machinery lubrication
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Revista sobre lubricacionTRANSCRIPT
Contents
September - October 2011
Machinery
Lubrication
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AS I SEE ITJustifying the Cost of Excluding a Gram of DirtAUTHOR: JIM FITCH
Many variables and factors infl uence the cost of excluding a gram of dirt. However, there are many more costly consequences associated with failing to exclude.
HYDRAULICS AT WORKHow a Band-Aid Solution Can Fix Your Hydraulics ProblemsAUTHOR: BRENDAN CASEY
There’s a negative bias toward the Band-Aid solution in engineering, but there are times when a convenient shortcut is needed. The trick is being able to recognize when a Band-Aid solution is appropriate and when it is not.
OIL ANALYSISLubricant Analysis in Steam TurbinesAUTHORS: BEATRIZ GRACA, JORGE SEABRA, PINTO SOUSA
Discover the potential of analytical ferrography in diagnosing the early stages of sludge and varnish problems so the root cause can be determined and corrective action taken before a catastrophic failure occurs.
10COVER STORY
Lube Room ChallengeMachinery Lubrication’s annual Lube Room Challenge showcases exceptional lube rooms submitted by readers who have transformed their lubricant storage and dispensing methods to best practices.
More 30 BOOKSTORE 40 PRODUCT SUPERMARKET42 TEST YOUR KNOWLEDGE
Editorial Features20 GET TO KNOW32 NOW ON MACHINERYLUBRICATION.COM
Departments 18 PRODUCT NEWS 22 CROSSWORD PUZZLER
CERTIFICATION NEWSEli Lilly’s Wenzel Embodies the Spirit of ICMLAUTHOR: SUZY JAMIESON
By successfully completing the very fi rst ICML exam 10 years ago, Rendela Wenzel not only became one of the fi rst ICML-certifi ed profes-sionals but also the very fi rst ICML-certifi ed female practitioner.
FROM THE FIELD6 Steps to Update Your Lubrication ProgramAUTHOR: STEPHEN SUMERLIN
When updating your lubrication program, it is important to think of every aspect of lubrication. Just working on one area will not yield the results you desire.
LUBE-TIPSOur readers provide excellent advice on a host of lubrication-related issues.
BACK PAGE BASICSComparing Gasoline and Diesel Engine OilsAUTHOR: JEREMY WRIGHT
While gasoline and diesel engine oils generally have the same anatomy and are formulated from the blending of base oils and additives, they actually are quite different when examining the lubricant’s required performance for each engine type.
2 | September - October 2011 www.MachineryLubrication.com
C o n t a m i n a t i o n C o n t r o l
For years Noria has been saying, “The cost of excluding a gram of dirt is probably only about 10 percent of what it will
cost you once it gets into your oil.” Recently, a Noria training client asked us to document proof of this statement.
It reminds me of a widely used quote from Benjamin Franklin: “If you think education is expensive, try ignorance.” Or another familiar one: “Pay me now or a whole lot more later.” Proactively investing in reliability and machine wellness is very often challenged by the need to justify. Management is always asking for fi nancial analysis and to “make the business case.”
Conversely, a fi nancial study rarely is produced to obtain funds to repair a failed machine, especially when plant production has stalled. Sadly, I’ve heard maintenance folks say that they’ve quit trying to propose proactive measures to management. They claim it’s easier to just let the machines fail.
This is like saying it’s easier to just wait until you have a heart attack than to proactively make the lifestyle changes needed to avoid heart disease (diet, fi tness, quit smoking, etc.). These differences are often deeply ingrained in management and business culture. Does your organization have the “here and now” folks or those who “plan and prepare?”
On the bright side, an increasing number of companies are led by managers who do “get it.” Much of this has been driven by the growing base of documented success stories from organizations and program leaders who have championed change and happily reported their results. They didn’t need to be beaten over the head but rather took the initiative and captured the benefi t.
The Cost to Exclude a Gram of DirtFor those wondering what is meant by excluding a gram of dirt,
it’s a rather simple concept. First, fi gure out what the contaminant is (dirt, coal dust, fl y ash, etc.) and then determine the point(s) of entry (tank vent, worn seals, hatch, etc.). Some do this by examining particles found in used fi lters and sump sediment aided by common laboratory tools (XRF, SEM, optical microscopy, etc.).
For many machines, the inhaling of airborne contaminants into reservoir and tank headspace is the primary source of contamination. Forced convection of air by thermal syphoning, machine-driven air currents (e.g., movement of gears, plunging oil return-line fl ow) and cyclical changes in the tank oil level (hydraulic cylinder movement) can
escalate the ingress. Air typically enters through vents and breathers, past shaft seals, unsealed hatches and cleanout covers, and other unprotected machine openings.
