turbo-
machinery to slow-turning gear reducers, lubricant selection,
application and condition have perhaps the single-largest effect on
the reliability and longevity of gearboxes. Here are some of the more
common questions and responses Ive received over the years on
the topic of gearbox lubrication and gear oils in general.
Question: What is the correct viscosity to use in a typical gear
reducer?
Answer: Viscosity selection for gearboxes is a careful balance
between load, speed/reduction ratio, gear geometry and operating
environment. Like most applications, a good place to start is with
the original equipment manufacturer (OEM) recommendations.
This information is commonly posted on the nameplate affixed to
the outside of the gear casing.
Its always a good idea to consult with a lubrication
engineer before selecting a viscosity grade other
than the one recommended by the OEM.
In surveying this data, well often see viscosity referenced not
in terms of ISO grades, but rather the American Gear
Manufacturers Association (AGMA) grade or occasionally in
Saybolt Universal Seconds (SUS). The AGMA grade is a numeric
rating that correlates directly with gear oil viscosity grades. For
example, an AGMA 5 oil is equivalent to an ISO VG 220 oil,
AGMA 6 to ISO VG 320, AGMA 7 to ISO VG 460, and so on. You
also may see the letters S or EP appended to the AGMA grade.
This refers to the need for a synthetic (S) oil or an oil formulated
with extreme-pressure (EP) additives.
For older gearboxes, lubricant specifications are sometimes
given in the older and now-defunct unit of SUS. For example, a
gearbox manufacturer may state the need to use a 700-second
oil. To convert to the appropriate ISO viscosity grade, a good rule
of thumb is to divide the SUS value by 4.6. Therefore, a 700-second
oil becomes an ISO VG 150.
8 May - June 2010 www.machinerylubrication.com
Q: Should I always stick with the OEMs recommendation?
A: The answer to this question is most definitely no! While you
certainly shouldnt be going against the OEMs recommendations
without good reason, extreme ambient operating conditions (e.g.
very high or very low temperatures), shock loading or extreme duty
cycles, or higher-than-normal load ratings may dictate that a
change to the OEMs recommendations is warranted. Its always a
good idea to consult with a lubrication engineer before selecting a
viscosity grade other than the one recommended by the OEM.
Q: When should I consider using a synthetic gear oil?
A: Synthetic gear oils offer some very real advantages in some
circumstances. For example, in extremely low temperatures, a
synthetic gear oil will have a much lower viscosity than the equiva-
lent grade of mineral oil. This can be an advantage during cold
temperature start-up when channeling can cause temporary lubri-
cation starvation, particularly in splash-lubricated gear drives.
Likewise, at higher operating temperatures caused by high ambient
temperatures or the process itself, synthetic gear oils will have a
higher viscosity than the equivalent grade of mineral oil and will
typically resist oxidative and thermal breakdown better than
mineral oil. A rule of thumb is to use a mineral oil if the operating
temperature is below 160 degrees Fahrenheit, but consider
synthetics or premium mineral-based oils (such as Group III gear
oils) if the operating temperature is likely to exceed 180 F. Of
course, there are other reasons why a synthetic oil might be advis-
able, such as for extended oil drain or other operational reasons.
When using synthetic gear oils, pay close attention to the type of
synthetic in use. Many synthetic gear oils are made from polyal-
phaolefin (PAO) basestocks, which are compatible with
conventional mineral oils. However, we increasingly see the use of
polyglycol gear oils, which have excellent lubricity while helping to
keep the gearbox clean of deposits due to their natural detergency
and clean-burning tendency. In fact, some gear manufacturers
are factory-filling their boxes with polyglycol-based oils. Polyglycols
are incompatible with hydrocarbon basestocks (mineral or PAO
synthetic), thus requiring extreme caution in helping to prevent
accidental mixing and cross-contamination. When switching from
a hydrocarbon oil to a polyglcol, perform a thorough cleaning and
Machinery Lubrication
 VIEWPOINT
flushing to help prevent hydrocarbon residues from reacting with
the polyglycol gear oil.
Q: We recently switched to a synthetic oil because of higher
operating temperatures. Our lubrication supplier is recommending
an ISO VG 460 synthetic in place of the ISO VG 680 mineral oil
weve always used. Why the change in viscosity grade?
A: When switching from mineral to synthetic gear oil, its not
uncommon to drop down one ISO grade. The reason is due to the
fact that synthetic oils typically have higher viscosity indexes than
mineral oils. As a result, when you compare the viscosity of, for
instance, a ISO VG 680 mineral oil to that of a ISO VG 460
synthetic, they will have very similar viscosities at 160 F. Before
applying this rule, its important to plot the viscosity-temperature
profile of each oil and consider the anticipated operating tempera-
ture along with high and low ambient temperatures to insure you
select the correct grade for the specific application.
Q: I heard that EP additives are corrosive to yellow metals such
as brass and bronze. Is this true?
A: In some circumstances, this can by true. Certain types of EP
additives are designed to react with metal surfaces under elevated
temperatures to protect them under boundary lubrication condi-
tions. These types of additives are often referred to as chemically
active, and at elevated temperatures (greater than 140 to 150 F),
they can indeed start to react with yellow metals. For this reason,
apply caution when selecting gear oils for worm drives; the ring gear
is often a yellow metal alloy.
A good way to check to see if an oil is chemically active is to look
at the specification sheet provided by the lubricant manufacturer. On
the sheet, you will typically see a test referred to as copper strip corro-
sion (ASTM D130). This tests how chemically reactive an oil is to
copper and copper-containing alloys. For gear oils, a 1a rating is typi-
cally a good indicator that the oil is chemically inert, while higher
ratings (such as 1b or 2a) might indicate possible problems when used
in certain gearing at elevated operating temperatures. Often, a lubri-
cant manufacturer will specifically state this oil should not be used in
gearboxes containing yellow metals; other times, the manufacturer
will simply state that the oil is appropriate for steel-on-steel applica-
tions the implication being that they should not be used in situations
where the ring gear is brass or bronze.
10 May - June 2010 www.machinerylubrication.com
Q: For some of our gear drives, the OEM is calling for a
compounded oil. What does that mean?
A: For certain gear geometries, particularly worm drives, the
dominant frictional force is sliding friction as opposed to rolling
friction. Under these circumstances, the lubricant must help reduce
the coefficient of sliding friction. To do this, special additives that
historically have been comprised of fatty acids are used to help the
surfaces slide relative to one another. Another name used to
describe this type of oil is steam cylinder oil because the same
effect is desired in lubricating steam cylinder walls. Compounded
oils are not commonly used for steel-on-steel gears.
Q: My lubricant supplier says that if we switch to a synthetic, we
can expect to see a 10 percent reduction in energy consumption. Is
this true?
A: The answer to this question depends on several factors. For
example, when applied to a spur gear, which will typically operate
with 95 percent or higher efficiency, its hard to understand that
there is sufficient frictional loss from the lubricant to justify this
claim. Likewise, if the dominant frictional loss is not due to fluid
friction but rather the process or some other mechanical factor,
again its unlikely that youll see any difference. However, in some
situations where theres plenty of sliding friction and the lubricant
is responsible for most of the energy loss, there are circumstances
where a 5 to 10 percent drop in energy has been seen. As with every-
thing, consider all factors rather than simply accepting anecdotal
evidence, no matter what the source.
Hopefully Ive addressed a question you may have had about
gear oils. If not, feel free to drop me a line.
As always, this is my opinion; Im interested in yours.
About the Author
As a skilled educator and consultant in the areas of oil analysis and
machinery lubrication, Mark Barnes has helped numerous clients develop
effective machinery lubrication programs and troubleshoot complex lubri-
cation problems through precision lubrication and oil analysis. As vice
president of Noria Reliability Solutions, Mark and his group work on proj-
ects in the areas of: plant audits and gap analysis, machinery lubrication
and oil analysis program design, lube PM rationalization and redesign,
lubricant storage and handling, contamination control system design and
lubrication, and mechanical failure investigations. Contact Mark at
mbarnes@noria.com.
Machinery Lubrication
THE EXPONENT

The Sound of a Train Not

Running: Act Now to
DREW TROYER
NORIA CORPORATION Rewrite Your Plants History
C hris Knight is among my favorite musical artists. Hes a
Kentucky-bred folk/Americana singer/songwriter who writes
real songs about real people. One of his songs is titled A Train Not
Running; its found on his album The Jealous Kind. Heres what
Chris says in the first verse of the song:
The sound of a train not running has been keeping me awake.
The Westmoreland mine aint run much coal since back in 88. I got
on at the sawmill, but Ive got to find a better way before the sound
of a train not running is going to carry me away.
The chorus goes as follows:
And every time you look at me, Mary, I want to tell you someday
well leave the sound of a training not running a thousand miles away.
Chris Knight has captured in song how a plant closing affects
people at a human level the sense of despair, the feeling of embar-
rassment because you cant provide for your family in the manner
youd like. He goes on in the song to discuss the economic impact
and the toll that takes on people and families. Its a powerful
message encapsulated in a short but very moving song penned by a
talented songwriter.
The Impact of a Plant Closing
A plant closing can dramatically affect a community. In many
instances, the plant is the prime mover in a communitys economy.
$250,000
$200,000
$150,000
$100,000
$50,000
Median House Price
Median with 3% Annual Inflation
$0
Apr-06
In a small community, the closure of a plant can render it a ghost
town. In these instances, property values drop precipitously
almost overnight in some cases. This costs each family tens or even
hundreds of thousands of dollars in lost equity. Even in a large city
like Detroit, median property values dropped by more than 37
percent between April 2006 and April 2010 even higher when the
figures are adjusted for inflation (see figure). More telling, the
value of the 25th percentile price house the working mans
house dropped by more than 53 percent in the same period,
falling from almost $118,000 to just $55,000 since 2006.
The toll doesnt stop there. Families are forced to liquidate
investments and retirement plans to make ends meet. The personal
toll is even higher. Families are forced to endure duress and are
frequently forced to move away from family and friends to seek
work elsewhere. Moreover, despair associated with economic hard-
ship can regrettably lead to substance abuse, domestic violence,
divorce and even suicide.
Crisis as Motivator
We know that plants close for many reasons; many of those
reasons are external and uncontrollable. For instance, many plants
are situated near the source of raw materials. When the raw mate-
rials are depleted, the need for the plant disappears. The recent
economic downturn was largely attributable to a macroeconomic
breakdown of our capital market.
Unfortunately, however, in many instances, the sound of a train
not running occurs because we failed to manage the business
effectively. There are several good examples of heroic 11th-hour
turnarounds like Dofasco Steel and Quaker Oats Danville, Ill.,
plant. But far too often, we wait too long. Quaker Oats thwarted
plant closure by coming together as a team and focusing its efforts
on creating value. It reduced per case costs by 37 percent! The
opportunity was there all along, but the risk of hearing the sound
of a train not running motivated them to act.
Why is crisis often a necessary ingredient to success?

Sep-06

Feb-07

Jul-07

Dec-07

May-08

Oct-08

Mar-09

Aug-09

Jan-10

Researchers Daniel Khaneman and Amos Tversky suggest that

humans tend to be very risk averse when things are going OK. We
Figure 1. The Detroit metro real estate market has been devastated only tend to exhibit risk-seeking behavior when our backs are
by the economic downturn. against the wall. I think theyre referring to complacency, the

12 May - June 2010 www.machinerylubrication.com Machinery Lubrication

essence of why Jim Collins in his seminal book Good to Great says
that good is the enemy of great.
A Reliability-Based Challenge
Those of us who specialize in reliability management possess
the skills to enable a manufacturing firm to be great. We cant
control external factors, but we can significantly impact the
plants ability to maximize profits when things are good and to
get lean and hunker down to survive the tough times. Our primary
measure of success is overall business effectiveness (OBE)/overall
About the Author
Drew D. Troyer is a champion of effective reliability management and
passionate about helping companies find hidden profits inside their plants. As
a highly sought consultant to Fortune 500 manufacturing firms, award-
winning columnist and teacher, he understands both management
expectations and plant-floor realities. Troyer is a Certified Reliability Engineer
(CRE), a Certified Maintenance and Reliability Professional (CMRP), and
chairs the standards committee of the Society for Maintenance and Reliability
Professionals (SMRP). Contact Drew at dtroyer@noria.com.
Crossword Puzzler Solutions: From Page 53

equipment effectiveness (OEE). OBE/OEE is a measure of our V V P E T R O L E U M

manufacturing effectiveness compared to perfection. If OBE/ I A Y P
S R A A R
OEE increases, return on net assets (RONA) increases and the C O N T A M I N A N T D O
world is good. O I K D L L
I challenge you to do some what-if analysis. Look at your S S Y N T H E T I C I I L
I H R K T T I
income statement assuming your current OBE/OEE. Then, recast T I E I H N
your income statement after asking yourself the question: What if Y F B B R V I G
we were the best we can be in terms of availability, yield and S E O E P R E S S U R E
U R L T S M L
quality? Ive done this with some of my clients; the result in terms M L R T O M A H A W K G E
of increased RONA and share price is often mind-boggling. In many E U O G R R M
instances, it creates the bold, outrageous goal to become discon- R O B I N G R A Y A U L L A G E E
L E R T A A N
tented with good and start going after great. I T A I G S T
Take action to improve your OBE/OEE by executing proven reli- N I P F O A M E
ability management strategies. Doing so may help you derail the P H A
S Y
sound of a train not running.

Machinery Lubrication www.machinerylubrication.com May - June 2010 13

 S TOR Y
CO V E R

14 May - June 2010 Machinery Lubrication

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Machinery Lubrication May - June 2010 15
 COVER STORY
Batman has Robin. So does The First Line of
Defense. In the latter case, it is Robin Gray,
the PCA mills veteran lubricant analyst.
No Run-of-the-Mill Mill
Company: Packaging Corporation of America, a
manufacturer of containerboard and corrugated
packaging. It has four production mills and 68
converting operations. PCA has annual sales
exceeding $2 billion and more than 8,000 employees.
Plant: PCA mill in Tomahawk, Wis., a town of
3,600 residents located in northern Wisconsin.
The facility officially opened in 1920.
Size: More than 500,000 square feet.
Plant employment: The Tomahawk mill employs
419 workers, including nearly 100 in maintenance-
related positions. Production workers are
represented by the United Steelworkers union;
maintenance workers are represented by the
International Association of Machinists.
Products: The mill has two semi-chemical corru-
gating machines that annually produce more than
500,000 tons. Each machine can produce grades
from 23 pounds up to 40 pounds. The mill also
produces a variety of performance and specialty
grades of corrugated medium.
FYI: The sites No. 4 papermaking machine is among
the largest and most productive corrugated medium
machines in the world. Built and commissioned in
1978, it runs 3,150 feet per minute.
16 May - June 2010
The mill is working hard to improve the storage
and handling of its lubricants.
Phil Dahl, a 25-year vet with 12 years
of lubrication experience
Brad Gaedtke, a 25-year vet with two
years of lubrication experience
Larry Dirkx, a 43-year vet with 30
years of lubrication experience
Dennis Thompson, a 36-year vet with
28 years of lubrication experience
Michael Fleming, a 31-year vet with
15 years of lubrication experience
Foes aim to avert the heightened
senses of these seven linemen.
Every day, these guys touch the
equipment, feel it, smell it, says
Weizenicker. If we relied purely on the
vibration analysts coming around once a
month, potential issues could fall
through the cracks and eventually
become big problems. But these guys are
there every day. Those basic care routes
and oil routes give you a heads up.
Each area lubricator works the day
shift (from 6:30 a.m. to 2:30 p.m.) and
covers a specific, mission-critical area of
www.machinerylubrication.com
the plant: the No. 4 papermaking line,
the No. 2 papermaking line, the power-
house, the wood room, the
semi-chemical cooking line and the
mobile equipment shop.
From a technical standpoint, they
report to maintenance. But on a daily,
organization chart basis, they report to
production, says Weizenicker. They
kind of have two supervisors.
More or less.
We could have five bosses or zero; its
all in how you look at it, says Gaedtke.
We have a lot of autonomy to decide
what to do and how to do it. It comes
down to accountability and responsibility,
which are part of the culture here.
Autonomy is also the result of knowl-
edge. PCAs lubrication program is
currently based on best practices defined
by Noria Corporation and sanctioned by
the International Council for Machinery
Lubrication (ICML). Since January 2005,
Noria (with instructors such as Jim Fitch,
Drew Troyer and Jeremy Wright) has
provided 20 days of on-site training to a
Machinery Lubrication
 COVER STORY
At right, Mighty Might offline filtration units
are found throughout the mill. Below, an
enormous roll of corrugated medium
engulfs a production area.
Maintenance leadership
at the mill includes
project engineer Mark
Micke (left), maintenance
reliability supervisor
Keith Weizenicker
(center) and superinten-
dent of maintenance
reliability Craig Slonski.
host of PCA employees, including the seven area lubricators and
each of their seven back-ups.
Slonski states: We needed to understand what good lubrica-
tion practices were in greater detail rather than heres an oil can,
now go do it. Even though we had some educational opportunities
at the local technical college, we needed much more than that. We
had to fill the gap. What else is out there? Noria was out there.
Mill leaders werent looking for attendance from the students.
They were looking for absorption and application of the training.
Having the right people with the right educational background
is a key, says Slonski. We want people who have a drive and
passion for this. That drive and passion is shown by taking these
classes and passing and understanding and demonstrating.
Passing is exemplified in the fact that 15 employees at the
Tomahawk mill have gone on to obtain 19 certifications through
ICML. For example, Gaedtke holds Machine Lubrication Technician
Getting the Upper Hand with the Help of Upper Management
The PCA mill in Tomahawk, Wis., is succeeding because of the health
and performance of its production equipment. That is a direct result of
the work being done by the plants maintenance and production
employees. And, that is a direct result of the support given by upper
management at the corporation.
Management supports predictive and preventive maintenance proj-
ects, both verbally and monetarily. Corporate management regularly visits
the Wisconsin mills vibration analysis office and oil analysis lab.
They are a huge supporter of what we are doing, says maintenance
reliability supervisor Keith Weizenicker. They come to discuss what we do
and how we do it. We are fortunate to have people at all levels of our
company that understand reliability and what you need to get to the
18 May - June 2010 www.machinerylubrication.com
(MLT) Level I and Level II certificates and is in the process of
pursuing a Machine Lubricant Analyst (MLA) certification.
Understanding and demonstrating is shown in how area lubri-
cators have applied the teachings.
Gaedtke says, All of these concepts are introduced in the
classes. You see how you can prevent all of this stuff (contamina-
tion, water ingress, etc.). Our company has been very supportive in
putting this into action. If it is not being done, do it. When you
have someone saying, Go ahead and do it, that makes the job
easier and more fun.
Among first steps, area lubricators eliminated milk jugs and
makeshift lubricant transfer containers and purchased sealable and
reusable containers specially designed for such tasks. Clean, single-
use paper funnels replaced metal funnels. Quick-connect couplers
were installed on gearboxes and hydraulic units to make it easy to
add or drain oil and to enable filtration for contaminants.
point where you run 56 days without a breakdown. That may be where
this company is a little different than other companies.
The difference is evident in the capital budget set aside for reliability
projects at Tomahawk.
With a capital budget, we dont have to beg, borrow and barter to get
what we need, says superintendent of maintenance reliability Craig
Slonski. We just need to make decisions on how best to use that budget.
Such support isnt lost on mill workers.
Management has said, These guys are going to save us lots of money.
Lets give them the tools with which to work, says area lubricator Brad
Gaedtke. As a result, there is nothing we cant do and theres nothing
that cant be improved.
Machinery Lubrication
 COVER STORY

Individual projects developed with time. For instance, Dahl has leak-detection dye. As soon as you dump that dye in, you can see
made it his personal mission over the past two years to find and fix the leaks. We used to go through a lot of oil because of the leaks.
every oil leak in his area. We still go through oil, but not anywhere like we previously did.
Where you have a ton of water, you normally cant see the
leaks. You could walk around for a day looking for the leaking oil An Arsenal of Weapons
and not find it, he says. But we purchased a five-gallon bucket of Batman has a cache of crime-fighting gadgets at his disposal,
both on his utility belt and in his cave. Iron Man has a high-tech suit
Swampy on the Outside, Clean on the Inside: How PCA that can produce rays, beams, pulse bolts and a defensive energy
shield. Every superhero has something. Therefore, its no surprise
Defeats the Goo Monster on Paper Machine No. 4 that The First Line of Defense is armed to the hilt for the fight
against contamination.
The Tomahawk mill has invested heavily in Mighty Might offline
filtration (OLF) units produced by Norman Filter Company. These
compact filtration systems transfer and filter water and particle
contaminants out of hydraulic, lube and gear oils. The dual-head
design of these units enables operation in two stages: the first
removes water, the second removes particulate matter. Oils are
filtered at a steady flow rate of four gallons per minute to achieve
purification down to 3 microns absolute.
We probably have 100 Mighty Mights, says Gaedtke. In-house
oil analysis shows you have some dirt or water or metals in a gearbox.
I go through, attach a Mighty Might to the quick-connect coupler,
and in a matter of seconds, I have an offline filter system on it.
PCA believes the OLFs are a step above single-pass filtration
Maintenance (especially lubrication) can be a
challenge in an environment like this.
systems.
You wont reach your ISO targets with single-pass, so you end
up changing the oil, says Weizenicker. If you change the oil, you
The environment in the Packaging machine is expected to run continuously are going to get 50 percent of the dirt; the other 50 percent is still
Corporation of America plant in Tomahawk, (24/7) between these outages. stuck at the bottom of the box. With the offline filters, you clean it
Wis., is tough on equipment. With the pres- The rotating equipment you see in the up. You get those multiple passes through there. You clean the
ence of raw material residue and 5.5 million pictures is on an automatic, dedicated pres- whole box, top to bottom. The oil is now good. It might run
gallons of water flowing through plant surized greasing system. The dosing another two or three years doing it this way. There is no sense in
processes on a daily basis, conditions can get frequency of this system is set to provide dumping a 30-gallon gearbox. If its dirty, clean it up. Its two years
downright swampy. What follows is mainte- fresh grease to the bearings and purge any old, so what? A couple of filters and you are good to go.
nance reliability leader Craig Slonskis contaminants several times per day.
OLF are one reason why the Tomahawk mill has reduced its
observations on the two plant-floor snap- We keep contaminants and water out of
oil usage 28 percent since 1997 (18,300 gallons vs. 13,200 gallons
shots in this sidebar. bearings in this area by selecting proper seals
in 2009).
These are pictures of the forming section for each application, providing correct instal-
on Paper Machine No. 4. This is the first part lation of these seals, and maintaining the
Area lubricators also bring together multiple tools to vanquish
of the machine which makes paper. As you seals with proper procedures. Also, we contamination.
can see, our rotating equipment lives in a provide fresh grease to purge the housings of They combine a Mighty Might with a desiccant breather kit from
pretty harsh environment. any contaminants which may have bypassed Y2K Fluid Power to pre-filter oil drums in lube storage areas. And, they
The goo on the equipment is a combi- the seals. marry an oil heating element to an OLF on filter carts to polish cold oil.
nation of water and very fine wood fiber Cold oil doesnt clean very well, says Weizenicker. So, we
which builds up on the machine during oper- took an oil heating element and put it into a tube. We put an offline
ation. This goo is difficult to clean off while filter system with it so the oil comes out of the unit, gets heated,
in production without causing sheet breaks, goes back in and sits there and flushes. You have 140- to 150-degree
which create downtime. During our sched- oil going through this cavity rather than just cold oil. That gets
uled outages, the operating department does much more dirt and junk out.
a thorough cleaning of the machine. The PCA also wards off water ingress through the use of Inpro/Seal
machine looks very good after a cleaning, bearing isolators and air seals.
which enables maintenance to perform visual
Bearing isolators are non-contact, permanent bearing protec-
inspections and repairs without the added
tion devices that consist of a rotor and a stator. The rotor turns
complications of goo.
with a rotating shaft while the stator is pressed into a bearing
The machine is scheduled down for
maintenance every five to six weeks. This
housing. The two components interact to keep contamination out
of the bearing enclosure and lubricant in.