New oil is also a source of contamination, as are invasive inspec-tion and repair activities. Hydraulic systems using linear actuators receive a high percentage of their particles from ingression past worn wiper seals and rod seals. Of course, mechanical wear, corrosion, oil degradation and surface exfoliation are also common sources of solid particles.
The cost of contaminant exclusion relates to both retrofi tted hardware and routine maintenance tactics for blocking contaminant entry. These costs include such things as transfer cart fi ltration, proper breathers on machines and lubricant storage vessels, improved seals (labyrinth, for instance), tighter system closures, greater awareness and care during internal inspections and part replacement (education and better procedures/tools), routine cleaning of
AS I SEE IT
JUSTIFYING the COST of EXCLUDING a GRAM of DIRT
JIM FITCH NORIA CORPORATION
machine exteriors and many other similar methods. Depending on the type of machine, this could generate initial costs ranging from $100 to $1,000 per machine. There is also an annual ongoing cost of routine maintenance relating to contaminant exclusion (e.g., replacement breathers).
The Cost of an Unexcluded Gram of Dirt1. The Cost of Machine Wear Caused by Ingressed, Unfiltered Particles
We are all aware that particles make parti-cles. The number of new particles generated from a single ingressed particle depends on many factors, including the type of machine, fi ltration, settling, number of frictional zones, working clearances and operating speeds. Basi-cally, it relates to how many surface scratches and indentations a particle is allowed to make before it is pulverized, settles to the tank fl oor or removed by an oil change or fi lter. If ingressed particles reach the fi lters fast, there is less damage and few new wear particles are produced. Conversely, if no fi ltration or poor fi ltration is the case, this leads to longer particle residence time in the fl uid and thus more damage and more production of wear debris.
An average ingressed dirt particle (left unre-moved in the oil) will generate somewhere between fi ve and 20 new particles (secondary particles). Some of these particles will make more particles (tertiary particles). The situation is self-propagating. Additionally, you can imagine that a single scratch mark from a grain of dirt can produce a corkscrew wear particle long enough to crush into fi ve or more particle segments.
Take a look at the data below from 17 hydraulic systems (ref. Pall Corporation). The highly fi ltered fi ve cleanest systems only had 7 percent wear particles (metallic). The destructive dirt was removed quickly, preventing the genera-tion of secondary and tertiary particles. On the other hand, the fi ve dirtiest systems generated
117,768 new particles, representing 42 percent of all the particles in the fl uid. If a better fi lter was then applied, the fi lter would plug quickly from the high concentration of particles, of which nearly half were formally a part of the machine.
The Costs: The high cost of machine repair and lost production (if no oil fi lter or poor-quality fi lters are used) is 10 to 10,000 times the cost of contaminant exclusion.
2. The Cost to Remove Ingressed Particles by Oil Filtration
In well-fi ltered, high-ingression systems such as off-road hydraulics, more than 90 percent of the particles found in oil fi lters are likely to be terrain dust (ingested from the air). For indoor equipment running in a relatively clean envi-ronment, the fi lter might be loaded with 50 to 90 percent metallic particles. By comparison, particles in unfi ltered systems such as splash-fed gearboxes might be more than 95 percent metallic due to self-propagating particle generation.
Filters cost less to maintain (last longer) when:• Particle ingression is kept in check (seals,
breathers, etc.).• High oil cleanliness targets are set and
maintained.
If you can’t keep ingression in check, you are left with using fi ltration to stabilize high oil cleanliness targets. This is best done by removing particles quickly. Remember, the longer particles are allowed to stay in the oil, the more secondary and tertiary particles are generated. Then, they too have to be fi ltered out (increasing the cost of fi ltration). One or more of the following methods are the best ways to remove particles quickly:
• Locate fi lters just downstream of ingression sources, such as on a hydraulic return line.
• Maintain a high fl ow rate through fi lters (to quickly carry particles to fi lters for removal).
• Employ multiple fi lters.
• Use high capture-effi ciency fi lters.