20 May - June 2010 www.machinerylubrication.com Machinery Lubrication

 With the air seals, we add 3 cubic feet per minute of air and it pres- We have a situation in the boiler house right now, he says.
surizes the gearbox so no water gets in, says Madlung. We used to The oil light on an OLF was changing. Something had altered it.
run 1,000 parts per million of water in some of our gearboxes. We used So, I cut the pleats of a used filter apart to see what was in the oil.
to change that oil out every year. Since putting the air seals on and Something in the system has changed. There are some indicators.
attaching a filtration system, we change the oil out now once every five My job is to find out the equipment issue or issues and why this is
years and the water level is consistently below 50 ppm. occurring. If I cant find the answers here, I will talk to the equip-
ment manufacturer and the oil vendor. Its a crime scene
The Investigator investigation going on.
Batman has Robin. So does The First Line of Defense. In the Saving the day is a tough job, but someones got to do it.
latter case, it is Robin Gray, the PCA mills lubri-
cant analyst. This Robin is no learning-to-fly
superhero-in-training. Gray has worked at the
plant for 34 years, including 23 years as a lubri-
cation technician. He has spent the past eight as
the main sampler and lone analyst of new and in-
service lubricants.
On average, I spend half of my day on the
plant floor, says Gray, who has MLA II and
MLT I certifications through ICML, and has
received tribology (levels I and II) training
through CSI/Emerson and ferrography training
through Predict. I get involved with lubrication-
related projects with the area lubricators and the
maintenance department. I spearheaded many
of the dedicated offline systems. I have to wear a
lot of hats.
The one Gray enjoys most is his inspector hat.
Over the course of a five-week interval, he takes
close to 300 samples. He then returns to the
mills oil analysis laboratory and becomes The
Investigator.
I love to investigate things and see what is
creating problems, he says.
Gray has a host of tools at his disposal a
computer, microscopes, beakers and graduated
cylinders, a Karl Fischer moisture analyzer, an
ultrasonic bath cleaner, scales, a mechanical
separator/screener. But his favorite device is the
labs 5200 Trivector Analyzer from CSI/Emerson.
It does a comparative analysis on new oil out
of the barrel and the used oil that we extract from
a piece of equipment, says Gray. It tests to
determine if the oil is still intact and clean. It tells
you what degree of contamination is in there. The
first test picks up metals. The second test meas-
ures water content. The third test is a laser
counter which counts particulate down to a 2-
micron level.
Gray analyzes more than fluids. He frequently
performs a postmortem examination on oil filters.
If you suspect something, you take Robin a
filter, says Gaedtke. He cuts the pleats apart
and sees what is going on inside. Using the tools
in his lab, he can identify if there is wear debris
and, if so, what type of metal it is brass, steel.
The Investigator recounts an ongoing filter case.

Machinery Lubrication www.machinerylubrication.com May - June 2010 21

 COVER STORY
You have to love this stuff, he says. It has to be in your blood.
Showing Off Super Speed
Look, up in the sky! Its a bird. Its a plane. No, its the mainte-
nance and production metrics at the Tomahawk mill. Thanks to
The First Line of Defense, The Investigator and the rest of the Justice
League, contamination doesnt conquer. Chaos is getting KOd.
Check out the comments by the good guys.
We are running faster than ever, longer than ever. We are
running speeds that were unheard of in the past, says Gray.
I have a machine that is designed to run 500 feet per minute,
and its averaging 1,600 feet per minute, says Madlung.
We have pushed oil life in some machines to three or four years
because of filtration and oil analysis, and I only changed the oil
because we were getting into uncharted territory, says Symonds. I
dont know how long this stuff will last.
Upper management looks at the bottom line. Six, seven or eight
years ago, the bottom line for lubrication improvements wasnt
that great or noticeable, says Gaedtke. They look at it now and it
is much better. They are aware and they are interested. They want
to see more from us.
We have 500 or so pumps in the mill. A dozen years ago, the
rack in our pump rebuild shop was full as a result of lubrication,
contamination and other issues, and we were working overtime to
get those rebuilt, says Weizenicker. If you look at the rebuild rack
right now, there are probably only one or two pumps, and we only
have one person doing the rebuilds.
22 May - June 2010 www.machinerylubrication.com
After Battling Moisture, Desiccant
Breather Gets a Breather
It seems as if you cant walk 50 feet at the PCA mill in Tomahawk
without seeing a desiccant breather. Area lubricators at the site reli-
giously use breather products to remove dissolved, emulsified and
free moisture from oil drums, gearboxes, hydraulic systems, feed
pumps and turbines.
I put breathers on virtually every piece of my equipment, says
area lubricator Brad Gaedtke. That has made a huge difference.
The hygroscopic agent inside the breather starts off as a partic-
ular color. As moisture is absorbed, the gel pellets change color.
That is a signal to a lubricator to replace the breather with a spare
and plug the wet breather into an air dryer. Overnight, the pellets
revert to their original color. This breather is marked with a paint
pen (signifying the recharging date and the number of times it
has been recharged). It eventually is put back into rotation on the
plant floor. A breather is used and recycled up to five times before
it is discarded.
Unscheduled downtime on Paper Machine No. 4 has dropped
37 percent since 1999 (from 3.50 percent to 2.21 percent in 2009)
and it has dropped 62 percent on Paper Machine No. 2 during that
timeframe (4.08 in 99 vs. 1.56 in 09), says Slonski.
In this battle of right vs. wrong, good vs. evil, cleanliness vs.
contamination, the superheroes are winning.
Machinery Lubrication
PRODUCT NEWS

Hose Reel Bend Restrictors Oil Analysis Spectrometer

Coxreels added bend restrictors to accompany its vast selection of reel
accessories. This hose option is available on low-pressure hose reels with
one-fourth, three-eighths and one-half of an inch of PVC, rubber and nitrile
hose handling 300 psi of working pressure. Bend restrictors are suggested
for hose assemblies that might receive substantial usage
and are recommended for oil, fuel, air, water and
other fluid transfer applications. They protect the
hose end from kinking, excessive wear and tearing.
The Spectroil Q100 Oil Analysis Spectrometer is an analytical instru-
ment that detects and quantifies metals in used (in-service) oils and
hydraulic fluids that are indicative of an abnormal condition. Use the
Spectroil Q100 to help predict mechanical failures in their early stages
so corrective action can be taken. The product works equally well in the
laboratory or in the field under less-than-ideal conditions. The standard
configuration is set up to analyze 22 wear metals, contaminants and
additives in 30 seconds.

Coxreels Spectro Inc., a subsidiary of QinetiQ North America

www.coxreelscom www.spectroinc.com
800-269-7335 978-486-0123

High-heat Spray Nozzle

Oil-Rite has designed a spray nozzle
that can be positioned within close prox-
imity to machinery operating at high
temperatures. The co-axial tubing
delivers both fluid and air to the target
area while keeping the dispensing mecha-
nism itself at a safe distance from the Halal-certified Lubricants
heat source. It is an effective and inex- Klber Lubrication now offers a full line of Halal-certified lubricants. With more than
100 products carrying the Halal designation, Klber has the largest number of lubricant
pensive tool for dispensing lubricant or
choices for food processing equipment in the world.
industrial fluids on ovens, molding
Klber has long supported the food
equipment, welding operations, heat-
and beverage industry by offering
sealing equipment and other applications high-performance NSF-registered
where heat is a factor. and Kosher-approved products. By
achieving Halal certification,
Oil-Rite Corporation food processors can meet
www.oilrite.com any requirements necessary
920-682-6173 to meet the needs of
customers.
Grease Fitting/Bearing Cleaner Klber Lubrication
The Grease Buster cleans grease fittings and bearings using
penetrating oil and hydraulic or pneumatic pressure. The product www.klubersolutions.com
addresses the common issue of plugged-up grease fittings and 800-447-2238
bearings. It consists of a heavy-duty adjustable hydraulic coupler,
a cylinder and a piston with a knob. Remove the piston, fill the
cylinder by pouring in a penetrating solvent, start the piston back Shaft Alignment Tool
into the cylinder, place the tool onto the grease fitting and force SHAFTALIGN is a high-precision, easy-to-
the solvent into the fitting/bearing by tapping the piston. use shaft alignment tool incorporating
human-error-proof functions. With its TFT
Grease Buster Tools backlit color display, it combines simplicity of
www.greasebustertools.net operation with precise measurement and state-
of-the-art technology. Intuitive auto-flow
513-897-5142
capability guides you to obtain the desired
alignment condition. The innovative Active
Clock measurement mode automatically
collects laser coordinates for the correspon-
ding shaft position. The product is upgradable
as alignment requirements increase.

Ludeca Inc.
www.ludeca.com
305-591-8935

24 May - June 2010 www.machinerylubrication.com Machinery Lubrication

 Return Line Filter Elements
SwiftGreen filter elements feature a reusable machined aluminum bypass valve
assembly. Because they can be used indefinitely with fresh filter elements, these
bypass valves significantly reduce expenses while minimizing disposal volume.
Since used filters are often classified as hazardous waste, SwiftGreen filter
elements provide an opportunity to reduce environmental footprint and save
money. Typical cost savings
average 35 to 40 percent
over traditional return
line filter elements.
Swift Filters Inc.
www.swiftfilters.com
877-887-9438
Multi-purpose Borescopes
Spectronics COBRA and COBRA-Plus multi-purpose borescopes feature a
built-in UV LED and white light LED. It allows technicians to accurately detect refrig-
erant and fluid leaks, uncover
cracks in heat exchangers,
conduct boiler and ductwork
inspections, diagnose evapo-
rator coils and much more.
The UV LED is ideal for
finding refrigerant leaks, fluid
leaks and surface flaws; the
white light is perfect for
general inspection. All compo-
nents are packed in a sturdy
plastic carrying case with a
foam insert.
Spectronics Corporation
www.spectroline.com
800-274-8888
Infrared Thermometer
Omegas handheld OS-DT8855W
infrared thermometer is a non-contact
temperature measurement instrument
that features a laser circle/dot sight.
The patented laser sight system defines
the target for point-and-shoot measure-
ment of temperatures from minus-58 to
2,498 degrees F (minus-50 to 1,370 C)
and reads surface temperature in less
than a second. It comes with a hard
carrying case, mini-tripod, power
supply, Type K thermocouple, USB wire-
less data receiver, software and
probe lead adaptors.
Omega Engineering Inc.
www.omega.com
203-359-1660
Machinery Lubrication www.machinerylubrication.com
Explosion-proof LED Light
Equipped with a handle, pedestal mount, 100-foot
cord and explosion-proof plug, the Magnalight EPL-PM-
1X30LED-100 from Larson Electronics is ideal
for cleaning tanks and vessels in
hazardous locations. The main
difference between the LED
model and standard incan-
descent model is the 30-watt
Par 38 LED light bulb that
delivers 5,400 lumens and draws
just a tenth of the electric power of
the 300-watt incandescent version.
The EPL-PM-1X30LED-100 is avail-
able for 120 volts and 220 volts.
Larson Electronics
www.magnalight.com
800-369-6671
Ultrasonic Inspection System
UE Systems designed the Ultraprobe 3000 to significantly impact
energy conservation by locating
compressed air and
steam trap leaks as
well as faulty steam
traps, which can lead to millions of
dollars in energy waste. Using UE Systems
data management software, plant techni-
cians can download data from a leak survey
and, in real-time, generate reports that
demonstrate loss and existing carbon footprint,
as well as cost reduction and energy savings.
UE Systems Inc.
www.uesystems.com
800-223-1325
Enhanced Turbine Oils
To address increasing performance demands on modern turbines
and provide a proactive solution to new cleanliness and varnish
concerns, ConocoPhillips Lubricants enhanced its baseline
turbine oil to offer a TOST (Turbine Oil Stability Test ASTM
D943) rating of 15,000 hours as opposed to the previous 7,500
hours. Simultaneously, the company introduced Ultra-Clean
turbine oil featuring a guaranteed cleanliness level of ISO
18/16/13 and a TOST rating of 15,000 hours.
ConocoPhillips Lubricants
www.conocophillipslubricants.com
877-445-9198
May - June 2010 25
HYDRAULICS AT WORK

Battle Plans for the

War Against Leaking
BRENDAN CASEY
Hydraulic Connections
T he problem of leaking connectors has been around for as long
as hydraulics themselves. It is beyond annoying. It wastes oil. It
poses a safety hazard. It can compromise machine reliability. And,
rectification consumes the finite resources of the maintenance
department. Its a big problem.
According to hydraulic hose manufacturer Gates, it is estimated
that 370 million liters of oil leak from hydraulic equipment every
year. That is a staggering statistic even more so when you
consider that as little as one liter of oil can pollute up to one
million liters of water.
Sealing technologies have advanced considerably over the past
30 years, but so too have hydraulic system operating pressures and
response times. In other words, seal technology has improved, but
the stresses they must endure also have increased. As a result, the
battle has not been won.
But far from waving the white flag, there is much that can be
done to ensure the best possible chance of victory in the war
against leaking connections.

Engineer Them Out

If a hydraulic system doesnt have connectors, they cant leak.
Sure, a system must have some connectors, but their number can
be significantly reduced through the intelligent use of manifolds,
cartridge valves and stack valves, known collectively as integrated
hydraulic circuits, or IHCs (figures 1 and 2).
Figure 2. Vertical Valve Stack
While the application of this technology normally falls within the
realm of the machine designer, if your plant has older machines
with line-mounted valves and lots of (leaking) connections, then
replacing these line-mounted valves with one or more IHCs will
simplify the plumbing and greatly reduce the number of potential
leakage points.

Use Reliable Connectors

Tapered-thread connectors such as NPT and BSPT are the least
reliable type of connector for high-pressure hydraulic systems
because the thread itself provides a leak path. The threads are
deformed when tightened and, as a result, any subsequent
loosening or tightening of the connection increases the potential
for leaks.
Connectors which incorporate an elastomeric seal such as UN-
O-ring, BSPP, ORFS and SAE four-bolt flange offer far superior seal
reliability.
So for leak-free reliability, replace pipe-thread connectors with a
Figure 1. Manifold Assembly type that incorporates an elastomeric seal, if possible.
26 May - June 2010 www.machinerylubrication.com Machinery Lubrication
 That said, the worlds most commonly used hydraulic connec-
tion, the JIC 37-degree flare, relies on a metal-to-metal seal. And it
means that a permanent, leak-free joint is not always achieved,
particularly in the case of tube-end connections. But leaking flare
joints can be eliminated by installing a conical washer between the
JIC nose and flare. One type of flare seal, manufactured by
Flaretite, consists of a stainless steel stamping, with concentric ribs
that contain pre-applied sealant. When tightened, the ribs crush
between the two faces of the joint, eliminating any misalignment
and surface imperfections. The combination of the crush on the
ribs and the sealant ensures that a leak-free joint is achieved.
Torque Them Correctly
A common cause of leaks from 37-degree flare joints and
compression-type tube fittings is incorrect torque. In the case of
flare joints, insufficient torque results in inadequate seat contact,
while excessive torque can result in damage to the tube and
connector through cold working. In the case of compression
joints, incorrect torque can result in too much or too little crush
on the ferrule. For optimum sealing reliability, consult the
connector manufacturers torque recommendations and then
apply them as directed.
Keep the Machine Cool
Having outlined the benefits of hydraulic connectors that incor-
porate an elastomeric seal, it is important to note that their
reliability is contingent upon fluid temperature being maintained
within acceptable limits. Operating temperatures above 85 degrees
Celsius result in an exponential reduction in service life for most
seal compounds. And, a single over-temperature event of sufficient
magnitude can damage all of the seals in a hydraulic system,
resulting in numerous leaks.
Short-Circuit Vibration
Vibration can stress hydraulic plumbing, cause fatigue and
affect connector torque. If vibration is apparent, the root cause
must be addressed. This may involve the installation of hoses
and/or rubber mounting blocks to eliminate vibration bridges
Machinery Lubrication www.machinerylubrication.com
between the hydraulic power unit, tank and valves. Plus, always
ensure that all conductors are adequately supported.
Measure to Manage
Do you know how much hydraulic oil each of your machines
consumes each year? The only way you can know this for sure
particularly if you have more than one hydraulic machine under
your supervision is if you measure and record all top-offs.
In my experience, most hydraulic equipment users dont do this.
But when clients have done so at my urging, they are often shocked
at how much oil a particular machine actually loses over a year.
Yes, I know that its one more thing to do, but its almost impos-
sible to control anything that you dont measure. And as the late
management guru Peter Drucker once said, What gets measured
gets managed.
Build Your Arsenal
Hydraulic connection leaks have long been considered an
inherent and undesirable characteristic of hydraulic machines.
While it is true that the war is not yet won, hydraulic equipment
users need to be aware of all the available weapons with which they
have to fight. When you consider the true cost of oil leaks which
includes make-up fluid, cleanup, disposal, possible contaminant
ingress and safety issues surrender is not an option.
Battle on.
About the Author
Brendan Casey has more than 20 years experience in the maintenance,
repair and overhaul of mobile and industrial hydraulic equipment.
For more information on reducing the operating cost and increasing
the uptime of your hydraulic equipment, visit his Web site,
www.HydraulicSupermarket.com.
Hungry For More Information?
The Machinery Lubrication Web site is the home for
hundreds of technical articles, columns and reports related to
lubrication research, solutions and best practices. Check out
www.machinerylubrication.com and learn more.
May - June 2010 27
FROM THE FIELD

Dont Miss Your Opportunities

to Improve with Lube Storage
STEPHEN SUMERLIN
NORIA CORPORATION

F or a complete and proper lubrication program to work effec-

tively and provide the most return on investment, every step
must be considered, from receiving to application. Throughout the
way, there are missed opportunities to increase equipment produc-
tivity and reliability and to maximize the returns of investing in a
professionally designed lubrication program. One of the biggest
and most costly missed opportunities is proper lubricant storage
and handling. With the advancements of technology in the lubri-
cant storage area, you can find just about any type of storage
device to suit your needs, whether it is a pail or a full rack-mounted
storage/filtration system.
Many facilities are unaware of the danger that improper lubri-
cant storage practices create and what inevitable fate it will lead to
in terms of equipment reliability and life cycles. Proper lubrication
is not only about the right amount at the right time at the right
place; it also is about keeping lubricants clean, cool and properly
identified. The following sections will outline best practices for
lubricant storage and handling.
Figure 1. A hard-plumbed filtration system works best in conjunction with a
rack-mounted storage system.
Figure 2. This is a good example of proper drum storage for
indoor and outdoor applications.
Bulk Storage and Handling of Oil
The first area of a lubricant storage and handling system that
requires attention is bulk storage. Whether storing lubricants in a
10,000-gallon tank or in 55-gallon drums, it is very important to
ensure that the lubricants quality is not tainted by contamination
or additive settling. To ensure that lubricants stay in an optimal
condition, determine how much lubricant should be stored at
one time. To aid in this process, certain steps can be employed,
such as:
1) Determine lubricant consumption rate. Consumption will
vary greatly depending on industry and equipment type. To ensure
that the right lube quantities are being stored at a facility, you must
determine the consumption rate. There are many factors that
contribute to consumption, ranging from leaks to excessive drain-
and-fill tasks.
2) Determine lubricant storage capacity. The required lubricant
storage capacity depends on consumption, but often, there are too
little or too many lubricants stored at one time. The proper storage
capacity should maximize shelf life but allow for a certain percent
excess of critical lubricants to be stored for emergency situations.
3) Determine lubricant supplier turnaround time. A lubricant
suppliers turnaround time should be a metric used to aid in deter-
mining the quantity of lubricants stored. If there is a short time
interval between deliveries, fewer lubricants can be stored on site;
but if there is a lengthy time interval between deliveries, the quan-
tity of lubricants stored on site should account for this.

28 May - June 2010 www.machinerylubrication.com Machinery Lubrication

 Once you determine the Notice from Figure 1 that each container is fitted with a
consumption rate and storage breather, sight glass, filter, lubricant label, quick-connect fittings
capacity, decide what type of and dedicated dispensing line. This system will ensure that the
storage containers will be used.
A correctly sized storage
container is a direct reflection
on the consumption rate and
storage capacity. If a large
consumption rate is deter-
mined, a bulk storage tank may
yield the best results; but if a
low consumption rate is deter-
mined, a rack-mounted storage
system or 55-gallon drums may
yield the best results.
Figure 3 Whichever storage container
you choose, it is best practice to filter the new oil after the storage
system is filled. Doing so will reduce the amount of contamination
that came with the new oil. Perform periodic filtration and agita-
tion to maintain certain ISO cleanliness levels and prevent additive
settling. Periodic filtration is a good practice to ensure that clean,
fresh oil will be used to perform top-ups and drain-and-fill tasks.
The two primary methods for filtration of bulk stored oils are a
hard-plumbed filtration system and a filter cart. The hard-plumbed
filtration system works best in conjunction with a rack-mounted
system (Figure 1), and filter carts work best with drums (Figure 2). Figure 4. Cabinets provide a great place to store grease cartridges.

Machinery Lubrication www.machinerylubrication.com May - June 2010 29

 FROM THE FIELD
lubricants are at an optimal condition when they
are needed and that the right product for the
application is dispensed.
When using 55-gallon drums, the same
approach can be taken for contamination
control. Each drum can be outfitted with
breathers, sight glasses, quick-connect fittings,
etc. Perform filtration on a periodic schedule
using dedicated filter carts for each lubricant
type. Figure 2 is a good example of proper drum
storage for indoor and outdoor applications.
Once the bulk storage system is properly set
up, consider the method for transporting oil and
filling machines. The best top-up method utilizes
a proper top-up container, one that is sealed
from the environment, has a built-in spout, hand
pump, etc. (Figure 3). If short cuts are taken at
this stage, the time and effort spent building and
designing the bulk storage system and ensuring
the quality of bulk oil with filtration will have
been wasted. Too many times, oil is highly
contaminated from the time it is dispensed into
the top-up container to the time it is added to
the machine.
Also, when the stored oil is transferred from
the bulk storage system to the top-up container,
it is best practice to filter the dispensing oil. This
can be made easy with the use of a hard-plumbed
filtration system and a rack-mounted storage
system, as in Figure 1 fitted with dedicated
dispensing nozzles. If using 55-gallon drums,
install quick-connect fittings, a hand pump and
an inline filter to achieve the same goal.
Storage, Handling of Grease
Grease storage is much simpler than oil
storage due to the lack of transportation and
contamination hazards. Grease tubes are sealed
from the factory and remain contaminant-free
until put into service. Once grease is opened and
put into service, whether it is by a grease gun or
automatic grease system, properly re-store it, if
needed, to minimize contamination. One method
is to use grease storage containers. These
containers are good at taking partially used
grease tubes and keeping them clean and fresh.
Another way to store grease cartridges, new or
used, is within a storage cabinet (Figure 4). Even
when storing used cartridges in a storage cabinet,
you should utilize the grease storage containers.
Storage cabinets are good devices to ensure that
grease cartridges and other top-up containers are
kept away from contamination and physical
damage. Also, correctly set-up storage cabinets
30 May - June 2010 www.machinerylubrication.com
promote ease of use by making top-up containers
and grease tubes readily accessible.
Grease and Oil Life Cycles
For both oil and grease, be aware of their
respective shelf life. Exceeding OEM shelf life
may render the product useless or severely
hamper its performance. For this reason, it is
best to use the First-In, First-Out (FIFO)
method. This simply requires the maintenance
professional to first use the lubricants that were
put into the storage system first. This will ensure
that lubricants do not accidentally exceed their
recommended shelf life.
Labeling and Identification
Lubricant labeling is an often-overlooked
aspect of storage and handling. Labeling is just as
critical as periodic filtration. Without proper
labeling, it is easy for lubricant cross-contamina-
tion to occur. Lubricant cross-contamination is a
result of mixing two lubricants together and can
yield a devastating result. This happens more
often in the dispensing equipment than the bulk
storage equipment.
A labeling system is a simple concept, but it
can be difficult to implement and maintain. You
must determine how to label each corresponding
lubricant. It can be a color-coded system, an
alphanumeric system that depicts important
performance data about the lubricant, or a
combination of both.
Any labeling system can ensure that the right
lubricant is used at the right location and prevent
cross-contamination. But in order to do this, the
system must be kept consistent and up to date
with current lubricants that are in use and being
stored.
About the Author
Stephen Sumerlin is a technical consultant with
Noria Reliability Solutions, working on Lubrication
Process Design Phase II projects for Noria clients. He is
a mechanical engineer and a certified Level I Machine
Lubrication Technician (MLT) through the
International Council for Machinery Lubrication.
Contact Stephen at ssumerlin@noria.com.
COMPARE LUBE
STORAGE PRODUCTS
Visit the exhibit hall at Reliable Plant 2010 in
Nashville, TN August 31 September. 2. See
Page 43 or visit conference.reliableplant.com
for details.
Machinery Lubrication
CONTAMINATION CONTROL

Rethinking Condition
Monitoring Strategies
for Todays Turbine Oils
BY GREG LIVINGSTONE, JO AMEYE AND BRIAN THOMPSON OF FLUITEC INTERNATIONAL

T urbine oils have had a fairly boring history over the last century.
There are only a few documented cases in scientific literature of
problems with turbine oils throughout the 1900s. Similarly, moni- Mixture Contour Plot of RPVOT (minutes)
toring the life of these fluids was accomplished by employing (component amounts)
long-established laboratory tests that provide early warning signals RPVOT
Phenol (minutes)
that allow maintenance personnel time to take proactive actions 0.45 < 500
prior to a negative impact on their plants operational reliability. If 500 - 1000
1000 - 1500
it was only that simple now. Things have changed dramatically over
1500 - 2000
the last couple of decades. Modern turbine oils are formulated 2000 - 2500
differently than their cousins of the recent past, starting with a 2500 - 3000

switch from Group I to Group II (and beyond) basestocks coupled 0.00 3000 - 3500
>3500
with the incorporation of more complex and effective antioxidant
chemistries. Reliance on antiquated analytical techniques has
caught many users off guard as these tests are no longer the predic-
tive tool that they once were. The time has come to rethink how we 0.45 0.00 0.45
monitor mineral-based turbine oils. Amine 1 Amine2

New Formulation Technologies

Before rethinking turbine oil condition monitoring strategies, it Figure 2. The Influence of Antioxidant Chemistries on RPVOT
is important to know what has changed in turbine oil formulations Values in Group II Basestocks
as well as the reasons for the changes. If you havent guessed by
now, most turbine oil formulations on the market and in use today oil formulations have been increasing demands by OEMs, upgraded
are quite different than those in the recent past. Todays turbine lubricant refining technologies, and an effort to reformulate for
oils are required to perform more functions in increasingly harsh enhanced differentiation and value proposition.
environments. In some of the more unforgiving scenarios, the same
reservoir of fluid simultaneously provides lubrication to the turbine OEM Influence
bearings, generator bearings, atomizing air compressors, lift oil Gas turbines are the most demanding application for turbine
system, trip oil system, the generator hydrogen seal system, load oils, which also has been the fastest-growing market in the United
gears and a multiplicity of servo valves within the hydraulic circuit. States for power generation. In 1998, 15 percent of U.S. electrical
There have been many driving factors contributing to these oil power was provided by gas turbines. In 2020, gas turbines are
formulation changes. The three most influential factors on turbine projected to provide 39 percent of the nations electricity. The effi-
ciency and firing temperature of gas turbines is continually rising
as more advanced metallurgies are developed. In general, the
Model Lubricant Reservoir Highest Bearing Typical Bulk Oil
Residence Time (mins) Temperature (F) Reservoir Temperature (F) stress on the turbine oil also increases with more efficient engines,
Class E 5.8 >500 ~135 and most turbine OEMs are demanding increased turbine oil
Class F 7.4 <250 ~135 performance. Since the countrys first power generation gas
turbine was installed in Oklahoma in 1949, there has been a
Figure 1. Comparison of the Turbine Oil Environment general consensus that an increase in firing temperature causes an
in Various Gas Turbine Technologies increase in bearing temperature, thus creating increased lubricant

32 May - June 2010 www.machinerylubrication.com Machinery Lubrication

stress. Some of the factors that determine how quickly turbine oil
degrades are summarized in Figure 1.
The stress on turbine oils, however, may be more complex than
just looking at the lubricants residence time, high-temperature
zones and reservoir temperatures. Figure 1 suggests that the Class
E system may impart more stress on its turbine oil when
compared to the Class F system. In reality, turbine oils lubri-
cating Class F units typically degrade faster and have more
performance challenges. Additional factors to consider when
assessing the stresses on the turbine oil in a system include the
environmental conditions of where the unit is located, its duty
cycle and the plants maintenance practices. In this particular
example, Class F units are known to exert further stress on the
turbine oil due to a phenomenon known as spark discharge, which
occurs in the units main lube oil filters.

Reformulating Turbine Oils

to Enhance Value Proposition
Oil manufacturers have brought significantly more refining
Figure 3. Heavy deposits in steam turbines are becoming a
capacities online to produce higher-refined basestocks, making more common observation during power plant outages.
Group II and III basestocks widely available. Today, most turbine
oils formulated in North America are now built with a Group II
Some of the antioxidants that generate very high RPVOT values
basestock. The shift from Group I oils to Group II and III oils also
also produce high levels of insolubles upon depletion and show
has resulted in a significant change in formulation strategies.
direct correlation to the formation of sludge and varnish within
Certain antioxidants are able to greatly enhance the oxidative
the lubricating circuit. To this end, the use of some antioxidant
stability of Group II and III turbine oils as measured by the rotating
chemistries that contribute to very high RPVOT values has been
pressure vessel oxidation test (ASTM D2272-RPVOT) and turbine
a contributing cause to the increase in varnish problems in gas
oxidation stability test (ASTM D943). As a result, newer turbine oils
and steam turbines. Clearly, there is not a relationship between
have much higher oxidation stability values compared to older
initial RPVOT values and field performance.
formulations.
Some oil manufacturers began using RPVOT values as a key RPVOT values can be strongly influenced by the addition of
selling feature to further differentiate their turbine oils by some corrosion inhibitors and metal pacifiers. These additive
attempting to correlate the high performance of their turbine oils species can negate the effects of the primary catalyst in the
oxidation tests to real-world applications. End-users welcomed RPVOT test, a copper wire coil, improving the test results and
differentiating values on oil specification sheets since virtually all
of the other specifications are extremely similar. Many turbine
oils over the last decade have been selected based solely on
RPVOT values.
An example of the influences antioxidants can have on RPVOT
values can be seen in Figure 2, based on research by Albemarle
Corporation.
Oil Degradation

In Figure 2, you can see that Amine 2 has a very positive influ-
ence on RPVOT values, exceeding 3,500 minutes at a concentration
ils
of 0.45 percent by weight. The phenolic antioxidant, however, eO
urbin
produced RPVOT results of less than 500 minutes at the same on al T
diti
concentration. When the phenol and Amine 2 additive are blended Tra
What happens at this point?
in at equal concentrations (0.225 percent by weight each), the How can it be monitored?
RPVOT value is less than 1,000, demonstrating the potential nega-
tive influence that phenols can have on RPVOT values. This is one Most Modern Turbine Oils
influential factor why amines have been the antioxidant of choice in Time
many of todays turbine oil formulations.
It is now accepted in the power generation industry that beyond
Figure 4. This chart shows the degradation trend of traditional turbine oils vs.
a certain point, RPVOT values do not directly relate to field most modern turbine oils. The selection of condition monitoring technologies
performance. This is evident for several reasons: becomes more critical with modern turbine oils

Machinery Lubrication www.machinerylubrication.com May - June 2010 33

 CONTAMINATION CONTROL

giving a false indication of the fluids antioxidant properties. the lubricant will start to degrade and generate system deposits.
Corrosion inhibitors typically deplete out of turbine oils fairly Instead of degradation occurring in a linear and predictable
quickly once put in service as they are polar and designed to fashion, many of these modern lubricants fail rapidly, as depicted
provide a protective film to metal surfaces. It is not unusual in in Figure 4.
some turbine oil formulations to see a sharp drop in RPVOT
values during the first year of service as a result of corrosion Condition Monitoring Strategies
inhibitor depletion. RPVOT retention is a much stronger indi- Oil analysis has been the primary tool to detect incipient lubri-
cator of turbine oil performance than initial RPVOT results. cant failure for the last half-century. The first step in determining
an appropriate test slate for turbine oil is understanding its mode
The RPVOT test has very low reproducibility for oils above
of failure. The authors were part of a research project that
1,000 minutes and is not a recommended test by ASTM for
concluded in 2005, during which five turbine oils were circulated in
these formulations. Most commercially available turbine oils
immersion heated baths at 120 degrees Celsius for eight weeks. A
now boast initial RPVOT values above, and in some cases well
wide range of analytical tests were performed in order to better
above, 1,000 minutes.
understand which specific testing methodologies would provide
New-generation turbine oils degrade differently than tradition- the highest value for detecting early signs of turbine oil degradation
ally formulated lubricants. The non-linear degradation of most and the associated by-products which negatively impact lubrication
modern turbine oils can be attributed to the specific antioxidant(s) systems. Figures 5 and 6 represent a summary of results averaged
employed, as well as the low natural oxidative resistance character- from all five samples over the eight-week test.
istics of Group II and Group III basestocks. As a result, the majority The traditional testing methodologies for monitoring the oxida-
of standard oil analysis tests provide little to no warning as to when tive health of used turbine oils are viscosity, acid number and
RPVOT. It is clear from this research that these tests do little to
reveal early turbine oil degradation and nothing to identify the
Viscosity AN RPVOT MPC Amines Phenols
-15% 100 fluids deposit tendencies. Here are a few of the more significant
90 discoveries:
-10% 80 The first physical sign of fluid degradation from this experiment
5% 70 was the creation of marginally soluble degradation products,
60
which are known to produce varnish. These are commonly
0% 50
referred to as soft contaminants. Their concentrations were
40
-5% measured directly and trended using the membrane patch
30
-10% 20 colorimetry (MPC) methodology. System varnish remains a
10 high-profile and growing problem in todays lubricating,
-15% 0 hydraulic and insulating systems.
1 2 3 4 5 6 7 8
The first chemical sign of fluid degradation was observed by
Figure 5. Graphical Representation of the Average Results from trending the depletion of the two primary antioxidants
Five Samples over the Eight-week Test aromatic amine and hindered phenols. Voltammetry is typically
the technique of choice for measuring antioxidants.

Test Start of End of Comments There are direct correlations between the depletion of specific
Test Value Test Value antioxidants and the formation of soft contaminants.
Viscosity (cSt @ 40C) 31.7 32.1 Insignicant; within test
ASTM D-445M reproducibility
What about RPVOT?
Acid number (mg KOH/g) 0.10 0.11 Insignicant; within test The RPVOT test became an ASTM standard in the mid-1960s and
ASTM D-664M reproducibility
has enjoyed several decades of high-profile use in helping end-users
RPVOT (minutes) 945 900 Insignicant; within test determine the remaining useful life of turbine oils. There has been a
ASTM D-2272 reproducibility
rising concern within the oil analysis industry, however, about using
Membrane patch colorimetry 2 57 Signicant; indicates high RPVOT on modern lubricant formulations that utilize complex antiox-
(E) ASTM WK-13070 varnish potential idant systems. The precision of the test in practice varies considerably
RULER Amines (% of new) 100% 91% Signicant; close relation- compared to the precision statement in the ASTM standard. ASTM
ASTM D-6971 ship to RPVOT values D2272 calls for a repeatability of 12 percent and a reproducibility of 22
RULER Phenols (% of new) 100% 17% Signicant; MPC increases percent for oils with values less than 1,000 minutes. Practically
ASTM D-6971 as phenols deplete speaking, the repeatability and reproducibility of the test is generally
accepted to be somewhere between 30 and 50 percent. A recently
Figure 6. Data of the Average Results from Five Samples conducted mini-robin at an international standards institute reported
over the Eight-week Test 39 percent reproducibility. The recognized poor repeatability and

34 May - June 2010 www.machinerylubrication.com Machinery Lubrication

reproducibility of the RPVOT test has made it much more difficult for
data analysts to interpret.
Is there a place for RPVOT testing in todays turbine oil formu-
lations? Our view is that there may be some value in performing
RPVOT tests on turbine oils, depending upon the objective and
situation. For example:
RPVOT testing has as much value as ever in older formulations
of turbine oils which are still in service in steam and hydro
generating applications.
If you have a reservoir with mixed brands or formulations of
turbine oils, performing RPVOT testing is recommended to be
part of a complete test slate to helping evaluate the condition
of the fluid.
These factors should be considered in the interpretation of
RPVOT results.
References
Bill Parks, Gas Turbines for Power Generation: A U.S. DOE Perspective;
www.eere.energy.gov. June 1, 2000
Akira Sasaki, Shinji Uchiyama and Mariko Kawasaki, Varnish Formation
in Gas Turbine Oil Systems, Journal of ASTM International, Vol. 4, No. 1,
Paper JAI101419; presented at the ASTM Symposium on Oxidation and
Testing of Turbine Oils in Norfolk, Va., on December 5, 2005.
Private conversation with Vince Gatto and William Marle (recently
retired) of Albemarle Corporation regarding their research.
Machinery Lubrication
Greg Livingstone, Brian Thompson and Mark Okazaki, Physical,
Performance, and Chemical Changes in Turbine Oils from Oxidation,
Journal of ASTM International, Vol. 4, No. 1, Paper JAI100465; presented
at the ASTM Symposium on Oxidation and Testing of Turbine Oils in
Norfolk, Va., on December 5, 2005.
About the Authors
Greg Livingstone is the executive vice president for marketing and tech-
nology, Jo Ameye is the executive vice president for global sales and Brian
Thompson is the executive vice president for operations at Fluitec
International. Fluitec is a global provider of condition monitoring tech-
nologies, contamination control solutions and consulting services. For
more information, visit www.fluitec.com.
The Key Tests for
Monitoring Modern Turbine Oils
If you enjoyed Fluitecs article in this issue of Machinery
Lubrication, please check out a follow-up article located on
the MachineryLubrication.com Web site. Based on several
bodies of research and Fluitecs cumulative experience at
analyzing used turbine oils samples, this second article outlines
key tests to consider in setting up your condition monitoring
program. To read this article, go to the Web site and type
Fluitec into the Search box found on the home page.
www.machinerylubrication.com May - June 2010 35
PRODUCT SPOTLIGHT

Synthetic Coating Lubricant Bio-based Lubes and Greases

Wirelife Almasol Syn Coating Lubricant from Lubrication
Engineers is an extremely tacky, non-asphaltic synthetic lubricant
with exceptionally high film strength. Perfect for extreme environ-
ments and conditions, it provides robust outer surface protection for
wire rope and cable and comes from the same advanced technology
that LE developed to protect large open gears in the mining and
quarry industries. Typical applications for Almasol Syn include
standing and running lines, draglines, cranes, derricks, hoists, and
drilling rigs. The products exceptional film strength and high load-
carrying capacity come from its heavy synthetic base fluid and its
synergistic blend of Almasol (LEs exclusive wear-reducing additive)
and an extreme-pres-
sure additive.
Lubrication
Engineers Inc.
www.le-inc.com
800-537-7683
Plews/Edelmann, a division of Tomkins Industrial and Automotive,
offers LubriMatic Green, a family of premium-quality bio-based prod-
ucts that includes a variety of spray lubricants, penetrants and greases.
These lubricants are formulated from renewable, biodegradable
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based products. They are less likely than traditional lubricants to thin
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or mix with conventional petroleum products for safer and more envi-
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crops and does not have the harsh odor found in traditional lubricants.
Plews/Edelmann, a division of Tomkins
www.lubrimaticgreen.com
800-545-1689

Synthetic Compressor Lube Synthetic-Blend Hydraulic Oils

Synf ilm Recip. from Royal Purple is a Summit HyPar FG Series synthetic-blend hydraulic oils are specially
long-life, high-f ilm-strength, energy-eff i- formulated for hydraulic systems operating in the food service, beverage
cient, synthetic lubricant that significantly and packaging industries. HyPar FG Series lubricants are NSF registered
increases the reliability and eff iciency of and meet USDA H-1 guidelines (lubricants with incidental food
reciprocating air compressors and recipro- contact). In addition, they are kosher approved. HyPar FG Series lubri-
cating shop compressors. It excels at cants are fortified with oxidation
reducing wear and keeping discharge valves inhibitors, corrosion inhibitors,
free of harmful carbon deposits, and is as well as anti-wear additives to
recommended for lubricating reciprocating enhance the superior qualities
air compressors (piston type). Synf ilm offered by the food-grade bases-
Recip. forms a better seal and reduces fric- tock. These oils are ideal for the
tion between the cylinder wall and piston lubrication of production equip-
rings for greater compressor efficiency. It is ment in beverage canning,
formulated with Royal Purples unique, bottling operations, meat and
proprietary Synerlec additive technology, poultry processing, dairy opera-
which is proven to make equipment run tions, fruit and vegetable
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efficiently. maceutical plants.
Royal Purple Summit Industrial Products
www.royalpurple.com www.klsummit.com
281-354-8600 800-749-5823