FIVE CLEANEST MIDDLE SEVEN FIVE DIRTIEST
Total Particles 980 33,000 280,400 (the cause)
Total Nonmetallic 911 20,643 162,632
Total Metallic 69 12,357 117,768 (the effect)
Percent Metallic 7% 37% 42%
Relative Filtration Cost 1 2 4
PUBLISHER Mike Ramsey - [email protected]
GROUP PUBLISHER Brett O’Kelley - [email protected]
EDITOR-IN-CHIEF Jason Sowards - [email protected]
SENIOR EDITOR Jim Fitch - jfi [email protected]
TECHNICAL WRITER
Jeremy Wright - [email protected]
CREATIVE DIRECTORRyan Kiker - [email protected]
GRAPHIC ARTISTS Steve Kolker - [email protected] Cervantes - [email protected] Backus - [email protected]
ADVERTISING [email protected]: 800-597-5460
MEDIA PRODUCTION MANAGERRhonda Johnson - [email protected]
CORRESPONDENCEYou may address articles, case studies, special requests and other correspondence to:
Editor-in-chief MACHINERY LUBRICATIONNoria Corporation1328 E. 43rd Court • Tulsa, Oklahoma 74105Phone: 918-749-1400 Fax: 918-746-0925 E-mail address: [email protected]
MACHINERY LUBRICATION Volume 11 - Issue 5 September —October 2011 ( USPS 021-695) is published bimonthly by Noria Corporation, 1328 E. 43rd Court, Tulsa, OK 74105-4124. Periodicals postage paid at Tulsa, OK and additional mailing offi ces. POSTMASTER: Send address changes and form 3579 to MACHINERY LUBRICATION, P.O. BOX 47702, Plymouth, MN 55447-0401. Canada Post International Publications Mail Product (Canadian Distribution) Publications Mail Agreement #40612608. Send returns (Canada) to BleuChip Interna-tional, P.O. Box 25542, London, Ontario, N6C 6B2.
SUBSCRIBER SERVICES: The publisher reserves the right to accept or reject any subscription. Send subscription orders, change of address and all subscription related correspondence to: Noria Corporation, P.O. Box 47702, Plymouth, MN 55447. 800-869-6882 or Fax: 866-658-6156.
Copyright © 2011 Noria Corporation. Noria, Machinery Lubrication and associated logos are trademarks of Noria Corporation. All rights reserved. Reproduction in whole or in part in any form or medium without express written permission of Noria Corporation is prohibited. Machinery Lubrication is an independently produced publication of Noria Corporation. Noria Corporation reserves the right, with respect to submissions, to revise, republish and authorize its readers to use the tips and articles submitted for personal and commercial use. The opin-ions of those interviewed and those who write articles for this magazine are not necessarily shared by Noria Corporation.
CONTENT NOTICE: The recommendations and information provided in Machinery Lubrication and its related information properties do not purport to address all of the safety concerns that may exist. It is the respon-sibility of the user to follow appropriate safety and health practices. Further, Noria does not make any representations, warranties, express or implied, regarding the accuracy, completeness or suitability, of the information or recommendations provided herewith. Noria shall not be liable for any injuries, loss of profi ts, business, goodwill, data, interruption of business, nor for incidental or consequential merchantability or fi tness of purpose, or damages related to the use of information or recommendations provided.
Award Winner, 2008, 2010 and 2011
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AS I SEE IT
Of course, all of this costs money, plus the hassle to maintain. In contrast, a fi lter used as an air breather will hold more particle mass (perhaps two to fi ve times more) than the same fi lter used to clean oil (same size and micron performance).
As a fi nal note on fi ltration, while many contaminant-exclusion tactics can prevent the entry of particles of all sizes, oil fi ltra-tion, on the other hand, is selective. It generally only removes particles above the micron rating (say, 10 microns), leaving the smaller particles undeterred and available to do damage to the base oil, additives and the machine.
The Costs: The cost to fi lter your way to clean oil is perhaps 10 times greater than the cost of exclusion.
3. Increased Oil Consumption Due to Uncontrolled Particle Ingression
Most people don’t associate particle contamination with lubricant service life, oil change frequency or the overall cost of lubricant consumption. We’ve reported many times in Machinery Lubrication on how oils age. For instance, one of the well-known drivers of oil oxidation is the presence of catalytic wear metals in the oil. Wear particles don’t get into the oil by themselves. One very common source of wear particles is particle-induced wear (secondary and tertiary, as previously discussed). Suspended dirt particles also provide a site for oil additives to hitch a ride. This ties up these additives, which suppresses their ability to perform their intended function.
So less dirt ingression means less wear debris production, which means less antioxi-dant additive depletion, which means less oil
consumption (from additive depletion and base oil oxidation) and less downtime from oil changes and fl ushing. We’ve also reported in the past the many hidden costs of an oil change. One consultant (Ken Brown) has estimated that an oil change can cost more than 40 times the cost of the oil and labor.
An oil change is disruptive to the machine. It not only can cause downtime but also an internal disturbance that can lead to collateral damage. One common and serious disturbance is called the “fi sh bowl effect,” which relates to the redistribu-tion of sediment as a result of an oil change.