36 May - June 2010 www.machinerylubrication.com Machinery Lubrication

PRODUCT SUPERMARKET
Keep your hands free and your lubricant spot-on
with perma automatic lubricators. Preloaded with
premium LE lubricants, they provide continuous,
precise application. The result: reliability, efficiency,
safety and savings.
Lubrication Engineers Inc.
www.le-inc.com 800-537-7683
Webleads@le-inc.com
Because viscosity measurement should be
simple, CANNON is excited to introduce the
SimpleVIS portable viscometer. Everything is
included to get you started, minus your sample and
solvent. Contact us for more information.
Cannon Instrument Company
www.cannoninstrument.com 800-676-6232
sales@cannoninstrument.com
Des-Case Extreme Duty breathers have been
designed to take contamination control to a whole
new level, standing up to a wide variety of applica-
tions in challenging environments. They attack the
cause of contamination, keeping dirt and water
where it belongs out of your equipment.
Des-Case Corporation
www.descase.com 615-672-8800
sales@descase.com
38 May - June 2010
PAID ADVERTISING SECTION
In addition to particle counting and automatic
type of wear classification into non-metallic,
cutting, fatigue, sliding, fibers, water droplets
offering images and trending, the new SpectroLNF
Q200 also reports dynamic viscosity.
Spectro Inc.
www.SpectroInc.com 978-431-1120
sales@SpectroInc.com
NEW PIG UNVEILS PIG BLUE ABSORBENT
MAT. PIG BLUE Absorbent Mat features a unique
blend of recycled cellulose and polypropylene
designed to absorb and disperse liquid evenly with
exceptional absorbency, retention and oor-gripping
power. The mats 70% recycled content provides an
environmentally responsible way to manage liquid
containment problems in the industrial workplace.
New Pig Corporation
www.newpig.com 1-800-HOT-HOGS (468-4647)
REMOVE VARNISH, PARTICLES AND WATER.
Three problems, one solution. C.C. JENSEN is
focused on supplying highly efficient and reliable
offline filters and filter carts. Guaranteed
performance. Contact us today for more informa-
tion or to purchase.
C.C. Jensen Inc.
www.ccjensen.com 800-221-1430
ccjensen@ccjensen.com
www.machinerylubrication.com
Harvards filter systems are designed and built
with quality materials and craftsmanship to provide
years of trouble-free service. Filter elements for
viscosity ranges from fuels to gear oils (ISO 1000).
Customers report clean fluids to ISO 13/12/8 in
operation. Contaminant capacity per element is
about four pounds. The product has demonstrated
the ability to remove one gallon of water from oil.
Harvard Corporation
www.harvardcorp.com 800-523-1327
Simple and cost-effective, LEs Clear Grease Gun
will make an immediate impact on your reliability
efforts. No more mistakes or cross-contamination.
Be confident in knowing you are using the right
grease, time after time.
Lubrication Engineers Inc.
www.cleargreaseguns.com 800-537-7683
Webleads@le-inc.com
Inolex Chemical Company synthesizes premium
ester base oils for high-performance lubricant applica-
tions such as chain formulations for oven temperatures
up to 550C. HX-1 food grade oils for baking chains
are available.
Inolex Chemical Company
www.inolex.com
1-800-521-9891
lubeinfo@inolex.com
Machinery Lubrication

An EP grease for extended, heavy-duty service, LEs
Almagard Vari-Purpose Lubricant stays put even in
severe conditions. It lengthens intervals, will not
harden with age, and extends bearing life by up to
threefold.
Lubrication Engineers Inc.
www.le-inc.com 800-537-7683
Webleads@le-inc.com
Summit Syngear FG Series Gear Oils are a full
synthetic, formulated for gear systems used in the
food service, beverage and packaging industries.
They are NSF registered H1, ISO 21469 certified,
Kosher approved and CFIA accepted.
Summit Industrial Products
www.klsummit.com 800-749-5823
info@klsummit.com
A new full-color 104-page catalog is available on
Oil-Rites lubrication equipment, featuring PurgeX
Centralized Lubrication Systems. Complete turnkey
systems are available for immediate delivery, liquid
or grease delivery, air or electric motor-operated.
The catalog also features an entire line of level
gauges, lubricators, valves, vent plugs and filters.
www.oilrite.com 920-682-6173
Machinery Lubrication
Quickly monitor the remaining useful life of
lubricants. The RULER provides an easy on-site
method for monitoring antioxidants and identi-
fying problems like lube oil varnish. Maximize
lubricant life with the RULER.
Fluitec
www.fluitec.com 888-557-9575
info@fluitec.com
MEMOLUB Lubrication Systems Precise,
Reliable. Lube up to 12 points with the reusable
MEMOLUB. Available in 3 sizes and 4 power
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cartridges with customer-specified grease or oil.
PLI, LLC
www.memolub.com 800-635-8170
sales@memolub.com
Best Practices for Lubricant Storage and Handling
video-based training provides procedures you can
implement right away for managing lubricants, from
delivery to dispensing to filling the machine. Preview at
Noria.com.
Noria Corporation
www.noria.com
800-597-5460
www.machinerylubrication.com
Easy Vac Inc. provides the right tool for an
important job! Vampire fluid sampling pumps ...
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CONTROL WATER CONTAMINATION. Remove
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JENSEN Desorbers. Proven, effective and reliable.
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ccjensen@ccjensen.com
SHAFTALIGN First low-cost color display shaft align-
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May - June 2010 39
LUBRICANT SELECTION
Synthetic Lubes, Contamination
Control and Oil Analysis Team Up
BY PdMA CORPORATION
T he combination of oil analysis and effectively deployed lubrica-
tion management and machine maintenance has enabled the
reliability team at Northampton Generating to deliver real benefit
to the organization. By identifying problem areas and dealing
directly with the issues, machine reliability is on the rise and main-
tenance costs are reduced.
The Northampton Generating Plant, located in northern
Pennsylvania, is a 110-megawatt co-generation facility that has
been providing electricity to GPU Energy since August 1995. In
addition to providing enough electricity for 110,000 homes, the
plant processes steam for use in Ponderosa Fibres of Americas
recycled liner-board mill. The Northampton Generating Plant fires
culm, the waste by-product of mining anthracite coal.
Approximately 545,000 tons of culm are burned each year in circu-
lating fluidized-bed boilers, an advanced technology for burning
waste coal cleanly. With cost-control pressures of deregulation
looming, co-generation stations like Northampton place a
premium on machine reliability to maintain high plant availability.
This maximizes the revenue from the sale of electricity while also
providing a dependable process steam source for Ponderosa Fibres.
When the generating plant came online, all of the equipment
initially was filled with mineral-based lubricants. As a proactive
measure, all mineral products were replaced with synthetic prod-
ucts at the first scheduled change interval. The decision to use
synthetics was driven by managements desire to ensure equipment
reliability and to reduce lubrication manpower requirements. Given
the plants northern location and the fact that most of the equip-
ment is located outdoors, mineral oil requires seasonal changes to
adjust for viscosity requirements. Due to improved cold-weather
performance and high viscosity index, synthetic oils need not be
changed seasonally, thus reducing lubricant consumption and
labor simultaneously. To further reduce costs and ensure reliability,
Cost Category Mineral Lubricants Synthetic Lubricants
Lubricant Purchases $2,340 $5,612
Labor $26,220 $2,280
Oil Analysis $10,668 $10,668
Total $38,228 $18,560
Figure 1. Annual Costs to Lubricate Machinery, Mineral Oils
vs. Synthetic Oils
40 May - June 2010 www.machinerylubrication.com
oil analysis was employed to guide oil change decisions and to alert
the team of any abnormal lubricant or machine conditions.
Initially, the use of synthetic lubricants and the elimination of sched-
uled and seasonal oil changes met with some skepticism. Through a
series of educational meetings, the decision to use synthetic lubricants
was accepted, but with a well see attitude. From the start,
Northamptons maintenance philosophy emphasized predictive and
proactive efforts over reactive methods. The use of synthetic lubricants
combined with oil analysis fit well with this philosophy.
Cost justification for the change to synthetics and condition-
based changes came quickly. The increased cost of both synthetic
lubricants and oil analysis were offset by reduced labor associated
with scheduled and seasonal changes and the reduction in inventory
required to stock warm- and cold-weather lubricants. Figure 1 details
the annual costs to lubricate the machinery with conventional
mineral oils vs. synthetic products. The plant-wide annual savings
totaled $20,668 in avoided lubrication costs alone. Moreover,
managements objective of maximized machine availability was
accomplished due to the success of the oil analysis program. And,
condition-based oil changes and extended intervals align well with
Northamptons desire to minimize environmental impact.
Contamination Control
Was a Major Focus
Northamptons contamination control efforts have been aggres-
sive. Recognizing contamination as a primary root cause of machine
failure, the gearbox vents were refit with breathers that restrict the
ingestion of airborne dirt and debris. In the highly contaminated coal
processing plant, gearboxes average ISO 19/14 after the change,
compared to a more typical 23/20 level for these systems. The reduced
strain on the bearings in these gearboxes due to this cleanliness
improvement reduces wear by an estimated 50 percent, according to
research. That life extension puts money on the bottom line in the form
of avoided maintenance costs and increased reliability and availability.
Efforts to control contamination also have been expanded to lubri-
cant storage. Lubricants are inventoried in a clean, controlled
environment. All drums and containers are clearly marked, and a
readily available log identifies precisely what machines receive what
products. These combined efforts have yielded very low ISO codes and
correspondingly low levels of elemental silicon when new oils are
tested for quality.
Machinery Lubrication
 With reliability goals dependent on oil analysis
and oil cleanliness, sample quality was critical. To
ensure sample quality and consistency, sample ports
were installed and specific sampling procedures have
been implemented to ensure consistency. The
sampling ports were installed at a central location,
between the drain and fill plug. When sampling,
pathways were aggressively flushed, disposable
sampling supplies were used only once, and precau-
tions were taken to not introduce airborne particles
and debris into the sample container as it was being
drawn. In every case, the sample was taken when the
equipment was running.
Oil analysis has proved to be a very effective tool
for assuring the reliability of equipment at
Northampton. The plant implemented vibration
analysis and oil analysis simultaneously. They have
proved to be an effective combination in the pursuit
of managements reliability goals. For gearboxes, oil
analysis has been deemed the best early indicator of
problems. Presently, vibration analysis is used only
on exception to aid in diagnostics. Oil analysis also
has assured effective lubrication of critical systems.
Oil Analysis Used to Find
Issue with Cooling Tower
Gearboxes
One particular situation where oil analysis proved
vital is the cooling tower gearboxes. These gearboxes
are critical to the operation. The loss of just one leads
to production losses. Moreover, they are inaccessible
between annual outages. At the early stages of the
new high-quality oil analysis program, it became
apparent that the gearboxes had been ailing, as
evidenced by high acid numbers (ANs) and rising
iron levels. Accordingly, the oil was quickly changed
back to a mineral product. The result of this action
was disappointing. AN and iron levels began to rise
Figure 2. Northamptons efforts to control
contamination carried over to lubrication
storage and dispensing.
Machinery Lubrication
even faster than before. The team had failed to find
and address the problems root.
Abandoning casual reactions, the team
addressed the situation systematically to uncover
the following facts:
The gearboxes run in a tough environment rich
with moisture, heat, air and catalytic iron all
of which promote oxidation.
The drain intervals had been extended.
The employment of high-quality oil analysis
was just under way. It is common to discover
new problems that had merely not been
uncovered previously.
The oil change was performed without a flush,
leaving residual oxidized oil that acts like
a cancer, quickly depleting oxidation
inhibitors and eventually attacking healthy
base oil molecules.
With these facts in hand, the lubrication
management team took the following steps to
rectify the situation:
The gearbox was drained.
The system was flushed to remove the residual
oxidized oil.
A refill with synthetic oil was implemented.
Oil analysis was standardized to ensure the
reliability of these critical systems.
Since taking these measures, AN and iron levels
have returned to normal. However, the lube team
knows that when a machine is critical and operates
in a challenging environment, you cant get too
comfortable and rest in the light of past successes.
Instead, oil analysis must be used in an ongoing
manner to ensure that the cooling tower gearboxes
remain well lubricated and in fit condition.
A proactive approach from the start has proved
very beneficial at Northampton. By combining
advanced maintenance practices, including oil
analysis, along with the employment of synthetics
and proper lubricant handling and management,
Northampton Generating is realizing manage-
ments reliability and availability goals. The
successful program has been expanded to the fuel
site, where improved reliability was seen in the
programs first six months.
About the Author
PdMA Corporation is an industry leader in the field of
predictive maintenance (PdM) and condition monitoring,
globally offering electric motor testing instruments. The
companys products and services are utilized by a wide
variety of industries such as: manufacturing, utilities, field
servicing, aerospace, petrochemical, pulp and paper,
steel/service, mining, automotive, etc. For more informa-
tion, visit www.pdma.com.
www.machinerylubrication.com May - June 2010 41
 BOOKSTORE

Welcome to Machinery Lubrications Bookstore, designed to spotlight

How to Grease a
lubrication-related books. For a complete listing of books of interest to Motor Bearing Training DVD
lubrication professionals, check out the Bookstore at www.noria.com. Format: DVD
Publisher: Noria Corporation
How to Grease a Motor Bearing provides plant
Lubricating Grease Guide personnel an overview of the best practices for lubricating
electric motor bearings. Anyone responsible for the main-
Author: NLGI
tenance, operation and reliability of electric motors will
This guide serves as a source of basic information on
lubricating grease and is a handy quick-reference book. benefit. Use it to train operators, lubrication technicians,
Written for the beginner or for the practitioner who wants mechanics, electricians and maintenance personnel for
to broaden knowledge. It includes a grease application years to come.
guide for beginners. Youll know when to select the right The product has three main benefits:
grease for your machinery and easily determine which Lubrication technicians will have a clear understanding
greases are compatible. of why proper motor bearing lubrication is critical.
Youll reduce motor failures, downtime, rebuilds and
replacement costs.
Practical Lubrication for Youll replace old-time
Industrial Facilities lubrication procedures
Author: Heinz Bloch with vendor-neutral, best-
Helps reliability professionals, mechanics, machinists or practice procedures that
lubrication specialists understand what matters most in a lubri- work.
cant, and to distinguish mere sales talk from relevant facts. It is
intended to assist the
professional in ensuring
that machinery operates The Practical Handbook of
at optimum performance Machinery Lubrication
levels with a minimum of
Author: L. Leugner
costly downtime.
If you want to establish yourself as the lubrication expert in
your company, this book is a must-read. Once you pick it up, you
Oil Analysis wont put it down until youve finished it. Its that easy to read.
Basics
Publisher: Noria Corporation
Written by the editors
Introduction to Lubrication
of Machinery Lubrication
magazine, Jim Fitch and Drew
Fundamentals Training DVD
Format: DVD
Troyer, this book is a great Publisher: Noria Corporation
resource for anyone involved The Introduction to Lubrication Fundamentals
in oil analysis or lubrication. training DVD teaches lubrication basics through high-
Oil Analysis Basics makes oil analysis for machinery quality animation and video. DVD training makes learning
condition monitoring easy to understand. You will learn fun and convenient while helping employers provide stan-
everything from how to take a proper oil sample to how to dardized training for every employee, every time.
select a test slate for your applications.

For descriptions, complete table of contents and excerpts from these and
other lubrication-related books, and to order online, visit:
www.noria.com or call 1-800-597-5460, ext. 104

42 May - June 2010 www.machinerylubrication.com Machinery Lubrication

 REGISTER NOW!
Register before
July 30 and SAVE $200
Visit conference.reliableplant.com or call 800-597-5460

ONE BADGE. THREE CONFERENCES. Opening Keynote Session

Mark Swenson
VP for vehicle production
and manufacturing
engineering,
Nissan North America
Voices of Experience
Presented by practicing professionals for professionals, including: PLUS Lubrication and
Kevin Desrosiers Samuel Bethea Claudia Faye Eric Bigelow Reliability Case Studies From:
engineer, director of N.A. reliability engineer, lean industrial Energizer Battery Frito-Lay
Anheuser-Busch maintenance and Alcoa engineer and Alabama Power Cargill
InBev reliability, continuous Eli Lilly Temple-Inland
Campbell Soup improvement expert,
Yamaha Motor
Yamaha Raytheon
 Welcome to Reliable Plant 2010

How Youll Benefit From

3 Co-Located Conferences Attending and Implementing
What You Learn
The three co-located events at Reliable Plant 2010 supply
the tactics and solutions for substantial advances in plant Secure answers and ideas to address specific
issues and needs at your plant
performance and profitability.
Acquire new skills you can immediately apply on
The leading conference devoted exclusively the job
to using effective lubrication practices to get Go home with the best tools and processes to
the most from a plants physical equipment implement and sustain a successful plant
assets. These unique presentations, delivered by subject matter experts and suc- reliability program
cessful lubrication practitioners, demonstrate how to achieve the efficiencies and
financial benefits of a proper, proactive lubrication program.
Company Advantages
Spotlights the winning strategies and best
practices that drive reliability results to the More time operating less downtime
bottom line. Industry experts deliver com- More output per hour yield
pelling, practical learning sessions, with particular focus on case studies where
Higher first-pass quality fewer rejects
the use of effective reliability strategies has led to measurable economic and pro-
ductivity benefits. Help develop a new generation of leaders
Teams leave with a common vision and
Identifies and examines the specific tools needed to quickly improve understanding
a plants total productivity, profitability, and safety and environ-
Low maintenance costs organizations
mental performance. Case studies reveal how best-in-class
with the highest reliability have the lowest
companies use lean tools to improve the reliability and performance of their mechan-
maintenance costs
ical assets and overall operations.

OUTSTANDING! Weve already seen a

Table of Contents HUGE RETURN on our INVESTMENT
Opening Keynote ....................................................................................3 in attending this conference and weve
Whats Included ......................................................................................3 only just begun to implement the
Conference Schedule ..............................................................................3
STRATEGIES we learned.
Certification ............................................................................................4 - Glenn Moore,
Pre-Conference Workshops ....................................................................5 Alcoa Mill Products
Lubrication Excellence Sessions..............................................................6
Reliability World Sessions ......................................................................9
Lean Manufacturing Sessions ..............................................................12
Exhibitor List..........................................................................................14
Take Home the Tools Game ..................................................................14
Hotel and Travel ....................................................................................15
Conference Fees....................................................................................15
Registration Form ..................................................................................16

For complete conference and expo information

2 and updates, visit conference.reliableplant.com
You wont find another educational opportunity like Reliable Plant 2010.
Make your decision to attend now and save $200 on conference
registration. See page 16 for information.
Opening Keynote Session
From Adversity to Competitive Advantage:
Nissan Turns Over a New LEAF Sponsored by:
Mark Swenson, vice president for
manufacturing engineering and vehicle
production engineering, Nissan North America
Tuesday, August 31, 8:00 am
Mark Swenson, vice president of engineer-
ing at Nissan North America, knows something
about responding to a crisis. Mark had just
been promoted to the Nissan leadership team
in the late 1990s when the company sal-
vaged its future by forming an alliance with
Frances Renault. Mark will share his obser-
vations on how that crisis molded the
company that Nissan became and how the
experience in handling adversity has given the
company a competitive advantage during the current economic
downturn. Nissan has a steadily growing market share and is
poised to become the market leader in mass-produced zero-emis-
sions, all-electric vehicles with the production of the Nissan LEAF
beginning later this year. In his keynote address, Mark will describe
how Nissans forward-looking vision to promote sustainability, ef-
ficiency and quality has become part of the culture.
Whats Included
When you register for the full Reliable Plant conference, youll
get all this:
Admittance to 80 skill-building sessions in the Lubrication
Excellence, Reliability World and Lean Manufacturing
conferences
Admittance to the Opening Keynote session (Tuesday)
Admittance to the Exhibit Hall (Tuesday through Thursday)
Three continental breakfasts (Tuesday through Thursday)
Two lunches in the Exhibit Hall (Tuesday and Wednesday)
Refreshment breaks
Admittance to the evening receptions in the Exhibit Hall
(Tuesday and Wednesday)
Conference Proceedings
A chance to win a giant Snap-on / J.H. Williams / Bahco tool set
See and evaluate the products and solutions youll hear about
during the conference when you visit the Exhibit Hall. Youll find
knowledgeable vendors eager to solve your challenges.
Save $200 on conference fees when
you register before July 30, 2010
Real Strategies.
Measurable Results.
Conference Schedule
MONDAY, AUGUST 30
7:00 am 6:00 pm Registration at the Nashville
Convention Center
8:00 am 4:30 pm Pre-Conference Workshops
5:30 pm 8:30 pm Certification Testing (ICML)
TUESDAY, AUGUST 31
7:00 am 6:00 pm Registration at the Nashville
Convention Center
7:30 am 8:00 am Continental Breakfast
8:00 am 9:20 am Opening Keynote Session
9:30 am 10:50 am Exhibit Hall Grand Opening
11:00 am 11:50 am Conference Sessions
12:00 pm 1:20 pm Lunch in Exhibit Hall
1:30 pm 5:20 pm Conference Sessions
5:30 pm 6:30 pm Meet and Greet Reception
in Exhibit Hall
9:30 am 6:30 pm Exhibition Hours
WEDNESDAY, SEPTEMBER 1
7:00 am 6:00 pm Registration at the Nashville
Convention Center
7:30 am 8:00 am Continental Breakfast
8:00 am 9:50 am Conference Sessions
10:00 am 10:50 am Refreshments in Exhibit Hall
11:00 am 11:50 am Conference Sessions
12:00 pm 1:20 pm Lunch in Exhibit Hall
1:30 pm 5:20 pm Conference Sessions
3:30 pm 4:40 pm Refreshments in Exhibit Hall
5:30 pm 6:30 pm Networking Reception in Exhibit Hall
6:00 pm 9:00 pm Certification Testing (ICML)
9:30 am 6:30 pm Exhibition Hours
THURSDAY, SEPTEMBER 2
7:30 am 11:00 am Registration at the Nashville
Convention Center
7:30 am 8:00 am Continental Breakfast
8:00 am 8:50 am Conference Sessions
8:50 am 9:20 am Refreshments in Exhibit Hall
9:20 am 11:10 am Conference Sessions
11:15 am Giveaways in Exhibit Hall
8:50 am 12:00 pm Exhibition Hours
3
 Need a Reason to Attend
TEAM D
Bring yo
ur te
ISCOUN
TS
Who Should Attend
session am and cover a Whether youre entry-level or a seasoned
s at Re ll of th
Reliable Plant 2010? See pag liable Plant 201 e
e 16 for
details. .
0
member of your plants management team,
youll benefit from the comprehensive schedule
of sessions, case studies and peer interactions.
Heres a preview of what youll be able to do after Attendees include:
attending the educational sessions: Asset Care Planners
CBM Coordinators & Specialists
Chief Engineers
Design Engineers
Make lubrication PMs more effective Provide efficient maintenance systems while Engineering Managers
satisfying customer demands Engineers
Choose the best personnel for lubrication jobs
Improve a condition monitoring program Facility Managers
Employ precision greasing for rolling element
bearings through continuous improvement and General Managers
measurement
Modify reservoirs and gearboxes for Hydraulic Specialists
contamination control and serviceability Systematically engineer costs out of your
maintenance budget Industrial Maintenance Supervisors
Use a rational and systematic approach to Industrial Mechanics
selecting a new lubricant supplier Use TPM to move from reactive to proactive
maintenance Infrared/Vibration Technicians
Design an effective contamination control Lab Managers
program Use more effective problem-solving methods
in maintenance Lean Leaders
Use best practices to consistently pull
data-rich, representative oil samples Engage and invest in your people to improve Lean Managers
your reliability program Lube Analysts
Spec a new filter cart to meet your exact needs
Develop a FRACAS system to drive equipment Lubrication Specialists
Reduce energy consumption and operating asset reliability
expenses with a lubrication program Lubrication Technologists & Technicians
Determine whether an electric motor is truly Machinery Engineers
Control sludge and varnish in lubricants green
Convert to lubricant storage best practices Maintenance Engineers
Build reliability and maintainability into new or
Maintenance Managers
Set oil target cleanliness levels modified assets
Maintenance Planners
Conduct an audit to identify gaps in your Integrate energy management into your
lubrication program reliability and maintenance strategies Maintenance Supervisors & Foremen
Managers of Maintenance & Reliability
Apply lean manufacturing concepts within Mechanical Engineers
a non-manufacturing environment
Operations Managers
Make effective use of kaizen teams and
PdM Analysts & Specialists
kaizen projects
Maximize the talent of a team so it works at Planners & Schedulers
the highest potential Dramatically reduce your cycle times, as
well as scrap and rework costs Plant Engineers
Reduce your changeovers from hours to Plant Managers
minutes with SMED Increase your inventory turns and on-time
delivery Preventive Maintenance Coordinators
Accelerate operational improvement results
Attain the lean goals of better, faster and Preventive Maintenance Specialists
by applying lean principles to maintenance
and reliability cheaper Production Managers
Project Leaders
Quality Managers
Reliability Coordinators
Certification Reliability Engineers
Set Yourself Apart as a Leader Among Peers Reliability Team Leaders
The International Council for Machinery Lubrication (ICML) will offer certification exam Reliability Technicians
opportunities during Reliable Plant 2010. Advance registration is required. All exams will be
Safety Managers & Directors
conducted at the Nashville Convention Center on Monday, August 30, from 5:30 to 8:30 p.m. and
on Wednesday, September 1, from 6:00 to 9:00 p.m. Senior Reliability Engineers
To learn more about the certification types, registration fees and exam preparation, visit the TPM Coordinators & Facilitators
ICML Web site at www.LubeCouncil.org or call 918-259-2950 and more
For complete conference and expo information
4 and updates, visit conference.reliableplant.com