Of course, dirty oil is also a primary cause of oil leakage. Particle contamination abrades seals over time. Some companies have reported more than an 80-percent reduction in leakage as a result of main-taining higher oil cleanliness.
The Costs: Oil consumption and associated costs (including seal repairs) may exceed 10 times the cost of contami-nant exclusion.
4. Energy Consumption Losses Due to Particle-induced Wear
Wear not only leads to machine opera-tional failure but also impedes performance in the intervening period leading up to repair or overhaul. During this period there is usually impaired productivity due to slug-gish or erratic machine function. There is also increased energy consumption. For instance, when hydraulic pumps and actua-tors wear, they lose volumetric effi ciency. This slows work (pumps and actuators move slower) and increases the consumption of energy (and heat distress to the lubricant). Gears and bearings also consume more energy as a result of wear.
Even diesel engines suffer from decreasing combustion effi ciency due to wear in the valve train, bottom-end bear-ings and combustion chambers (rings, piston, cylinder wall, etc.). A corresponding increase in fuel consumption results. Wear in these zones is often associated with particles in the lubricating oil. One simple way to exclude particles from entering the crankcase is to enhance the quality of the induction air fi lter.
The Costs: The cost of lost work and increased energy consumption over the life cycle of the machine may exceed 20 times the cost of contaminant exclusion.
The TallyAs you can see, many variables and
factors infl uence the cost of excluding a gram of dirt. However, there are many more costly consequences associated with failing to exclude. The quote at the beginning of this article claimed a 10-to-1 difference. On closer inspection, the actual difference is arguably more than 100-to-1 when taken across the life of the machine.
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 courses on these subjects. Jim has published more than 200 technical articles, papers and publica-tions. 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 Lubrica-tion. He is the CEO and a co-founder of Noria Corporation. Contact Jim at jfi [email protected].
6 | September - October 2011 www.MachineryLubrication.com
Last year there was a book on the New York Times best-seller list called Have a New Kid by Friday. It was written by
psychologist Kevin Leman and has sold more than 400,000 copies. To capitalize on this book’s success, Leman is hurrying out another titled Have a New Husband by Friday.
Leman’s literary success is testimony to the appeal and popu-larity of the quick (and effortless) fi x for a problem. Don’t get me wrong, I have no issue with the concept of a quick fi x where one is legitimately available, but as a parent I know you can’t replace a child’s bad behavior with good in seven days. Most parents can’t even read the book in seven days. As a husband, I also know my bad habits won’t be eliminated in seven days. My wife may well be able to replace me in seven days but not change me.
Any thinking person knows instant results for anything but the simplest of problems are an illusion, but this is not to say that the notion of a quick fi x or even a Band-Aid solution doesn’t have its place.
Last week I had a conversation with a longtime client who’s been having a long-running battle with the manufacturer of a hydraulic machine he purchased three years ago. The machine has never
performed to either my client’s satisfaction or the manufacturer’s advertised specifi cations.
This client is an owner/operator, which means his machine is his livelihood. And he’s had enough. So now he’s taking the machine’s manufacturer to court — a decision he hasn’t taken lightly.
Although he didn’t consult me directly about this issue, I was aware of the problems he was having and the way in which the equipment manufacturer was responding to them. The crux of the issue, and one which will now be argued in court, is the machine model my client bought was marketed as a “professional” version, meaning it was designed to be used a minimum of eight hours a day, fi ve days a week. This is in contrast with hobbyist or weekender use of typically a couple of hours in a stretch, a couple of days a week.
The trouble is, when the “professional” model my client purchased was operated continuously for more than a couple of hours, its performance dropped off dramatically. The primary reason for this, which was blatantly obvious to me, was insuffi cient installed cooling capacity, or more accurately, no cooling capacity at all.
Not only did I share this assessment with my client, but because I’d done work for him before and didn’t want to see him lose work and income as a result of the machine’s obvious design fl aw, I presented him with a Band-Aid solution — switch to a high-VI synthetic oil.
Now don’t get me wrong. I’m all for doing things right. The correct solution to this issue was to install a heat exchanger of suffi -cient capacity to maintain an appropriate and stable operating oil temperature and therefore viscosity. But in this case, there were two major barriers to this happening. The fi rst was the compact nature of the machine, which allowed for little or no space to retrofi t a hydraulic oil cooler. The second was my client quite rightly expected the machine’s manufacturer to do this under warranty, which meant they fi rst had to admit the machine had a design fl aw.
HOW a BAND-AID SOLUTION can FIX your HYDRAULICS problems
HYDRAULICS AT WORK
BRENDAN CASEY
H y d r a u l i c s
of people have used a Band-Aid solution for a problem, according to a recent survey at www.machinerylubrication.com
of people view Band-Aid solutions negatively, based on survey results from www.machinerylubrication.com91% 81%
The trick is being able to recognize when a Band-Aid solution is appro-
priate and when it is not.