Case Studies at Reliable Plant 2010
Learn from These Practical, Real Life Examples
Pre-Conference Workshops Monday, August 30
How to Optimize
Preventive Maintenance Plans
Eliminate useless tasks and get more ROI
from PM activities
Drew D. Troyer, Noria Corporation
8:00 4:30, August 30
Are you getting the return on investment youd like from preventive
maintenance activities? Do wasteful PM activities continue to drain your
resources? In this workshop, learn the logic and process for creating
effective, optimized PM plans.
Youll first learn how to critically evaluate current PM plans to assess
their value proposition. Then, youll learn effective decision-making
approaches and when to choose each approach. Next, youll learn the
process of building an enterprise-level PM plan for various equipment
classes, and determine how to apply those plans at the site-specific and
equipment-specific levels. The objectives for this workshop are to teach
you how to:
Assess the value proposition of current preventive maintenance plans
Eliminate tasks that fail to add value or actually create problems
Reduce the ambiguity of maintenance tasks
Avoid PM stacking, where condition monitoring tasks are incorpo-
rated in the plan but you fail to eliminate the time-directed tasks theyre
intended to replace
Standardize PM plans for enterprise-level deployment
Pre-Conference Workshops
One-day with Full Conference Registration ..................................................$375
One-day without Full Conference Registration ..............................................$450
Save $200 on conference fees when
you register before July 30, 2010
Real Strategies.
Measurable Results.
How to Rate and Select Oil Filtration
Make informed filtration decisions and eliminate
costly trial and error
Jim Fitch, Noria Corporation
8:00 4:30, August 30
Every day, contamination is robbing industrial lubricants and machin-
ery of precious life. Most plants realize significant losses from lubricant
contamination. But smart companies are taking action. By systematically
reducing in-service lubricant contaminant levels, they are boosting ma-
chine and lubricant life. Small improvements in oil cleanliness are
handsomely rewarded with dramatic declines in bearing replacements,
pump failures, turbine and gearbox repairs, and more.
The opportunity is significant, but selecting the right filtration for the
job can be confusing. Filter performance ratings dont align with oil clean-
liness codes and there are hundreds of filter sizes and types to choose
from, making it easy to specify too much or too little filtration.
After this workshop, youll have a clear understanding of oil filter rat-
ings and how to achieve oil cleanliness goals quickly and efficiently. Youll
make informed filtration decisions and eliminate costly trial and error.
Contamination is the No. 1 cause of bearing
damage that leads to premature removal.
TRW Bearings Division
You will learn:
How to achieve target cleanliness levels at the lowest possible cost
3 types of filters to replace or upgrade immediately
How to understand oil filter performance and test specifications
Filter strategies that remove more contamination for less money
When and where offline filtration makes sense
Effective strategies for filtering high-viscosity oils
7 simple methods for getting longer filter life and reducing filtration costs
New and practical ways to reach oil target cleanliness levels
5
 Learning Sessions

Essentials for Best-Practice Lubrication A Comprehensive Look at Strategic Greasing for Rolling
PMs and Inspections How a Temple-Inland Plant Element Bearings
Changed its Lubrication Program
Jim Fitch, Noria Corporation Stephen Sumerlin, Noria Corporation
Daily one-minute inspections can often be more effective Randy Hall, predictive maintenance technician, Temple-Inland When it comes to greasing, there are many ways to get
than even the most sophisticated oil analysis program per- In this case study session, Randy Hall will share his in- it right and get it wrong. There are a lot of misperceptions
formed monthly. The key is high frequency (daily) and the sights on the progress of the Temple-Inland Gypsum that greasing is a simple task and doesnt require any skill
revealing quality and thoroughness of the inspection. Simi- Wallboard plants lubrication program. Included in this or dedication. Greasing element bearings is more of an
lar to fishing, you cant catch a fish unless your hook is in the presentation are the improvements made to the lubrication exact science than not, stemming from weighing a shot of
water (inspection frequency), and youve got to know how storage shed, servicing equipment and bulk oil filtration. grease from your grease gun to calculating re-grease vol-
to fish (quality of the inspection). Leading organizations have He will highlight the modifications that were made to reser- umes and frequencies. When compared to other lubrication
learned these skills. In this session, youll learn the tech- voirs and gearboxes to help prevent contamination and tasks, greasing is one of the more simple tasks in execution,
niques of these essential inspection practices. make servicing easier. He will share some ideas that did- but it can prove to be a difficult task to execute without flaw.
nt work very well and what was done to correct them. This session will explore the strategies for proper greasing
He also will provide a list of items used and where they techniques for element bearings, and will expand your per-
were purchased. ception of the dedication and precision that is required to
What It Takes to Build an get the most from each stoke of the grease gun.
Award-Winning Lubrication Program
Staley, predictive maintenance analyst, Energizer Battery Company Oil Analysis Gets to the Root of a
In this session, Rick Staley will discuss the lean journey Power Plants Gearbox Problem One Hydraulic Filter for Your Entire
Energizers lubrication program went through from dirty Factory Is it Possible?
oil entering the plant to its current status as an interna- James D. Pete Peterson, senior CBM specialist,
Alabama Power Company Garret Hendrix, owner, Hendrix Engineering
tional award-winner (2009 Augustus H. Gill Award
This case study session explores the action plan of Ala- Purchasing, tracking and stocking dozens of different hy-
recipient). He will stress pitfalls, challenges and how to
bama Power Company when a problem was discovered on draulic filter elements burdens many companies and has a
gain support from management to get buy-in. He will
negative impact on hydraulic reliability when replacement
a pulverizer gearbox. This was the very first find that the
cover oil analysis trending, how early detection paid huge elements arent available. This session will introduce you to
speaker was involved in after being brought on to the
benefits and proper sampling techniques. The presentation hydraulic filter standardization based on SAE Standard
plants condition-based maintenance team. It provides a
will consist of the fundamentals, which is the foundation to J6022, with the ultimate goal of using only one filter element
good demonstration of the importance of having in-house
a strong program. Also covered will be setting standards type for the entire factory. A case study of a standardization
oil testing capabilities.
that must be maintained to prevent setbacks (its much project implemented for a Tier 1 automotive supplier having
easier to hold a standard than to slip and have to rebuild), Routine analysis of the oil from the pulverizer gearbox
more than 160 hydraulic power units, and approximately 80
performing audits for these set standards, and choosing showed a high ferrous index. Further investigation revealed
different filter types and sizes will be presented.
the correct personnel for positions. a wiped thrust bearing, which was replaced. Three years
earlier, before the in-house oil lab was set up, a similar Filter standardization lowers inventory expenses, in-
problem (wiped thrust bearing) was not detected, resulting creases hydraulic reliability, reduces machine downtime,
in a catastrophic failure of the gearbox, leading to a com- increases asset life and leads to a lower overall cost of pro-
What Makes a Good Lubrication PM? plete gearbox rebuild. duction. In these times of lean manufacturing and
heightened competitiveness which surely will not subside
Mark Barnes and Jason Kopschinsky, Noria Corporation going forward, filter standardization is yet another method
Lubrication preventive maintenance (PM) tasks tradition- to achieve a reliable plant and a lower cost of operation.
ally have been vague at best. It is still not uncommon to Designing Your Contamination
come across a lubrication PM for a critical machine that sim- Control Strategy
ply states: Lubricate the machine. This special double Oil Sampling Fundamentals:
session will explore what really makes a good lube PM and Jarrod Potteiger, product and educational services manager,
what format it should be presented in. Youll learn why and
Des-Case Corporation A Step-by-Step Guide to Doing it Right
how to use a variety of formal PMs, which include full refer- Studies show that fluid contamination is responsible for
as much as 82% of machine wear. By eliminating these Jeremy Wright, Noria Corporation
ence procedures for the new lube technician, task sheets for Proper oil sampling is critical to an effective oil analysis
contaminants, you can eliminate the majority of machine
the experienced tech and visual documents for operators.
wear and ultimately maximize equipment life. Of course, program. Without a representative sample, further oil analy-
you cant eliminate all contaminants, but you can reduce sis endeavors are futile. There are two primary goals in
them. The aim should be to control contamination to the obtaining a representative oil sample. The first goal is to
extent that provides the greatest benefit. maximize data density. The sample should be taken in a way
Selecting a New Lubricant that ensures there is as much information per milliliter of oil
Supplier Beyond Price This session will help you design an effective contamina- as possible. This information relates to such criteria as
tion control program and the topics covered include: defining cleanliness and dryness of the oil, depletion of additives,
Jason Kopschinsky, Noria Corporation optimum fluid cleanliness levels, identifying the most cost- and the presence of wear particles being generated by the
Theres more to selecting a new lubricants supplier than effective measures to achieve those targets, and finally how machine. The second goal is to minimize data disturbance.
the price of lubricants. Price does play a role, but today, to effectively measure contaminant levels. Youll learn the The sample should be extracted so that the concentration
most suppliers offer a range of products and services to most common lubricant contaminants, how they affect ma- of information is uniform, consistent and representative. It
support your lubrication excellence initiatives. This session chinery and how to stop them. Plus, youll leave with some is also important not to contaminate the sample during the
will help you navigate the window dressing and help you simple-yet-effective methods for analyzing the cost and ben- sampling process. In this session youll learn the sampling
formulate a rational and systematic approach to selecting efits of contamination control to ensure that available procedures, sampling hardware and sampling locations for
a new lubricant supplier. resources are deployed in the most effective way possible. getting the best possible, consistent oil samples.

For complete conference and expo information

6 and updates, visit conference.reliableplant.com
Your full-conference badge gets you into
sessions from all three co-located conferences.
Specifying Filter Carts
Correctly for Maximum ROI
Jeremy Wright, Noria Corporation
Filter carts are an ideal way to periodically decontami-
nate lubricated systems. Every filter cart should be
compatible with the lubricant and the intended application.
When considering the addition of a filter cart to your con-
tamination control program, there are many things to
consider. This presentation will cover all of the variables
that need to be accounted for to help determine exactly
what details you need to provide your supplier. The leading
suppliers will be able to design the filter cart to meet your
exact needs, giving you the most for your investment.
The 100 Failure Modes of Lubrication
from RCM Analysis
Terry Harris, president, Reliable Process Solutions
Understanding failures modes of your equipment,
processes and individual components is an important func-
tion. Every manufacturing or processing plant has rotating
equipment that is performing plant functions. When this
equipment stops working, your processes cease to perform
their designed expectations. The negative impacts are oper-
ations downtime, reduced capacity, lower quality and EH&S
incidents. Reliability-Centered Maintenance can be used to
define these failure modes. Lubricants and lubrication pro-
grams have more than 100 failure modes that can be defined
and controlled. Understanding each failure mode can help
your plant decide how to prevent and eliminate each of them.
Cyber Caf - FREE E-Mail
Stay connected with the office and home while youre in
Nashville. Take advantage of free e-mail access in the ex-
hibit hall. Available during show hours.
Sponsored by:
Save $200 on conference fees when
you register before July 30, 2010
Preventing Ingress Contamination
through Bearing Cavity Pressurization
Henry Dombroski, president, Air-Tight LLC
In this session, youll learn about prevention of ingress
contamination by means of: 1) hermetically sealing the bear-
ing cavity; 2) pressurizing the bearing cavity with low air or
nitrogen pressure; 3) controlling the pressure in the bearing
cavity 24/7; 4) giving a visual indication of the amount of
pressure; and, 5) indicating bearing cavity integrity 24/7. If
you have current bearing contamination issues, and have
tried everything, attend and learn about these alternative
methods for preventing ingress contamination.
Lubrications Role in Equipment
Energy Consumption
John Sander, vice president of technology,
Lubrication Engineers Inc.
Today more than ever before, plant managers are driven
to reduce operating costs. Yet due to government regula-
tions, they are now being asked to do things that are in
direct contradiction to reducing costs, such as increased
safety measures and reducing plant emissions. Surpris-
ingly, one of the major ways to achieve these goals is
through their lubrication program. It may seem far-fetched
that something as seemingly minimal as lubricants can pro-
vide hidden returns. This session will describe exactly how
a plants energy consumption and emissions can be de-
creased while reducing and operating expenses through a
plants lubrication program.
Bookstore
Conference was great! I will be
applying many of the products and
processes in my plant immediately.
Real Strategies.
Measurable Results.
Expert Advice on Creating a
World-Class Lube Room
Rick Staley, predictive maintenance analyst,
Energizer Battery Company
Rick Staley was instrumental in transforming the lubri-
cation storage room at Energizers factory in Maryville,
Mo., into a world-class example of organization, cleanli-
ness and functionality. In this session, he will share the
lessons learned from the transformation at Energizer and
will outline whats required for creating a world-class lu-
brication storage room at your facility. Topics and tips will
range from storage and filtration to breathers and spill con-
tainment systems to identification and safety measures.
Attend this session and gain the knowledge to make over
your lube room.
Best Practices for the Use of
Off-line Filtration Units
Christopher Eger, product manager for oil services, Schroeder
Industries
To have the best off-line filtration requires that you un-
derstand three basic areas: What are particulate, water
and gas contamination? What does contamination cost
you? Where are you in regards to contamination and where
do you need to be? After understanding the basics of con-
tamination, what products are available in the market to
provide you with a solution? Off-line filtration systems in-
clude filtration carts and skids, contamination monitors,
dehydration systems and diagnostic equipment.
Looking for more information on a
session topic? Excited about learn-
ing more from an expert speaker?
Review and purchase a wide range
of helpful titles in the bookstore.
Sponsored by:
7
 Learning Sessions
How to Use a Lubrication Program Audit
to Increase Equipment Reliability
Tom Hiatt, reliability engineer, Covance Inc., and
Wayne Ferguson, associate consulting engineer reliability,
Eli Lilly and Company
This session provides an overview of the development
and performance of a lubrication program audit. These au-
dits lead to the creation of an action plan that addresses
the gaps in your lubrication program, and if implemented,
will lead to an improvement in equipment reliability. Lubri-
cation audits measure your current program practices
against industry best practices.
Setting Up a Cost-Effective Preventive
Maintenance Program
Tor Idhammar, president, IDCON
This presentation discusses how operations and main-
tenance should closely integrate equipment and process
inspections and preventive measures in a cost-effective
manner. Several simple steps, tools and thought processes
that you can apply in your plant immediately will be dis-
cussed. You will see examples of inspection standards for
common components using colorful documents and easy-
to-understand Excel data sheets that you can use in your
organization to analyze cost-effective PMs. Financial tools
for analyzing which maintenance method is most cost ef-
fective will also be presented.
Managing Risk with Food-Grade
Lubricants and the HACCP Program
Stephen Sumerlin, Noria Corporation
Determining where food-grade lubricants should and
should not be used is sometimes a tricky and tedious task
simply due to misguided regulations and improper in-
house techniques. The Hazard Analysis and Critical Control
Points (HACCP) program was developed to aid in deter-
mining critical points and their safety hazards related to
contamination and key health and safety risks. The pri-
mary area of use for the HACCP program is the food and
beverage industry, but industries such as pharmaceuticals
and cosmetics are adopting the program now as well. This
session will discuss the HACCP program and show how
food contamination can be limited with the use of food-
grade lubricants.
Causes, Effects and Mitigation of Varnish
Jim Fitch, Noria Corporation
Varnish, sludge and surface deposits are a persistent
problem among lubricant users. Often, the problem has
been extremely chronic, leading to expensive repairs and
lost production. While we know much more today about
the causes and some solutions, no silver bullet is currently
available to eradicate the problem entirely. This session fo-
cuses on the current state of these problems and the future
needs for a permanent solution.
8 and updates, visit conference.reliableplant.com
Dynamic Equilibrium Revisited
The Behavior of Large Particles
in Lubricating Oil
Thomas G. Barraclough and Daniel P. Walsh, Spectro Inc.
Particle limits are often not readily available or published
by OEMs. This is especially true if a machine can tolerate
particle levels that are outside of standard particle count-
ing codes that are applicable to keeping systems clean in
the application of contamination control. This often makes
it difficult and confusing for end-users who are new to oil
analysis to be able to set defined limits for various particle
sizes for machinery that by its nature will continually cre-
ate benign wear particles during its lifetime.
The fundamental premise of machine condition monitor-
ing by wear particle analysis is that an abnormal wear
mode causes an increase in the size and concentration of
wear particles above a previously defined baseline. This
baseline is not fixed and the level will depend upon a num-
ber of factors related to operating conditions of the
machine itself. The term dynamic equilibrium describes
the process by which particles of a given size range reach
their own unique equilibrium level. It is these levels which
can be used to trend and set alarms. This result is often
not intuitively obvious when setting up an oil sampling
strategy. This session revisits some previously docu-
mented mathematical models on this subject that show
from first principles how particles of a given size reach a
ceiling value.
When understood and used in conjunction with various
wear particle trending techniques, dynamic equilibrium
analysis can provide end-users with an ideal predictive
screening tool to prevent and establish the root cause of
pending failures.
Reduce Water Content, and Save Oil
and Cash with Vacuum Dehydration
Jon P. Michel, engineering and maintenance manager,
ArcelorMittal, and Richard Trent, technical field services
manager, Hy-Pro Filtration
Water contamination in lube oil systems (i.e. steel mills,
paper mills) compromises lubricating properties of the fluid,
leading to premature failures and unplanned downtime.
High water levels also reduce useful fluid life, can lead to
unnecessary leakage and necessitate decanting to drain
excessive water, which greatly increases the amount of lu-
bricating fluid consumed and the cost and environmental
impact of disposing of the fluid.
In this case study session, learn how in a recent steel
mill rolling mill application, vacuum dehydration reduced
the water content of an 8,000-gallon reservoir from 29,000
ppm (2.8%) to 17,735 ppm (1.7735%) in one day. Over two
weeks, the water content fell to 383 ppm (.0383%). Ap-
plying vacuum dehydration also allowed the mill to end the
decanting routine, saving 25,200 gallons of oil (valued at
approximately $201,600) annually and decreasing lubricant
disposal costs.
For complete conference and expo information
How to Set Oil Target Cleanliness Levels
Jim Fitch, Noria Corporation
Controlling particle-induced machinery failures must
begin with defining a customized standard of oil cleanli-
ness for each machine that it affects. This session reviews
the range of methods used to define the correct target
cleanliness level and the most critical influencing fac-
tors. Youll learn the most reliable and effective tools used
in the lubrication field relating to setting cleanliness goals
and establishing contaminant tolerance.
Methods for Comprehensive
Contamination Control in
Industrial Fluid Applications
Christian Bauer, staff scientist, Pall Corporation
In this session, youll learn the common types of con-
tamination in industrial hydraulic and lube systems, the
devastating effects of these types of contaminants and ef-
fective methods for controlling and reducing them. The
benefits of implementing a comprehensive approach to
cleanliness control, coupling high-efficiency filtration sys-
tems for the removal of particulate contamination with
vacuum dehydration purifiers for the removal of free and
dissolved water, and diagnostic instrumentation for meas-
urement of levels of particulate and water contamination
will be discussed.
An Explanation on the ISO-Based
Changes to ICML Certification Programs
Suzy Jamieson, executive director,
International Council for Machinery Lubrication
ISO 18436-4 is the first international standard on quali-
fication and assessment of field lubricant analysis
personnel. This session will explain in easy-to-
understand terms the career path outlined in this ISO
standard for lubrication and analysis professionals. The
presentation will cover the purposes, categories, require-
ments and syllabus as per this standard, as well as the
alignment ICMLs certification program has undergone to
reflect its equivalence to ISO 18436-4 categories and the
role it has played in the development of this and other up-
coming standards of interest for the lubrication and
analysis professional.
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Building The Total Maintenance System
Samuel Bethea, director of North American maintenance and
reliability, Campbell Soup Company
This session will examine how the application of process
management, Six Sigma and other facets can enhance
maintenance processes and the implementation of an op-
timized maintenance strategy. Driven by the need for
improved supply chain efficiencies such as lower invento-
ries and by producing to the demand schedule of
customers, maintenance teams have had to become nim-
ble and flexible in their approach to establishing
maintenance efficiency. Youll learn ways to navigate the
needs to satisfy customer demands while providing effi-
cient maintenance systems. Methods of integrating
maintenance best practice tools into the day-to-day man-
ufacturing process to facilitate optimized maintenance will
also be discussed.
How to Maximize Your Condition
Monitoring Program and Really
Impact the Bottom Line
Alain Pellegrino, reliability technician and senior technical
consultant, Laurentide Controls
In recent years a lot of plants have invested in condition
monitoring technologies. Many realized early successes
and reduced downtime, improved availability and lowered
maintenance costs. But many investments havent realized
their full potential. We have new tools but still use them the
old way. Using a real case study of a large zinc smelter, this
session describes the strategies deployed to improve a con-
dition monitoring program through continuous improvement
and measurement. Youll see how these improvements im-
pact the plants bottom line, and how small, continuous
improvements can change the way you do business into a
new business as usual that is more efficient and cost ef-
fective, directly impacting the bottom line.
Improve Operator Confidence and
Reduce Errors with Decision Trees
Julien Le Bleu Jr. and Robert X. Perez of SageGuides.com
Decision trees logical, visual tools that list relevant
questions and likely outcomes can be highly beneficial
in leading trained operators to fact-based conclusions. To
be useful, the questions asked must be straightforward,
such as those that operators are likely to run into on a reg-
ular basis (Is the oil too hot? Is the level too low? Is
there too much vibration?) The beauty of a decision tree
methodology is that, if agreed to by management and fol-
lowed faithfully by operating personnel, it makes doing the
correct thing clear-cut and easy.
Management will see better decisions and reduced practices 30 years ago aboard U.S. Navy nuclear sub-
maintenance costs by incorporating decision trees into the marines, achieving greater than 99% system reliability. These
operating culture. For example, by training operators to use practices are directly transferable to manufacturing industry
a logic tree for pump decisions, a petrochemical facility re- today. Design. Train. Clean machines. Follow procedures.
duced maintenance overtime by 30% by reducing the Standardize. Lube. Listen. Inspect. Record/Analyze. Stock.
number of pumps that were not repaired on an emergency Motivate. Be accountable. Drill. How can these practices be
or expedited basis.
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Real Strategies.
Measurable Results.
Failure Reporting, Analysis and How to Maximize the Life Cycle
Corrective Action System (FRACAS) Costs of Production Equipment
Strategies for Manufacturing
Claudia Faye, reliability engineer, Alcoa
Drew Troyer, Noria Corporation If 85 to 97 percent of base life cycle costs are commit-
ted by the time that equipment is handed over to
Data is the difference between deciding and guessing. In
operations and maintenance, then life cycle costs (equal
a benchmark study by the Aberdeen Group, 59% of top-
to approximately 20 times the total installed cost) can be
quartile performers utilize real-time and historical asset
most influenced during the capital process. However, 3 to
performance data to drive decisions and actions, compared
15 percent of life cycle costs can be influenced outside the
to 21% for the laggards. Top performers report 88% OEE
design, purchase, construction and installation of new
and 2% unscheduled downtime, compared to 75% OEE and
equipment. How can businesses really affect their cost of
18% unscheduled downtime for the laggards. FRACAS is
production? Attend this session and find out!
about leveraging data to improve decisions and is the
process for gathering information about failures and other
losses, analyzing them, and creating and implementing cor-
rective actions as required.
Successful Reliability Program
Unlike FMEA, which is predominantly utilized in the de-
sign phase of the assets life cycle to hypothesize potential
Implementation Begins with Strategic
failure modes and effects, FRACAS is more real world Planning and Key Partnerships
and empirical. In this session, youll learn how to develop
Clay Calk, Lubrication Engineers Inc.
a FRACAS system and then use the collected information
Most maintenance professionals understand the impor-
to drive equipment asset and manufacturing process relia-
tance of implementing or upgrading a reliability program,
bility and profitability.
and they already have the knowledge and training about
what to do and how to do it. Unfortunately, because of the
daily demands and responsibilities of their jobs, the need to
Effective Problem Solving in the increase production outputs and the constant firefighting
Maintenance and Reliability Organization required to keep critical systems running, they often fail to
allocate enough time to the strategic planning that is cru-
John Crossan, former manufacturing and maintenance leader cial to program success.
(recently retired), Clorox Corporation, and Randall Quick, Strategic planning and key vendor partnerships can sim-
engineering manager, Manufacturing Solutions International
plify the strategic planning process and provide the
Most companies still use the traditional approach of hav- answers to these questions, paving the way for a seam-
ing elite groups solve problems, and then pass their less, turnkey program customized to fit the companys
solutions on to those who must now actually do the work. reliability objectives. To be successful, the program should
Using this approach, you can get to adequate performance. address the needs of the maintenance staff, source all ma-
You might even get to good, depending on your definition terials required for installation, ensure onsite assistance
of good. But you will never get to excellent. Excellence through all phases of implementation, provide education
takes routine involvement at all levels, using problem situ- and training to staff, and set up the metrics and tracking
ations as ways to involve and develop people, rather than that justifies the programs overall cost.
just as issues to solve. John Crossan and Randy Quick
have worked on operational and maintenance improvement
at the shop-floor level in plants for many years. In this ses-
sion, they will describe ways to build this routine Bearing Life: If 90% of Bearings
involvement and development. Outlast the Asset Theyre Put In,
Why Dont Mine?
Dave Staples, business development manager,
All I Really Need to Know About SKF Reliability Systems
Maintenance I Learned in a In order to make predictions regarding bearing life, most
Nuclear Submarine do the L10 math. However, theory doesnt always repre-
sent reality. The bearing didnt reach end-of-life because of
Ned Mitenius, senior consultant, Periscope Consulting metal fatigue; it failed sooner. It failed, perhaps, due to fac-
Share everything. Play fair. Dont hit people. Hold hands tors not considered in the L10 calculation, like wear,
and stick together. We learned these practices in kinder- contamination, misalignment, corrosion, or as a result of
garten and can apply the wisdom of them to life today. The cage, lubrication or seal failure. The L10 calculation is an
speaker for this session learned maintenance and operational older theory based on traditional ISO and ABMA standards.
This does not take into consideration operating conditions
that are considered by newer calculations like the New
Life Theory or the Adjusted Life Theory. Bearing life can
be calculated with different degrees of sophistication and
(as a result) accuracy, depending on the knowledge of the
real operating conditions and environmental variables. This
applied today to your factory to improve your reliability? session will take a look at these newer calculations.
9
 Learning Sessions
Equipment Failure Modes: Your
Components Can Last Forever!
Terry Harris, president, Reliable Process Solutions
In this session, youll learn the various failure modes that
lead different components down the path to early wear-
out. By using methods from RCM analysis and FMEA,
youll explore the failure modes of some basic equipment
and equipment components in most industrial plant oper-
ations. For every example, a proactive or precision
technique will be presented and discussed. Can a motor
last for 10 to 15 years without failures? Can a bearing last
30 years without failing? Can belts and chains last five to
six years without failing? These and many other compo-
nents of plant operating equipment will be studied. For
every dollar you save in maintenance due to improved
equipment reliability, there is another $5 to $10 added to
the bottom line.
Strategies for Energy Management
and Energy Reduction
Johnny Bofilios, director of global asset sustainability, INFOR
It is well known that there is a direct connection be-
tween the reliability of assets and their consumption of
energy. In fact, energy use is a leading indicator of predic-
tive performance of an asset. But what are the strategies
to start managing and reducing your plants energy? Did
you know that you can factor energy use with asset man-
agement to maintain and extend the life of equipment and,
therefore, lower your costs? In this session, find out the
best practices to integrate energy into your reliability and
maintenance strategies so you can start identifying, opti-
mizing and automating proactive maintenance, comparing
both the asset performance and its energy usage across
your enterprise. This presentation will be based on case
studies of a high-profile paper manufacturer, a well-known
East Coast university and a Tier 1 automotive manufac-
turer, who have already reduced energy consumption by a
minimum of 6% and reduced their carbon emissions at the
same time.
Predictive Maintenance/Condition
Monitoring Through Airborne
Ultrasound Technology
Doug Waetjen, development team member and director of
worldwide sales, UE Systems Inc.
Instruments based on airborne/structure-borne ultra-
sound technology offer many opportunities for plant-wide
predictive maintenance activities, ranging from determin-
ing a lack of lubrication to locating compressed air leaks.
Usually portable, these instruments are used to trend and
analyze bearing condition, detect leaks, identify electrical
problems such as corona, arcing and tracking, and identify
potential problems in operating mechanical equipment. This
presentation will provide a brief overview of the technology,
its applications and suggested inspection techniques.
10
How to Systematically Engineer Costs What Makes a Good PM, and How to
Out of Your Maintenance Budget Make Sure It Is Executed Properly
Drew Mackley, product line manager, Jeff Shiver, managing principal, People and Processes
Emerson Process Management In a recent survey of more than 1,300 plant profession-
In an increasingly competitive market, organizations are als in 40 countries, 62% said they either did not have a
challenged to run their plants more profitably and with preventive maintenance program or are in the process of
greater efficiency. Yet mechanical equipment deteriorates, building one. Do you have a real program? A better ques-
causing a decrease in performance, a reduction in through- tion might be How would my engineering and operations
put and a rise in operating costs or an unplanned partners respond to a similar survey? Can you truly meas-
shutdown grinds production to a halt, resulting in a large ure and communicate the success your PM program
loss in revenue. Deterioration in machinery health and per- generates to ensure a favorable survey response from
formance is usually associated with misalignment or those partners? What would happen if you were asked that
imbalance, corrosion and wear, fouling, sediment buildup or question in a court of law? Does your CMMS data support
poorly lubricated parts. Detecting these underlying prob- perceptions or reality? Do you know if your data is the
lems early allows you to correct issues before they affect result of pencil-whipping? Are the PM task activities the
your process, optimizing the performance of your plant. In right work and value-added? How can you tell?
this session, we will focus on best practices for planning This presentation will address the components of a good
for and implementing the predictive maintenance tech- PM and methods to ensure the PM activities are executed
nologies and services necessary for cutting expense out of properly. In addition to the PM components necessary, learn
your maintenance budget. Real-world examples and case tools and techniques for establishing an effective PM process,
histories will be included. adding a continuous improvement loop for optimization,
measuring the value of the PM program and inspecting to en-
sure the right execution. Understand why pencil-whipping
occurs and how to break the habit. Gain insights on commu-
Moving from Reactive to Proactive:
nicating and managing the perceptions with your operations
How to Get TPM Working for You and engineering partners to eliminate disconnects so that
Ellis New, senior management consultant, Productivity Inc. everyone is on board with the value your organization adds.
Moving from reactive maintenance to proactive mainte-
nance requires a whole new look at the way the maintenance
process is managed. To reach this goal, you must declare war How to Determine Whether a
on unplanned equipment downtime due to failure and build a
maintenance organization unburdened by firefighting. Mov-
Motor is Truly Green
ing from technical fixing to equipment management means Tim Owens, president and CEO, PdMA Corporation
having reliable and available equipment providing the flexibil- The ever-present emphasis on technological efficiency
ity necessary to substantially reduce costs and generate is just one of several forces behind the pressure on com-
additional income by increasing overall capacity. panies to go green despite a trying economy. The ultimate
In this session, we will look at what it takes to transi- criterion that determines whether a motor is truly green is
tion from reactive to proactive by using the principles of energy efficiency. Technology, long the key to efficiency,
Total Productive Maintenance in an accelerated and cost- can help resolve this issue through detailed computerized
effective manner. Well look at the pillars of TPM and how analysis of the motor, the power environment in which it
and when you implement them to get the biggest return in operates, and even its reliability.
the shortest period of time. Plus, we will talk about the
proper use of predictive technologies and learn what is nec-
essary to build strong, effective teams to support an overall
equipment reliability improvement effort.
So Whats the Need for
Predictive Maintenance?
During this session we will explore:
Terry Haycraft, national reliability manager, Frito-Lay
The role of TPM in a lean implementation
Each 0.1 percent of equipment downtime reduction gets
The benefits of a team-based approach to equipment
care tougher to get each year. As seasoned mechanics retire
from Frito-Lays workforce, the companys cannot afford
Root cause tools like visual management, checklist the learning curve for new mechanics. In many cases, ac-
and CMMS to guide your transition cording to this sessions speaker, there is no direct feedback
The use of predictive maintenance technologies as on corrective or preventive maintenance jobs in the CMMS.
part of the overall effort Frito-Lay needed tools to start the transition from
The importance of building peoples capabilities to sus- time/usage PMs to condition-based predictive maintenance
tain the effort and help it avoid the premature failure due to unnecessary
over-lubrication of equipment. This session will provide a
The significance of having operators involved mainte- brief overview of the companys Alpha / Beta sites utilizing
nance activities the Ultraprobe 10000 and Utraprobe 201 Grease Caddy that
Transition metrics, standard work and proactive main- achieved enough positive results to quantify the implemen-
tenance policies tation of the predictive technology on a national level.
For complete conference and expo information
and updates, visit conference.reliableplant.com
Your full-conference badge gets you into
sessions from all three co-located conferences.
Effective Inspection of Steam Traps
and Valves Through Ultrasound
Paul Klimuc, national service manager, SDT North America
This presentation will cover how ultrasound allows for workforce. The key for success in any reliability or lubrica-
the effective inspection of steam traps and valves. It will tion program is the people.
also explain the basic principles of how ultrasound detects
leakage and other basic faults.
Overcoming the Challenges to
Implementing an ISO-Certified
Asset Management Process
Ramesh Gulati, asset management and reliability planning
manager, Aerospace Testing Alliance at Arnold Engineering
Development Center
This paper will discuss quality systems requirements for
physical asset management and what challenges are faced
to establish an effective system that is compliant with in-
ternational standards ISO 9000 and PAS 55. ISO 9000 is a
family of standards for quality management systems, in-
cluding the management of physical assets. PAS 55
Optimal management of physical assets is a Publicly Avail-
able Specification published by the British Standards
Institution. The latter gives guidance and a 28-point re-
quirements checklist of good practices in physical asset
management. Asset management at the Arnold Engineering
Development Center (AEDC), located at Arnold Air Force
Base, has been an ISO-certified organization since 2004.
The Secret Asset: Whats Missing
in Your Reliability Program?
Larry Hoing, reliability and engineering systems manager,
Wells Dairy
Asset performance is the name of the game in every-
ones book. The thought process is, if we can increase our
asset performance, which increases our return on net as-
sets (RONA), then this will help us lower the total cost of
goods sold and increase our profit margins. Simple, right?
So, why is it that a large number of companies never fully
achieve the net positive results of the investment to im-
prove their assets, or if they do have some improvement,
they cannot sustain it for any period of time? Have you con-
sidered your people assets in the same way that you do
your physical assets? Most every company mission or vi-
sion statement includes the following sentence. Our
people are our greatest assets. Is this really true? Do we
really invest in and continuously improve our people as-
sets? How many improvement or updating activities did
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Nashville Convention Center
Wednesday, September 1
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we do for them in the last fiscal year? Oh yeah, thats right,
the training budget was the first thing to go in the budget-
cutting process. The fact of the matter is we cannot
perform at a higher level of asset reliability and not invest
in a skilled, well-informed, well-educated and engaged
Lubrication is the cornerstone for any reliability program.
The cornerstones for a successful lubrication program are
the people. How do you invest in your people to make them
successful? How do you grow or revive a lubrication pro-
gram? What are the keys to success? Attend this session;
we will explore some of the possibilities of how to engage
some of your greatest assets your people.
The Critical Elements of Procedure-
Based Manufacturing
Drew Troyer, Noria Corporation
Standard operating and maintenance procedures can
profoundly influence the reliability of your equipment as-
sets and manufacturing processes. A recent study found
that 70% of top-quartile performers employ documented
operating and maintenance procedures, compared to 20%
of the lower-quartile performers. Top-quartile performers
enjoy an 88% OEE, compared to 75% for the lower-quartile
performers. Their downtime is only 2 percent, compared
to 18% for the lower-quartile performers. In another study,
it was discovered that 75% of what goes wrong in the fac-
tory is, in fact, human error. The same study revealed that
lack of procedures tops the list of reasons why. In this ses-
sion, well discuss: why procedure-based maintenance is
so critical to your success, how to convert tacit knowledge
into documented knowledge, and how to deploy your pre-
ferred practices enterprise-wide.
Get Your Head in the Clouds -
Machine Condition Monitoring
and PdM over the Web
Robert D. Corak, Eric J. Olson and Daniel P. Walsh, Spectro
Inc./QinetiQ North America
CMMS and LIMS software in typical deployments leave
large gaps in a comprehensive condition-based PdM pro-
gram. Their inability to connect oil analysis data, vibration,
thermography and ultrasound measurements to asset his-
tory, operational condition, maintenance activity and root
cause analysis leave predictive tools limited in their ana-
lytical capabilities. The new capabilities of cloud
connectivity (Internet) are changing the paradigm and
Real Strategies.
Measurable Results.
asset owners can make maintenance decisions based on
holistic machine condition, by giving them end-to-end data
access. This session will focus on the benefits of an asset-
centric system vs. the traditional LIMS system and detail
some significant advantages that Web-based systems can
have over traditional systems.
Design for Maintainability and
Reliability: How to Get Everyone
on the Same Page
Ramesh Gulati, asset management and reliability planning
manager, Aerospace Testing Alliance at Arnold Engineering
Development Center
Most reliability programs focus on creating an effective
maintenance program for existing assets. Those who have
been involved with a Reliability-Centered Maintenance
analysis project on existing assets know that some designs
create additional challenges that may have been avoided if
operators and maintainers had an opportunity to provide
input based on resident knowledge and experience. This
session will discuss how Arnold AFB/ATA capital project
managers and designers work in conjunction with opera-
tors and maintainers to build reliability and maintainability
into new or modified assets. Attend this session and learn
how to truly optimize your life cycle costs.
Reliability: The Ultimate Green Initiative
Robert Apelgren, Reliability-Centered Maintenance analyst,
ITT Corporation
There is a new focus in society for going green in al-
most everything we do. Manufacturing is no exception and
has been negatively impacted by diverting funds to green
initiatives. This generates no revenue and can carry in-
creased cost, which affects a companys competitive
viability. Many times, these diverted funds come from other
areas that have a heavy impact on reliability. Reliability is
the ultimate green initiative. Though rarely referred to as
green, it is most beneficial to the company, consumer
and the environment. Reliability is achieved through the
culmination of training and various tools from reliability
analysis, root cause, maintenance planning and schedul-
ing, and predictive technologies. Proper employment of
these tools leads to many green benefits, which include
energy efficiency, waste reduction and increased produc-
tivity. In this session youll learn how to employ
Reliability-Centered Maintenance effectively, how to set
goals, and how to determine when to start investing in
other green initiatives.
11
 Learning Sessions