8 | September - October 2011 www.MachineryLubrication.com
HYDRAULICS AT WORK
Switching to a high-VI synthetic oil would do nothing to address the issue of insuffi cient cooling capacity, but it would help the machine cope with it. So in this respect, it defi nitely qualifi ed as a Band-Aid solution.
Unfortunately, my client didn’t act on this advice. Maybe it was because, despite the apparent widespread popularity and seduc-tive appeal of the quick fi x, we have been conditioned to think of Band-Aid solutions in negative terms. This negative bias toward the Band-Aid solution in engineering is particularly strong, and in many situations, rightly so. For example, there’s no way a Band-Aid solu-tion is appropriate for the recent problems of the Rolls-Royce Trent 900 engines fi tted to the Airbus A380. But if you have a mini-digger with a chronic overheating problem that is not easily corrected, being open to a Band-Aid solution can be very constructive.
As mentioned earlier, I’m all for doing things the right way, and I consider quick-fi x, silver-bullet, magic-pill, cure-all solution-seeking as lazy and unrealistic. But as author Malcolm Gladwell says, “There are times when we need a convenient shortcut…” The trick is being able to recognize when a Band-Aid solution is appropriate and when it is not.
I wish this client the best of luck with his lawsuit. He deserves to win. But more than that, having declined the Band-Aid solution, now he has to win.
About the AuthorBrendan Casey is the founder of HydraulicSupermarket.com and the
author of Insider Secrets to Hydraulics, Preventing Hydraulic Failures, Hydraulics Made Easy and Advanced Hydraulic Control. A fl uid power specialist with an MBA, he has more than 20 years of experience in the design, maintenance and repair of mobile and industrial hydraulic equip-ment. Visit his Web site: www.HydraulicSupermarket.com.
In his book, The Tipping Point, author Malcolm Gladwell describes why Band-Aid solutions should be viewed in a positive light.
“But that phrase (Band-Aid solution) should not be considered a term of disparagement. The Band-Aid is an inexpensive, convenient and remarkably versatile solution to an astonishing array of problems. In their history, Band-Aids have probably allowed millions of people to keep working or playing tennis or cooking or walking when they would otherwise have had to stop. The Band-Aid solution is actu-ally the best kind of solution because it involves solving a problem with the minimum amount of effort and cost. We have, of course, an instinctive disdain for this kind of solution because there is something in all of us that feels that true answers to problems have to be comprehensive, that there is virtue in the dogged and indiscriminate application of effort, that slow and steady should win the race. The problem, of course, is that the indiscriminate application of effort is something that is not always possible. There are times when we need a convenient shortcut, a way to make a lot out of a little...”
The Best Kind of Solution
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Machinery Lubrication recently issued its annual Lube Room Challenge for readers to submit exceptional lube rooms that
incorporate best-practice features. Several readers met the challenge with
evidence of how their lubricant storage and dispensing methods have been transformed. The following entries showcase how designing a proper lube room is one of the fi rst steps to achieving lubrication excellence.
www MachineryLubrication com September October
Agrium
One of the company’s previous lube rooms used typical barrel racks, no desiccant breathers or oil filtration. Oil inventory space was small, forcing some stock to be left outside exposed to the elements.
The new oil filtration and dispensing room allows oil to be deliv-ered directly to the inside of the room, avoiding hazards and exposure to the elements. This room is climate-controlled and large enough to fit all oils that are used in the plant’s equipment.
This is a close-up of the oil dispenser. Each type of oil has been tagged on the on/off switch, fill piping and at each drum filter. The dispenser tray is engineered to hold more than 55 gallons in the event of an upset. Also, the floor is designed to contain all oil stocked inside this room in case of accidental spills.
The view from the inside of the new oil filtration and dispensing room shows oil filter units, dispensers, desiccant breathers and oil inventory. Instructions for the operating filter system are available on the bulletin board. The floor is covered with a non-slip epoxy coating, which improves the safety of personnel and is tough enough for the heavy loads from the oil drums. Desiccant breathers are installed on all oil barrels when put into service. When an empty barrel is replaced, the new oil is allowed to multi-pass in the filter system for two hours before dispensing. This results in typical ISO-rating improvements from 20/17/14 at the beginning of multi-pass to 15/14/13 when complete.
The old-style lube room required all oil drum delivery from vendors to be done outside and then moved through a narrow doorway, exposing personnel to hazardous conditions.
Tim Johnson at Agrium’s Conda phosphate operation in Soda Springs, Idaho, was just waiting for a chance to show the improvement that had been made to his plant’s lubrication program. The photos below illustrate just how far the company has come in a relatively short period of time.b
m JTim
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COVER STORY
The Eugene Water and Electric Board (EWEB), Oregon’s largest public utility, is no stranger to promoting sustainable practices. Its lube room is no exception. It consists of two double-walled storage tanks that are used for synthetic-blended motor oils. It also entails a modifi ed IFH storage and dispensing system that handles hydraulic and transmission fl uids, as well as Rhino Tuff poly tanks for coolant and washer fl uids. The room features concrete walls, a sealed fl oor, a fi re sprinkler system and an automated climate-control system that maintains the room at a consistent temperature throughout the year.
Through lab testing of incoming oils and fl uids, EWEB identi-fi ed that in many cases the oil and lubricants that were purchased were fi lthier than the fl uids that were being removed. Because of this, EWEB equipped all of its storage tanks with quick couplers,
enabling all the new oil and fl uids to be fi ltered. Hydraulic fl uids are fi ltered to an ISO 4406 cleanliness standard of 17/15/13. Motor oil and transmission fl uids are kidney-looped with 10-micron fi lters for a period of up to 24 hours. Fluids are then dispensed through Graco pumps and separate 10-micron fi lter assemblies. Transfer carts are also equipped with the same quick couplers, and they receive the same fi ltering process before they are used.
To minimize contamination, the vents from the IFH tanks are independently plumbed to a centralized overfl ow container system, which is vented with a desiccant fi lter. Transferring the fl uids consists of a sequence that uses different types of pumps specifi c for a type of fl uid being pumped. Hydraulic and specialty fl uids are dyed to specifi ed colors for easy identifi cation. EWEB uses a series of containers that are also color-coded and labeled for the same specifi c fl uids. Spill containment is utilized for all storage tanks and racks. The lube room also includes spill clean-up materials, spill dikes and absorbent wipes.
The room has been equipped with an emergency shower and eye-wash station. The facility is certifi ed in Oregon as an Eco-Biz facility, meaning that it has reached the highest standards in mini-mizing its environmental impact. EWEB employees have taken pride in implementing proper material-storage methods and hazardous waste-management techniques within the lube room.
EWEB’s lube room consists of two double-walled storage tanks for synthetic-blended motor oils, a modified storage and dispensing system that handles hydraulic and transmission fluids, as well as tanks for coolant and washer fluids.
The EWEB lube room also has an emergency shower and an eye-wash station.
Cargill
The Cargill facility uses color-coded containers with like-colored tags that track when the oil and filters were last changed.
Eugene Water and Electric Board
Cargill’s facility in Newark, Calif., follows best practices by fi ltering and dispensing in designated containers. Previously, lubricant was dispensed in what-ever container was available. Now color-coded containers with like-colored tags are
posted at each piece of equipment.
BeforeAfte
r
…in many cases the oil and lubricants that were purchased were filthier than
the fluids that were being removed.
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COVER STORY
S b O b 2011 M hi L b i i
MillerCoors fi rst upgraded its lube room in Golden, Colo., several years ago with some signifi cant changes. Although the more recent upgrades are minor in comparison, they are still important in the company’s journey to world-class lubrication. The MillerCoors lube room now has an exhaust ventilation system, fi re-protection system and explosion-proof lighting fi xtures. A training room has been created specifi cally for lubrication with a 3-hour class offered. A bi-weekly “Lube-Tips” style e-mail is sent out to all the packaging teams on best lubrication practices and lubrication safety issues. The e-mails provide a great way to keep people thinking about lubrication and its importance to the reliability of the equipment.
This old drum pump setup (left) had basic transfer pumps. Although breathers were later installed on each drum, the oil was still not being filtered, and the operators had to hook up an air hose to the pumps. No 5-S visuals were in place. The picture on the right shows the new pump systems with 10-micron filters and 5-S visuals on the floor with oil identification placards on the wall behind each drum.
This old wooden workbench (left) was being used for filling Oil Safe secondary containers and for cartridge replacement of grease guns. It was replaced with a stainless-steel table (right) similar to those used for food preparation in restaurants. It provides a cleaner setting to do this work.
Utilizing Oil Safe secondary containers helps in the identification of the many lubricants being used as well as contamination control. Although a lubricant identification system was in place, Miller-Coors’ Richard David came up with new identification cards that also incorporate symbols to go along with the color coding. Between the two systems, it is almost impossible to mix up lubricant types. David’s lubricant identification cards also promote good visual factory practices.