The 3 Critical Steps to Integrate Sustaining the Gains through Using Traditional Lean Tools in a Non-
Lean Six Sigma into a Corporate Culture Standardization and Leveraging Traditional Manufacturing Environment
Aqua Porter, vice president, strategic projects and business Jeff Slater, Operating Excellence leader, Sonoco Kelly Moore, lean manufacturing leader,
results for Corporate Lean Six Sigma Operations, A consultant study of Operating Excellence productivity Syngenta Crop Protection
Xerox Corporation projects at Sonoco showed that over a three-year span, St. Gabriel, La., is home to Syngentas largest agrichem-
At its core, Lean Six Sigma is a change management ini- approximately 50% of the benefits were no longer being ical manufacturing and formulation site in North America,
tiative. To successfully deploy Lean Six Sigma and sustain achieved. Back-sliding and project erosion has made it and is comprised of eight continuous and batch chemical
results in the long term, organizations must create an en- harder for Sonoco to attain its net productivity goals. A production areas. In late 2006, a declining agrichemical mar-
vironment with reinforcing loops to encourage smart good rule of thumb is that without a system to sustain the ket and generic competition drove Syngenta to a strategic
decision making and facilitate momentum. In her keynote gains, an additional 15 to 20% per year of productivity proj- decision that the St. Gabriel plant would become a lean
address, Aqua Porter will discuss three areas critical to art- ects will be required to overcome erosion. A system locks manufacturing site. In early 2007, the facility took its first
fully integrating Lean Six Sigma into a corporate culture: in the gains through: 1) Standard metrics to insure that tentative steps on its lean journey. Six months later, in mid-
The executive team creates a vision for using Lean Six gains are sustained; 2) Standardized work to insure that 2007, an unexpected market uplift turned the journey into a
Sigma in an organization. Leading from the front involves the gains are delivered everywhere; 3) Continuous im- sprint. Syngenta will share the experiences and learnings
getting hands dirty and empowering employees with re- provement to identify the next improvement to become the gained from using traditional lean tools in a non-traditional
sources to be successful. How do executive leaders standard; and 4) Leveraging insures everyone understands lean manufacturing environment. The companys continued
become Lean Six Sigma champions? the standard and new potential improvements are identi- stumbling and victories prove that a lean journey is an on-
fied. Attend this session and learn the keys to workforce going marathon and not a 50-yard dash. The Syngenta case
Organizations need to embrace the upside-down and in-
productivity, methods to attain management simplification study is a story of application of lean manufacturing princi-
side-out communication flow created by social media. ples in a continuous process agrichemical world.
Information doesnt always flow from the top anymore. Em- and agility, and the manner in which to achieve standard
ployees use social networks to create a community and performance through a lean system across your companys
share best practices with each other and peers in the in- divisions and plants.
dustry. How can organizations use this collaboration already How Does a Utility Implement Lean?
taking place to further Lean Six Sigma use in everyday work? Best Practices from the Countrys
People are the most critical change agents, and culti- Applying Lean Practices to Largest Nuclear Plant
vating strong project teams is the key to innovation and Maintenance and Reliability
implementation. For Lean Six Sigma to take hold in the cul- Kirk Gould, process improvement consultant in the Center of
ture of the ranks, employees must be engaged and Darrin Wikoff, education facilitator, Life Cycle Engineering Process Excellence, Arizona Public Service Company
consulted. What is the best way to maximize the talent of Lean manufacturing, Lean Six Sigma or simply just lean Arizona Public Service is a power utility based in the
a team so it works at the highest potential? are all common terms used in todays manufacturing or- southwestern United States. With more than one million
ganizations to describe a method of operational customers, Arizona Public Service must build and maintain
improvement. But what about maintenance and reliability the electrical infrastructure and keep the air conditioners
improvement? Do lean principles and practices apply to the on for a large part of the Southwest. APS is a part-owner
How is Machine and Line Reliability a maintenance system? In 2007, IndustryWeek reported that of the Palo Verde Nuclear Generating Station, the largest
Key Factor in Lean Manufacturing? 74% of companies engaged in lean efforts were not satis- power plant of any kind in the United States. APS operates
fied with progress being made and the subsequent results. the plant for the other six corporate owners. This presen-
Lonnie Wilson, owner and principal consultant, tation will be a case study on the journey Arizona Public
Quality Consultants We now understand that a significant risk to lean imple-
Service has taken to apply business process management
This session will explore how high levels of reliability mentations is the lack of a stable foundation for and lean manufacturing concepts within this non-manu-
must be achieved to attain the lean program goals of bet- improvement. This instability is a result of inadequate main- facturing environment.
ter, faster, cheaper. Furthermore, it will explain not only tenance and reliability systems. In this session,
how reliability has helped lean, but how lean has helped participants will discover how lean principles can be ap-
reliability, and how these two concepts work together to plied to maintenance and reliability to accelerate
make your manufacturing facility a more secure work en- operational improvement results. Master the SMED System in Your Plant
vironment and a better money-making machine.
Mike Wroblewski, senior operations consultant,
Gemba Consulting
Employee Involvement and In this session, lean lessons spanning more than two
Learning to See: Finding Gold Empowerment in Lean: decades on mastering the SMED system will be shared
on the Plant Floor A Yamaha Case Study which can enable companies to achieve year-over-year
success in a lean transformation. The SMED system, or
Mark Steward, senior manager for lean productivity, large- Eric Bigelow, lean industrial engineer and continuous single-minute exchange of dies, is one of the most power-
scale food manufacturing company improvement expert, Yamaha Motor Corporation ful methods in the lean approach, yet it is still not widely
In many ways, we are often blinded by those things that This session will explore the subject of employee in- used or successfully applied in many manufacturing com-
are right in front of us. Our perception in day-to-day life is volvement and empowerment within a lean environment panies. You will learn about the challenges and practices of
key to discovering pockets of gold as we make our way in using a diagram that the speaker calls Lean Agri-Culture. incorporating and sustaining the SMED system. See why
a life of continuous improvement. In this session, the The presentation will illustrate in a dynamic style the pos- 5-S is an important foundation to the SMED system. In-
speaker aims to help you gain a set of fresh eyes to use sibilities and the successes that a company can experience cluded in this presentation are several case studies with
in your daily life around the plant. The lessons explored in when the basic rule of kaizen is followed: People come first, concrete examples of using the SMED system. Find out
this session were gained from years leading lean program and everything else comes second. The speaker will pro- how to achieve maximum productivity and flexibility using
improvements at large manufacturing companies in the vide examples of the concepts in action at Yamahas this amazing system to reduce your changeovers from
power management and food products industries. 1,000-employee recreational vehicles plant in Newnan, Ga. hours to minutes.

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12 and updates, visit conference.reliableplant.com
Your full-conference badge gets you into
sessions from all three co-located conferences.
Lean Safety A Safe Path to
Achieve Lean Results
Robert B. Hafey, RBH Consulting LLC
Without trust, lean is a bust! A common requirement to
attain either world-class lean or world-class safety is the
ongoing engagement of the workforce. Lean thinkers all
agree that it is this culture-changing employee engagement
activity that leads to long-term lean success. Too often,
lean has been employed as a cost-savings methodology
by management and, as a result, gaining employee interest
and buy-in can be at best difficult. This keynote session sug-
gests a different path to lean success a safe path that
focuses the power of lean improvement on the universal
topic of workplace safety. By utilizing lean thinking, along
with some of the common tools in a lean thinkers toolbox,
and focusing on safety instead of cycle time, you can easily
start to build an understanding and the acceptance of lean
while you improve safety in your facility. Lean has to be
taught, and when you use safety as your textbook or road
map, you will gain everyones attention. Everyone will rally
around safety for it is and should be everyones first priority.
On the safety side, safety compliance to mandated reg-
ulations (OSHA) is most often the focal point of safety
programs. Reacting to injuries, near-misses or changes to
these mandated regulations may be the only times that
changes occur in a safety program. Yet an opportunity ex-
ists to proactively engage the workforce in a meaningful
safety improvement-focused program. To a lean thinker, the
continual improvement of safety should be no different than
improving a production process. How better to show re-
spect for people and begin to earn their trust than by
engaging them in the continual improvement of safety.
Examples and case studies of lean tool usage that si-
It is obvious that we had lost the magic that made the
multaneously drove safety and lean improvement will be
covered in this session. implementation of lean so successful. What we have since
Hy-Pro Filtration Meet and
Greet Reception
Nashville Convention Center
Tuesday, August 31
5:30 - 6:30pm
Sponsored by:
An extremely valuable conference. If youre looking to
get the most bang for the buck, this is the one event of
the year I would recommend to anyone involved in reliabilty
Save $200 on conference fees when
you register before July 30, 2010
Real Strategies.
Measurable Results.
learned is, in a sense, what weve always known. Leader-
Raytheon Gets Back to Basics ship is essential to a successful lean deployment. But now
(and Back on Track) with Lean we know its more than words and theres more to it. Lean
leadership behaviors, follow-up and accountability need to
Julie Goswick, senior manager and Operations Excellence
leader, Raytheon Missile Systems condition the atmosphere that drives, supports and sus-
Tucson-based Raytheon Missile Systems (formerly tains lean. In addition, the lean management system
Hughes Aircraft) had everything going for it in the world of provides the structure through standard work, account-
ability and follow-up that sustains lean on a daily basis.
lean. From 1996 to 2004, the defense industry buzzed
Without lean leadership and a lean management system,
about Raytheons successes leaning out 14 factories using
the production process will lapse back into the natural in-
their homegrown version of the Toyota Production System.
ertia of expediting hardware and fire-fighting problems on
In a matter of just a few years, the company won the Ari-
an ad hoc basis.
zona Governors Award for Quality; the U.S. Navy
designated the Agile Improvement Process as an Industry Follow the Raytheon Lean Team as we embark on Back
Best Practice; Hughes was recognized by Industry- to Basics, a case study of what we missed along the lean
Week with Americas Best Plant award; and in 2004 journey the first time, and what we know now that we
(now Raytheon) won the coveted Shingo Prize. The Mis- must do to get back on track.
sile Systems Lean Team had developed and implemented
a proven, repeatable deployment process, the employees
were trained on lean and focused on the elimination of
waste, and the results realized were amazing. Cycle times
were dramatically reduced, inventory turns were
increasing, scrap and rework costs were decreasing, and
on-time delivery, cost and quality were at new levels. So
what happened ...?
Fast forward to 2010. Today, pockets of lean excellence
can be found throughout many of the original factories in
Tucson. Employees on occasion can be heard discussing
lean terms such as error-proofing, takt, kanbans, and 7-S TEAM DISCOUNTS
with a new and aggressive commitment for safety. Walk-
ing through the factories though, one can clearly tell that
Bring your team and cover all of the
something is missing. sessions at Reliable Plant 2010
and save up to $645 per person
- Doug McBride
13
Exhibitor List (as of May 14, 2010)

The exhibits at Reliable Plant 2010 work in tandem with sessions and work- Interested in exhibiting at Reliable Plant 2010?
shops to enhance your experience. Youll have the opportunity to compare Contact Brett OKelley at 800-597-5460 extension 112 or e-mail
products, solutions and services from leading vendors. Take what you learn bretto@noria.com. Sponsorship opportunities also available.
in the classroom to find and evaluate solutions you need on the exhibit floor.

Academy of Infrared Training (AIRT) Hy-Pro Filtration Quality Filtration

Air Sentry IDESCO Corporation R&G Laboratories, Inc.
Air-Tight LLC Indiana Bottle Company Rhino Tuff Tanks
ALS Laboratory Group Infor Royal Purple Ltd.
Argo-Hytos, Inc. Inpro/Seal Company SDT Ultrasound Solutions
Brady Corporation Insight Services SenGenuity (Division of Vectron Int'l.)
Cannon Instrument Company Internormen Technology Shell Lubricants
CheckFluid, Inc. JAX INC. SKF USA, Inc.
Chevron Product Company JLM Systems Limited Snap-on Industrial / J.H. Williams Tool Group
CITGO Petroleum Corporation Kaman Industrial Technologies Specialty Manufacturing, Inc.
Des-Case Corporation Koehler Instrument Company, Inc. Spectro, Inc.
Dexsil Corporation Life Cycle Engineering Tannas Company
Donaldson Company, Inc. Lincoln Industrial Thermal Lube
Dupont Performance Lubricants Liquidynamics UE Systems, Inc.
EasyVac, Inc. Lubrication Engineers, Inc. Utilx Corporation
Emerson Process Management Ludeca, Inc. Y2K Fluid Power
Esco Products, Inc. Midland Manufacturing *Sponsors shown in orange

Fluid Technologies, Inc. MP Filtri USA

Fluidall, LLC Noria Corporation
Hach Company Novinium
Harvard Corporation One Eye Industries, Inc.
Hendrix Engineering, Inc. Pamas USA
Herguth Laboratories, Inc. PerkinElmer, Inc.
HYDAC Technology Corporation/ POLARIS Laboratories
Schroeder Industries Productivity, Inc.

Take Home the Tools Game

How to Win: Check out the latest products and services from the sponsoring
exhibiting companies, get your entry form stamped and then register to win. Visit our
Web site at conference.reliableplant.com for complete contest rules.
Come compare the tools for building a reliable plant and you might go home with one of three
Snap-on/J.H. Williams/Bahco tool sets for the garage or workshop. Three sensational prize pack-
ages one each day. Snap-on tools have inspired the trust and confidence of professional craftsmen
since 1920. Designed to deliver superior performance, durability and comfort, Snap-on tools not only
last for years, they last for generations.
Giveaways sponsored by:
CITGO Petroleum Corporation, Des-Case Corporation, Emerson Process Management, Fluidall, Herguth, HYDAC / Schroeder Industries, Hy-Pro Filtration, Infor,
Life Cycle Engineering, Lubrication Engineers, Midland Manufacturing Company, MP Filtri USA, POLARIS Laboratories, Rhino Tuff Tanks, Shell Lubricants, SKF USA,
Spectro, Y2K

For complete conference and expo information

14 and updates, visit conference.reliableplant.com
 Real Strategies.
Measurable Results.

Hotel and Venue Conference Fees (USD)

Reliable Plant 2010 is held at the Nashville Convention Center in Nashville,
Tennessee. Reliable Plant 2010 attendees receive discounted room rates at
the Renaissance Nashville Hotel, which is connected to the Nashville Con-
vention Center. You can take advantage of these rates by booking your
room(s) directly with the Renaissance using the group name Reliable Plant
Conference at the time of reservation. Availability is limited and you are
encouraged to make reservations early.
Renaissance Nashville Hotel
611 Commerce Street
Nashville, TN 37203-3725
Telephone: 800-266-9432 / 506-474-2009
Room Rates Book Early and Save
Before Aug. 14 - Single Occupancy: $135.00
Rates Expire: August 14, 2010
* All room rates exclusive of state and local taxes or applicable service,
or hotel specific fees in effect at the time of the meeting. Hotel tax
rates are subject to change without notice.
Reserve Your Room Today!
Call the hotel directly at 800-266-9432 or 506-474-2009.
Be sure to provide the group name: Reliable Plant Conference.
Make all hotel reservation changes or cancellations directly with
the Renaissance.
Full Conference Registration
(Tuesday through Thursday)
On or Before July 30, 2010 ....................................................................$795
After July 30, 2010 ................................................................................$995
Group Discounts
3 to 9 Attendees: Send three or more full conference registrations for only
$550 each, plus a 20% discount on all pre-conference workshop fees.
10 or More Attendees: Send 10 or more full conference registrations for
only $350 each, plus a 20% discount on all pre-conference workshop fees.
Multiple registrations must be purchased at the same time.
Call 800-597-5460 to take advantage of this offer.
Conference Registration Includes:
All sessions in the 3 co-located conferences
Conference Proceedings in CD-ROM format
Opening General Session
Exhibition Hall Access (Tuesday-Thursday)
Lunches in the Exhibit Hall (Tuesday-Wednesday)
Daily Refreshment Breaks (Tuesday-Thursday)
Daily Continental Breakfasts (Tuesday-Thursday)
Networking Receptions (Tuesday-Wednesday)

Airlines and Car Rental 1-Day Conference Registration ....................................$395

1-Day Registration Includes:
Air Travel Days sessions in the 3 co-located conferences
Opening General Session (Tuesday Only)
American Airlines is offering discounted fares for attendees of Reliable Plant Exhibition Hall access for one day
2010. Some restrictions may apply for airline tickets and discounts may not Lunch in Exhibit Hall one day (Tuesday-Wednesday)
be available on all fares. For reservations and ticketing information, call Amer- Days Refreshment Breaks
icans Meeting Services Desk at 800-433-1790 from anywhere in the U.S. or Days Continental Breakfast
Canada and reference Authorization Number: 2780AP Days Reception (Tuesday and Wednesday Only)
Discount fares are valid for round-trip travel on American Airlines, Ameri- Exhibition Only Registration
can Eagle, American Connection Service and all oneworld Alliance Partners. With Exhibitor Guest Pass (Advance and On-site) ............................................FREE
The percentage discount may be applied to American and American Eagle
Without Guest Pass (After July 30, 2010) ..........................................................$50
flights booked online by visiting www.aa.com and entering the authorization
number as the aa.com discount code. Valid group travel dates are August 28 Pre-Conference Workshops
- September 5, 2010. One-Day (with Full Conference Registration) ............................................................$375
One-Day (Workshop Only) ..............................................................................$450
Car Rental Workshop Registration Includes:
Course Materials Opening General Session (Tuesday Only)
Refreshment break(s) Exhibit Hall Access (Tuesday Only)
Discounted group car rental rates are available from August 23 -
September 9, 2010. Reservations can be made by calling 800-331-1600 Spouse/Family Registration..............................................$135
or online at www.avis.com and reference Discount Code: J907635 for Spouse/Family Includes:
group discount rates. Opening General Session (Tuesday Only)
Exhibition Hall Access
Daily Lunches in the Exhibit Hall (Tuesday-Wednesday)
Discounted group car rental rates are available from August 24 - Daily Continental Breakfasts (Tuesday-Thursday)
September 9, 2010. Reservations can be made by calling 800-654-2240 or Receptions in the Exhibit Hall (Tuesday-Wednesday)
online at www.hertz.com and reference Discount Code:CV#04B10002.
Save $200 on conference fees when
you register before July 30, 2010 15
 REGI
Registration befor STER
e
and s July 30
ave $
Nashville, TN - August 31 September 2 200

August 31 - September 2 Nashville Convention Center Nashville, Tennessee

1. Registrant Information 4. Conference Proceedings on CD-ROM

Please print your name clearly. Your name and company will appear on your badge. With full conference registration . . . . . . . . . . . . . . . . . . . . . . . . . . .Included
PLEASE photocopy this form for an additional registrant.
Purchase without registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .$99
First Name __________________________________________________
Last Name __________________________________________________
First Name for Badge __________________________________________ Total Payment Due: $ ______________
Payment due upon receipt of invoice and prior to conference. No registration materials will
Title ______________________________________________________ be distributed without full payment. Customers outside the U.S.: We accept checks drawn
on U.S. banks in U.S. dollars.
Company ____________________________________________________
Address 1 __________________________________________________
Address 2 __________________________________________________
5. Method of Payment
City ____________________________State/Province ________________ Payment must be received prior to the conference.
Zip/Postal Code __________________ Country ____________________ Check # _____________ is enclosed or will be mailed
Please make check payable to: Noria Corporation
E-mail (required) ______________________________________________
Charge my: Visa MasterCard AmEx Discover
Phone Number (required) ( ______ ) ______________________________ Noria Corporation is authorized to charge the credit card below for my conference
registration fees in the amount indicated on this form.
Fax Number ( ______ ) ________________________________________
Card Number ____________________________________________

2. Conference Fees Expiration Date ______ - ______

Name on Card ____________________________________________

Individual Full Conference:
5/28/10 to 7/30/10 . . . . . . . .$795
After 7/30/10 . . . . . . . . . . . .$995
Endorsing Organization Member
5/28/10 to 7/30/10 . . . . . . . .$745
After 7/30/10 . . . . . . . . . . . .$945
Write-in
Guest-Spouse/Family . . . . . .$135
(Must accompany paid attendee)
Cardholders Signature ______________________________________
Individual 1-Day
Individual 1-Day . . . . . . . . . .$395 Bill Me/My Company - Purchase Order No. ______________________
Exhibition Hall Only:
Through 7/30/10 . . . . . . . . . . .$35
After 7/30/10 . . . . . . . . . . . . .$50 Register using any of the following:

BESTE!
Organization

@ Online: By Phone:
Group Discounts VALU conference.reliableplant.com 800-597-5460 or
Three to Nine full conference registrations only $550 each or Ten or More for $350 918-749-1400
each. Group discounts include a 20% discount on pre-conference workshop fees. Group M - F, 8 - 5 (CST)
registrations must be purchased at the same time. Call 800-597-5460 to take advantage
of this offer.
By Fax: By Mail:
Fax your completed Send this form and payment:
registration form to: c/o Noria Corporation
918-746-0925 1328 E. 43rd Ct.
3. Pre-conference Workshops Tulsa, OK 74105 U.S.A.

Save With Full

Registration
Cancellations/Substitutions
Monday, August 30 You may cancel a registration before July 31, 2010. Cancellations must be in writing. A $75 cancellation fee will be applied to all
cancellations received after July 31, 2010, but you will also receive a $75 coupon good for use against the cost of a Noria training
How to Rate and Select Oil Filtration . . . . . . . . . . . . . . . . .$450 . . . . . . .$375 course or conference. This coupon is fully transferable. If you dont cancel and you dont attend, you will be charged the full regis-
tration fee. Substitute attendees are welcome at no extra charge with written notice prior to the event.
How to Optimize Preventive Maintenance Programs . . . . .$450 . . . . . . .$375

For complete conference and expo information

16 and updates, visit conference.reliableplant.com
 Get a Printable Version
CROSSWORD PUZZLER of This Puzzle Online at:
MachineryLubrication.com/puzzle

1 2 3 4 5

9 10

11 12

13 14

15 16

17 18

19

20

ACROSS DOWN
3 Derived from the Latin words meaning rock and 1 The measure of the resistance to flow (or shear) of a
oil. fluid (internal friction).

7 This term describes any amount of material (or 2 A product of oxidation.

energy) that constitutes a chemically reactive hazard
or that mechanically impairs the proper functioning of
the equipment and the performance of the system.
9 The type of lubricants showcased in this issues
Product Spotlight section.
14 What the P stands for in RPVOT.
16 The Packaging Corporation of America mill
featured in this issues cover story is located in this
Wisconsin city.
17 Name of lubricant analyst at the PCA mill featured in
this issues cover story.
18 The void space above the oil level in a sample bottle;
also known as headspace.
20 A result when air is trapped in oil.
Get the solution on Page 13.
4 Senior designer of Machinery Lubrication magazine
(see Page 5).
5 Anti-scuff additives are also known as this.
6 A class of bearings where surfaces are separated by
rollers, balls or needles.
8 Considered to be the most commonly used grease.
10 The study of friction, lubrication and wear between
moving surfaces.
11 A method of wear metal detection employed in oil
analysis.
12 A means of representing a filters capture efficiency.
13 Last name of Machinery Lubrications From the
Field columnist.
15 Name of Machinery Lubrication e-mail newsletter.
19 Abbreviation for the manufacturing association and
internationally recognized body that publishes
specifications for (among others) open gear lubrication.