Oil drum transfer pumps were often left in poor environments (left) where they could be exposed to contaminants. A storage drum for the pumps was provided to keep them cleaner and in one place (right). There are also separate hoses to avoid cross-contamination of lubricants. Both the pumps and the hoses have identification tags.
These color-coded grease guns (left) help with easy identification of grease types. They also have the health hazard tags included on them. The guns pictured were just out of the box and had not yet been fitted with coupler tip covers that are used for contamina-tion control. MillerCoors also carries different sizes of disposable funnels (right) and tries to promote their use.
Although this area is not inside the MillerCoors lube room, it is a big part of the company’s lubrication efforts. Realizing the impor-tance of proper lubrication, the management team allowed for the creation of a training room specifically for lube training. A 3-hour class is offered that covers basic lubrication best practices, the importance of lubrication and how it is instrumental to the reliability of the equipment. The Noria DVD “Lubrication Basics for Machinery Operators” is used to reinforce much of what is covered in the class.
MillerCoors
MM
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Before overhauling its lube room, the Georgia-Pacific mill faced a significant challenge to meet its cleanliness objectives.
Initially, the oil storage room at the Georgia-Pacifi c mill in Muskogee, Okla., needed a lot of attention.
When the room was overhauled, an HVAC unit was installed to maintain room temperature, the entire room was cleaned and repainted, new lighting was installed, new cabinets for equipment fi lters and oil transfer pumps were put in, press fi lters were added to clean the oil before it enters storage totes, new oil containers were purchased and proper labelling was instituted.
The plant’s next steps toward achieving lubrication excel-lence will be to change from a 10-micron f ilter to a 5-micron f ilter to improve particle counts, implement monthly preventive maintenance, train all operations and maintenance staff on the fundamentals of lubrication, revise the sampling program and install proper oil sampling ports on the equipment.
Georgia-Pacific
In
After the lube room was modified, the condition of the storage room and its contents were dramatically improved.
Before
After
16 | September - October 2011 www.MachineryLubrication.com
COVER STORY
The lube room at Rio Tinto Minerals in Boron, Calif., was built in 2007 and has been maintained thanks to the hard work of the lube crew and support from upper management. The company transfers oil from 55-gallon barrels into totes using dedicated fi lter carts. The totes are then fi ltered to achieve the desired ISO standard and fi tted with desiccant breathers. Oil samples are taken monthly to verify continued compliance. All oil is dispensed into color-coded containers, which are cleaned after being used.
Rio Tinto transfers oil from 55-gallon barrels into totes, which are then filtered and fitted with desiccant breathers.
At the new Rio Tinto lube room, all oil is dispensed into color-coded containers, which are cleaned after use.
The Temple-Inland lube room in Cumberland City, Tenn., boasts drums with air-powered pumps and 5-micron fi lters, sample ports and quick disconnects on the drums and Oil Safe containers. Oil is fi ltered as the Oil Safe containers are fi lled, and the lids do not need to be removed to fi ll. The pumps can also be utilized to polish the oil before use.
These photos show the Temple-Inland lube room before changes were made.
Power Partners
Rio Tinto
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Temple-Inland
Power Partners Inc. in Athens, Ga., never really had a lube storage room, but company offi cials thought they were fi ne until they read a few articles in Machinery Lubrication and attended a Reliable Plant Conference. They quickly realized they had a big problem.
The company has come a long way over the last 14 months. While there are a few more things they want to accomplish, they are extremely proud of their efforts.
With the new lube room and enhanced policies and procedures that go with it, Power Partners has realized an annual cost savings of more than $28,000. Factor in the other reliability programs they have implemented in the shop, and the annual cost savings total more than $46,000.
The original Power Partners lube room featured metal funnels out in the open along with buckets and barrels everywhere.
The company’s new lube storage room has dedicated storage totes, a communications corner, clear grease guns with calibra-tion stickers, an oil matrix that details which oil goes in which machine, and oil transfer jugs that are tagged and color-coded.
ThhTh
Before
After
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www.MachineryLubrication.com September - October 2011 | 17
At Temple-Inland’s new lube room, oil is filtered as the Oil Safe containers are filled.
The initiative to modify the lube room of Cerveceria Bucara-manga, a SABMiller plant in Colombia, began after company personnel read an article in Machinery Lubrication on the advances of Clopay Plastics’ lube room. They felt encouraged to improve their lube room and received advice from Noria Latin America as well as a lot of training, which was important to their success. They also have included several practices from the Oil Analysis Basics book by Noria Corporation.
With the improvements, Cerveceria Bucaramanga now has an oil cleanliness level of ISO 4406 (14/12/8) on its oil storage tanks. The lube tasks also are ergonomic and easier to perform, having been optimized by more than 15 percent. The workers feel proud of this and take great care to maintain this goal and even improve upon it.