Machinery Lubrication www.machinerylubrication.com May - June 2010 53

GET TO KNOW
Talking Turkey and Lubricants With
a Jennie-O Maintenance Leader
Bob Wieckowicz, the subject of this issues Get to Know ...
section, is the maintenance supervisor at the Jennie-O Turkey Store
processing plant in Barron, Wis. Jennie-O is a wholly-owned
subsidiary of Hormel Foods Corporation and is one of the worlds
largest turkey processors. He has worked 36 years for the company
after spending some time in the construction industry. In his current
role, he helps oversee lubricants, equipment performance and a
staff of 52 maintenance technicians. Lets learn more about Bob.
When did you get your start in machinery lubrication,
and how did it happen?: I always have had a role in lubrication
at the plant. I was hands-on for many years as a technician. Since
moving into management in 1989, Im still hands-on, but now its
more on the strategy and training end of it. At this site, lubrication
always has been central to machine maintenance.
What types of training have you taken?: I have two certifica-
tions, but those are for steam systems and pipe welding. From a
lubrication perspective, Hormel brought in Noria for a training seminar
in Austin, Minn., a few years back. Before that, for years, one of our
lubricant suppliers would regularly put on seminars. I also have done a
lot of reading and research on my own. In my training role, I try to share
that information and my years of in-plant experience.
Whats a normal work day like for you?: We have more than
4,000 machines in this plant, and any one of them may be the focus for
the day. When you work at a plant that processes a million pounds of
turkey per day, thats what you are going to get. I cover process equip-
ment, packaging equipment, material handling equipment,
compressors, pumps and electric motors up to 500 horsepower.
What have been some of the biggest lubrication project
successes for which you have played a part?: Converting
all of our lubricants to a USDA H1 or higher rating that was huge.
Our single-largest oil system is 8,000 gallons. We get all of our main
four oils hydraulic, ISO 460, ISO 220, ISO 100 delivered in bulk.
We use a couple thousand gallons a month. As a result, it was quite
a process to complete.
Another would be in terms of consolidating suppliers and lubri-
cants. We used to work with several suppliers, but after becoming a
Hormel subsidiary in 2001, we began to sole-source with the
54 May - June 2010 www.machinerylubrication.com
Bob Wieckowicz supervises maintenance at the Jennie-O
plant in Wisconsin.
supplier who has Hormels national account. Tied to that, we had
carried a myriad of lubricant types. Every time a manual gave a
name or a new piece of equipment was installed, we were buying
another tank of oil. Working with our supplier, we now have
brought it down to four primary lubricants and then several
secondary ones. Its more efficient. Theres less confusion and less
chance to use the wrong oil. Theres less inventory, and it costs less.
Finally, three years ago, Hormel specified that our vacuum pump
applications, which are huge users of oil, all should be converted to
synthetic oils. I was heavily involved with the conversion process.
What lubrication-related projects are you currently
working on?: Again, it comes back to H1 lubricants. It is essential
to have USDA H1 compliance throughout our plant. It is a contin-
uous requirement to provide appropriate lubricants while
maintaining food safety compliance.
How does your company view machinery lubrication in
terms of importance, strategy, etc.?: It is the cornerstone of
our preventive maintenance program. A meat processing plant is a
very harsh environment for machinery. Consistent lubrication is
essential to machine reliability.
Get to Know features a brief question-and-answer session with a
Machinery Lubrication reader. These articles put the spotlight on
industry professionals and detail some of the lubrication-related projects
they are working on. If you know of an ML reader who deserves to be
profiled, e-mail editor-in-chief Paul V. Arnold at parnold@noria.com.
Machinery Lubrication
WEB PREVIEW
Get Even More Information
on Our Publication Web Sites
E very day, thousands of industrial professionals from around
the world visit our Web sites. See what makes these sites so
popular and so informative. Visit us today and every day at
www.machinerylubrication.com and www.reliableplant.com.
Articles & White Papers
How to Flush Gearboxes and Bearing Housings
What constitutes a thorough sump flush? Are there any partic-
ular problems that you should be careful to avoid? What
equipment can or should be used for this purpose? What items
should be included in a detailed flushing procedure? Find the
answers to these and other questions by reading this article. Get it
by typing Flush gearboxes in the Search bar on the ML Web site.
A Guide to Maintaining Clean Oil
This guide outlines the problems and causes of insufficient oil
cleanliness, and details the remedy for such problems. Topics include
filtration basics, oil sampling advice, filter economy ideas, basic
filtration definitions, oil handling tips and recommendations for
buying oil. Find this guide in the White Papers section on the ML site.
Best Practices for Lubing API
Centrifugal Pump Bearing Housings
In this article, you will learn about optimal ways of lubricating
the bearings in API process pumps, including data on discs vs. oil
ring lubrication, maintaining the proper level and contamination
control. Bearings that are properly lubricated with minimal
contamination will operate at lower temperatures and for longer
Were Your Source for Free White Paper Reports
MachineryLubrication.com is the place to turn for free white paper reports on
a host of maintenance and reliability topics. Heres just a sampling of some of
the white papers currently available for download.
Cost-Effectiveness of Automatic Lubricators
Industrial Food-Grade Lubricants Guide
Automatic Grease Lubricators: What You Need to Know
Engineering an Effective Oil Analysis Program
Elements of a Good Preventive Maintenance Program
Controlling Gearbox Lubricant Contamination
Choosing the Correct Oil or Fuel Purification System for Water
Contamination Removal
Hidden Benefits of Lubricant Consolidation
Check out the full list of white papers. Visit www.machinerylubrication.com
and click on the White Paper link on the home page.
56 May - June 2010 www.machinerylubrication.com
periods of time. Find this article in the Web Exclusives section on
the RP site or type Lubing API in the RP Search bar.
Also
Term Glossary
Nearly 100 lubrication and oil analysis terms are defined in the
Glossary on the ML Web site. Maintenance, reliability and lean
terms are defined on the RP Web site. Just click on the Glossary
link on the top of each home page.
Watch Videos
More than 160 free videos, vodcasts and slideshows on lubrica-
tion and oil analysis topics are available for viewing on the ML Web
site. Simply click on the Videos box on the ML home page. More
than 1,500 videos on maintenance, reliability, lean and manufac-
turing topics can be found on the RP site.
Industry News
Stay informed by reading news stories posted most every day.
Check out the Industry News box on the home page.
Write a Blog
We are looking for industry pros to write for a new blog section
of our Web sites. If you wish to be a blog author on the subject of
machinery lubrication or oil analysis, e-mail parnold@noria.com.
E-mail Newsletter
Sign up for Lube-Tips and Filtration Tips, Norias free lubrication-
related e-mail newsletters, which contain helpful articles, tips, trivia
and more. Just click on the Newsletters link at the top of the ML
home page. Additional newsletters are available via the Newsletters
link on the RP home page.
Subscription Services
Ensure that you will continue to receive award-winning Machinery
Lubrication magazine by filling out the free subscription form. Simply
click on the Subscribe link at the top of the ML home page.
Education On The Road
Get all the details on Norias industry conferences, seminars and
other educational events, including new and expanded Machinery
Lubrication and Oil Analysis courses. Just click on the Events link
found at the top of the ML and RP home pages.
Machinery Lubrication
CERTIFICATION NEWS

Free MLA I Upgrade Exam

Offered to Certain MLT I Holders
BY SUZY JAMIESON, ICML

A re you a certified Machinery Lubrication Technician (MLT)
Level I who attained certification before January 1, 2010? Do
you also have an interest in a career in oil analysis, but do not want
to start from scratch? If so, you may enter the career path by
following ISO 18436-4, Condition Monitoring and Diagnostics of
Machines Requirements for Qualification and Assessment of
Personnel Field Lubricant Analysis.
The International Council for Machinery Lubrication (ICML) is
offering qualified MLT I holders who attained certification prior to
the ISO alignment of January 1 a one-time upgrade exam, free of
charge, for a chance at a second certificate as a Machine Lubricant
Analyst (MLA) Level I. Granted that you meet the experience
requirements of ISO 18436-4, Category I (same as MLA I), you can
sit for a 30-minute, 16-question upgrade exam covering the oil
analysis subject areas that were added to the MLT I Body of
Knowledge when ICMLs MLT I was used as the base for Category I
of ISO 18436-4. Candidates must have at least 12 months of expe-
rience in the field of lubricant analysis-based machinery condition
monitoring (based on 16 hours minimum per month of sampling
and analysis experience).
The Body of Knowledge for this upgrade exam is as follows:
Oil Sampling (7 questions)
A. Objectives for lube oil sampling
B. Sampling methods
C. Managing interference
1. Bottle cleanliness and management
2. Flushing
3. Machine conditions appropriate for sampling
Lubricant health monitoring (7 questions)
A. Lubricant failure mechanisms
1. Oxidative degradation
a) The oxidation process
b) Causes of oxidation
c) Effects of oxidative degradation
2. Thermal degradation
a) The thermal failure process
b) Causes of thermal failure
c) Effects of thermal degradation
3. Additive depletion/degradation
a) Additive depletion mechanisms
b) Additives at risk for depletion/degradation by the
various mechanisms
B. Testing for wrong or mixed lubricants
1. Baselining physical and chemical properties tests
2. Additive discrepancies
C. Fluid properties, test methods and measurement units
applications and limitations
1. Kinematic viscosity (ASTM D445)
2. Absolute (dynamic) viscosity (ASTM D2893)
3. Viscosity index (ASTM D2270)
4. Acid number (ASTM D974, et al)
5. Base number (ASTM D974, et al)
6. Fourier transform infrared (FTIR) analysis
7. Rotating pressure vessel oxidation test (ASTMD2272)
8. Atomic emission spectroscopy
Wear Debris Monitoring and Analysis (2 questions)
A. Common machine wear mechanisms
Criteria for Approval
Candidates must answer 12 of the 16 questions correctly to be
deemed successful on the upgrade exam. Since the upgrade exam is
a one-off opportunity, if a candidate is not successful, retakes
toward MLA I certification would be via the regular MLA I exam,
which consists of 70 questions covering the complete MLA I Body
of Knowledge, not the 16-question, one-time upgrade exam.
If the candidate is approved, an MLA I certificate will be issued,
with its expiration date matching that of the current MLT I certifi-
cate. Recertification criteria must be met individually, per each
certificate at the expiration date, as these will be treated as sepa-
rate certifications MLT I and MLA I.
If you are a current MLT I certificate holder, certified prior
to January 1, 2010, and meet the above requirements, contact
ICML via e-mail at info@lubecouncil.org to inquire about
an upgrade exam. You can join an existing exam location
(www.lubecouncil.org/exam/locations_bydate.asp), or if none of
the listed sessions is suitable, ICML will try to coordinate a local

58 May - June 2010 www.machinerylubrication.com Machinery Lubrication

exam. Local exams may incur proctoring fees
payable directly to the venue in question,
however no exam fee will be charged by ICML
for this one-time upgrade offering.

About ICML
The International Council for Machinery
Lubrication (ICML) is a vendor-neutral, not-for-profit
organization founded to facilitate growth and devel-
opment of machine lubrication as a technical field of
endeavor. Among its various activities, ICML offers skill
certification testing for individuals in the fields of
machine condition monitoring, lubrication and oil
analysis. ICML is an independently chartered organiza-
tion consisting of both paid professional staff
members and volunteer advisors. It provides lubrica-
tion and oil analysis standard development support,
scholarship, skill-based testing and certification, and
recognition of excellence. For more information
about ICML, visit www.lubecouncil.org.

Need to take an exam?

ICML regularly holds exam sessions throughout
the United States and the world. Upcoming dates
and locations for ICML exams can be found at
www.lubecouncil.org

Machinery Lubrication www.machinerylubrication.com May - June 2010 59

PERSPECTIVE
Screening vs. Testing:
Know the Difference When
JASON KOPSCHINSKY
NORIA CORPORATION Monitoring Contaminants
W hen it comes to contaminant monitoring, the difference
between what is referred to as screening and what could be
referred to as testing and analysis is really like talking about
apples and oranges. This is an important distinction to remember
when dealing in used oil analysis. When referring to contaminant
monitoring, screening is often done at the plant level by plant
personnel with field equipment. Conversely, testing is often the
job of a lab. It is precise testing done to an exact standard by
certified laboratory technicians using laboratory equipment.
Make sure that you know the difference when monitoring for
contaminants in the field and in the lab.
If we examine the traditional offering of screening tests done in
a plant environment, the three most popular screening tests tend to
be water, particle count and viscosity.
Identifying Water Content
Water always has been one of the most destructive contami-
nants in a lubrication system. Not only can water have lasting or
irreparable effects on the lubricant (specifically the base oil and the
additive package), but water in oil also affects the machine itself. It
goes without saying that this would be an important contaminant
to measure. However, the method by which we measure water
concentration in oil in a field environment can be much different
than the method used by a lab technician.
Many commercial used oil analysis laboratories measure water
content using a Karl Fischer titrator. Karl Fischer titration is a
classic method in analytical chemistry that uses coulometric or
volumetric titration to determine trace amounts of water in a
sample. This test follows a set of steps developed and published by
the American Society for Testing and Materials. For this reason, the
results are repeatable and highly accurate, providing results in parts
per million (ppm). In the field, it would be rare to run the same test
to determine the amount of water concentration in a used oil
sample. Karl Fischer involves the use of chemical reagents and
apparatus not suitable for an industrial field environment. Also,
such accurate results are not always required in the field when
making maintenance decisions.
Simple pass/fail screening tests may provide you with enough
information to take action. The crackle test has long been a field
favorite for determining if water is present in an oil sample. The
crackle test involves placing two drops of used oil on a pre-heated
60 May - June 2010 www.machinerylubrication.com
hot plate. Based on the formation and audible explosion of bubbles
when the drops hit the hot plate, a skilled technician can even
determine the approximate quantity of free and emulsified water in
the sample down to about 500 ppm. However, the crackle method
is limited and highly subjective. As with any field test, you will not
want to seriously compare results to a lab result. In the case of
crackle vs. Karl Fischer, these methods use two different apparatus
and measure different states of water coexistence.
Measuring Particle Count
Particle count can provide a wealth of information that can limit
a potential failure to a less-than-catastrophic issue mitigated with
some filtration or breather upgrades. In recent years, the quality
and accuracy of particle counters available for the industrial envi-
ronment has grown significantly. There are several types of on-site
particle counters that you can get your hands on for industrial
applications, including light blockage, laser scattering and mesh
obstruction.
Laser light scattering certainly offers the most popular particle
counters for labs and for the field, but you may come across the
other technologies. The challenge when performing particle counts
in the industrial environment is being able to work around water or
air contamination and color (clarity) of the sample. These contam-
inants can make it difficult to get accurate results, and the sample
may require additional preparation just to run the particle count.
The preparation can be difficult and is less likely to be done in an
industrial environment. Additionally, prior to testing the sample for
particle count, the sample must be mechanically agitated. Hand
shaking or automatic stir plates will not resuspend the particles to
an even and representative distribution. The agitation needs to be
aggressive and violent. Reciprocating paint shakers are generally
considered to be the best choice for this application.
Considering all of the variables and challenges, particle counting
can still be done on-site. Mesh obstruction, pore blockage particle
counters make easy work of particle counting and are not as
affected by moisture and air contamination or color as optical
particle counters, which make them a great choice for the industrial
environment. However, these types of counters are heavy on the
labor side and are limited in the area of automation. Because of
this, they are less likely to show up in your commercial lab for
routine samples. Therefore, field-to-lab comparisons wont be
Machinery Lubrication
comparing the same thing. Likely, you will have two different testing
methods or two different types of equipment, which may provide
two different results. Its best to use the on-site equipment for
regular screening and for directing maintenance decisions. I believe
the on-site lab shouldnt replace the commercial lab; rather, they
should work in concert. Trending, tracking and confirmation may
be best suited for your commercial lab.
Determining the Viscosity
Perhaps the most important property of a lubricant is its
viscosity. Viscosity can be tested with several different on-site tools,
including a Visgage comparator. This piece of equipment compares
a known reference viscosity to the used oil sample. Both oils are
normalized to the same temperature, and testing can be performed
to an accuracy of 95 percent.
This is a great tool for front-line confirmation that viscosity is where
it needs to be. However, keep in mind that on-site viscosity testers and
commercial laboratory results will not accurately correspond to each
other. Most on-site viscosity testing units measure resistance to internal
flow and shear, known as absolute viscosity, while commercial labora-
tories use equipment that tests the lubricants resistance to flow,
known as kinematic viscosity. The two measurements can be calculated
off of one another, but they will never be exact due to the difference in
how the tests are performed. This is yet another case for not directly
comparing field tests to laboratory tests.
Machinery Lubrication
A Two-Pronged Approach
to Oil Screening
As mentioned earlier, the goal for on-site used oil screening is
not to replace your commercial lab. Ideally, you will want to work
in parallel with your commercial lab. On the front line, you can
catch problems before they occur and take action on them while
your commercial lab confirms results and performs exception
testing to further hone in on the root of the problem.
About the Author
As technical operations director for Noria Reliability Solutions, Jason
Kopschinskys primary responsibilities include managing numerous and
varied projects in the areas of: plant audits and gap analysis, Lubrication
Process Design, oil analysis program design, lube PM rationalization and
redesign, lubricant storage and handling, contamination control system
design, and lubrication and mechanical failure investigations. Contact
Jason at jkopschinsky@noria.com.
Hungry For More Information?
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hundreds of technical articles, columns and reports related to
lubrication research, solutions and best practices. Check out
www.machinerylubrication.com and learn more.
www.machinerylubrication.com May - June 2010 61
BACK PAGE BASICS
Make Infrared a
Heat-Seeking Weapon
JEREMY WRIGHT
NORIA CORPORATION in Your PdM Arsenal
T o understand infrared thermal imaging, we must first under-
stand wavelengths of the electromagnetic spectrum. Infrared
radiation is part of the electromagnetic spectrum and occupies
frequencies between visible light and radio waves, spanning wave-
lengths from 0.7 micrometers to 1,000 micrometers (microns).
The amount of radiation emitted by an object increases with
temperature; therefore, thermography allows one to see variations
in temperature. An infrared thermometer measures temperature by
detecting the infrared energy emitted by all materials which are at
temperatures above absolute zero (0 degrees Kelvin). The most
basic design consists of a lens to focus the infrared (IR) energy onto
a detector, which converts the energy to an electrical signal that can
be displayed in units of temperature after being compensated for
ambient temperature variation. This configuration facilitates
temperature measurement from a distance without contact with
the object to be measured. As such, the infrared thermometer is
useful for measuring temperature under circumstances where ther-
mocouples or other probe-type sensors cannot be used or do not
produce accurate data for a variety of reasons.
History and Other Lessons
Designs for an infrared thermometer (IRT) have existed since at
least the late 19th century, and various concepts on the subject
were featured by Charles A. Darling in his book Pyrometry,
published in 1911. However, it was not until the 1930s that the
technology was available to turn these concepts into practical
measuring instruments. Since that time, there has been consider-
able evolution in the design, and a large amount of measurement
and application expertise has accrued. At the present time, the
Figure 1. The Electromagnetic Spectrum
62 May - June 2010 www.machinerylubrication.com
technique is well accepted and is widely used in industry and in
research.
The appearance and operation of a modern thermographic
camera is often similar to a camcorder. Often, the live thermogram
reveals temperature variations so clearly that a photograph is not
necessary for analysis. A recording module is, therefore, not always
built in.
Thermal images, or thermograms, are actually visual displays of
the amount of infrared energy emitted, transmitted and reflected
by an object. Because there are multiple sources of the infrared
energy, it is difficult to get an accurate temperature of an object
using this method. A thermal imaging camera is capable of
performing algorithms to interpret that data and build an image.
Although the image shows the viewer an approximation of the
temperature at which the object is operating, the camera is actually
using multiple sources of data based on the areas surrounding the
object to determine that value rather than detecting the actual
temperature.
The Math and the
Science Behind Infrared
This phenomenon may become clearer upon consideration of
the formula:
Incident Energy = Emitted Energy + Transmitted Energy +
Reflected Energy
Where
Incident Energy is the energy profile when viewed through a
thermal imaging camera.
Emitted Energy is generally what is intended to be measured.
Transmitted Energy is the energy that passes through the
subject from a remote thermal source.
Reflected Energy is the amount of energy that reflects off the
surface of the object from a remote thermal source.
If the object is radiating at a higher temperature than its
surroundings, then power transfer will be taking place and power
will be radiating from warm to cold following the principle stated
in the Second Law of Thermodynamics. So if there is a cool area in
the thermogram, that object will be absorbing the radiation
emitted by the warm object. The ability of both objects to emit or
absorb this radiation is called emissivity.
Machinery Lubrication
 BACK PAGE BASICS
The thermal imaging camera would next employ a series of
mathematical algorithms. Since the camera is only able to see the
electromagnetic radiation that is impossible to detect with the
human eye, it will build a picture in the viewer and record a visible
picture or video.
In order to perform the role of non-contact temperature recorder,
the camera will change the temperature of the object being viewed
with its emissivity setting. Other algorithms can be used to affect the
measurement, including the transmission ability of the transmitting
medium (usually air) and the temperature of that transmitting
medium. All of these settings will affect the ultimate output for the
temperature of the object being viewed. This functionality makes the
thermal imaging camera an excellent tool for the maintenance of
electrical and mechanical systems in industry.
By using the proper camera settings and by being careful when
capturing the image, electrical systems can be scanned and prob-
lems can be found. Faults with steam traps in steam heating
systems also are easily located.
With Knowledge Comes Power
Infrared thermometry is a mature but dynamic technology that
has gained the respect of many industries and institutions. It is an
indispensable technique for many temperature measurement appli-
cations. When the technology is adequately understood by the user,
and all the relevant application parameters are properly consid-
ered, a successful application will usually result, provided that the
64 May - June 2010 www.machinerylubrication.com
equipment is carefully installed. Careful installation means ensuring
that the sensor is operated within its specified environmental limits,
and that adequate measures are taken to keep the optics clean and
free from obstructions.
A factor in the selection process, when choosing a manufacturer,
should be the availability of protective and installation accessories, and
also the extent to which these accessories allow rapid removal and
replacement of the sensor for maintenance. If these guidelines are
followed, the modern infrared thermometer will operate more reliably
than thermocouples or resistance thermometers in many cases.
References
Darling, Charles R.; Pyrometry: A Practical Treatise on the Measurement
of High Temperatures. Published by E.&F.N. Spon Ltd. London. 1911.
http://www.omega.com/techref/iredtempmeasur.html
http://en.wikipedia.org/wiki/Thermal_and_infrared_imaging
http://www.antonine-education.co.uk/physics_gcse/Unit_1/
Topic_5/em_spectrum.jpg
About the Author
Jeremy Wright is a certified Machinery Lubricant Analyst (MLA) Level I
and Level II and Machinery Lubrication Technician (MLT) Level I by the
International Council for Machinery Lubrication (ICML). In addition, he is
a Certified Maintenance and Reliability Professional (CMRP) by the Society
for Maintenance and Reliability Professionals (SMRP). Contact Jeremy at
jwright@noria.com.
Machinery Lubrication