These photos show the old Cerveceria Bucar-amanga lube room before the improvement project began.
After strategic improvements were made, the new lube room at Cerveceria Bucaramanga in Colombia includes a used oil storage area and dedicated filters for intermediate oil containers.
Cerveceria Bucaramanga
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Safe con
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Before
Before
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18 September - October 2011 www.MachineryLubrication.com
FOOD-GRADE PENETRATING OILThe new Food Grade Penetrating Oil from CRC is an effective and effi cient non-silicone lubricant for use on all food-processing equipment. The highly refi ned white mineral oil is colorless, odorless and tasteless to meet NSF and FDA standards. The general-purpose penetrant can be used to loosen rust, scale and corrosion around fasteners and hose fi ttings on food-processing equipment.
CRCwww.crcindustries.com800-556-5074
FILTER PACKThe new FilterPak from Y2K Fluid Power incorpo-rates a sturdy diamond-plate aluminum frame, a milled-aluminum grip and a 1-hp Viking pump with a capacity of 2.5 to 5 gallons per minute. It also sports a visual indicator with 50 psi bypass, a 10-foot swivel discharge hose, a 7-foot swivel suction hose, a 3-foot electrical cord and an on/off switch.
Y2K Fluid Powerwww.y2kfluidpower.com888-925-8882
FOOD-GRADE LUBRICANTSThe new UltraLube food-grade lubricants not only meet NSF standards but also offer four times the natural lubricity of petroleum-based oils. These bio-based oils instantly penetrate into areas where lubrication is needed most and create a long-lasting bond to metal and plastic surfaces. Specifi cally formulated with EP additives to provide protection under heavy shock loads, UltraLube H1 Food Machinery Grease is ideal for lubricating bearings, gears and machine slides. It also offers superior adhesion and protects all ferrous metal components from rust and corrosion.
UltraLubewww.UltraLube.com800-545-1689
PORTABLE LUBRICATION SYSTEMThe new mobile lubrication system from the IFH Group provides storage and dispensing of lubricants for industrial plants requiring lubrication maintenance at multiple loca-tions over a large area. The new system is delivered on a pallet that allows it to be placed in the bed of a truck for mobility anywhere within the plant. It includes two 50-gallon and two 25-gallon steel containers with PVC sight gauges. Air-operated piston pumps provide a 5-to-1 pumping ratio, while fi lters on the side remove any dirt or small par-ticulates. Startup is quick and easy with the onboard gas-operated air compressor.
The IFH Groupwww.ifhgroup.com
800-435-7003
MOTOR OILValvoline’s NextGen motor oil features a new formula made from 50-percent recycled oil to deliver 100-percent engine protection. Developed through years of research, technology and innovation from scientists coupled with improvements in the oil re-refi ning process, NextGen motor oil is good for engines and the environ-ment, exceeding industry specifi cations with reduced environmental impact compared to non-recycled motor oil.
Valvolinewww.valvoline.com 800-832-6825
PR
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www.MachineryLubrication.com September - October 2011 19
PRESSURE SWITCHSKF’s new DSB1 pressure switch for monitoring centralized lubri-cation systems is designed to attach directly to the lubricant line. This position is in contrast to conventional pressure switches that branch off to a cul-de-sac where grease is never mixed, which can form a blockage, harden and render the pressure switch ineffective. The new DSB1 pressure switch is installed before the last distributor, where the grease consumed by the distributor constantly fl ows past the switch, effectively preventing blockage.
SKF www.skf.com267-436-6000
FOOD-GRADE COMPRESSOR LUBRICANTSUltrachem has developed a new line of Omni-lube food-grade rotary screw and reciprocat-ing air-compressor lubricants with improved wear, oxidation and lubricity. These fully synthetic compressor oils are formulated from high-quality polyalphaolefi n (PAO) base oils with a proprietary additive package to achieve long life. The oils meet all of the requirements of the USDA and FDA H-1 regulations, and conform to NSF requirements. They are also approved for Kosher use.
Ultrachemwww.ultracheminc.com302-325-9880
METAL-WORKING FLUIDDeveloped for use in high-pressure applications, the new Cimpe-rial 1072-HFP fl uid from Cimcool is recommended for all metals and heavy-duty machining operations including turning, drilling, tapping, reaming, gear cutting and broaching. It prevents, controls and reduces foam even when fl uids are used in high-pressure delivery systems. Cimperial 1072-HFP also provides excellent lubricity, extends fl uid life, is operator and machine friendly and helps prevent corrosion on parts and machine components.
Cimcoolwww.cimcool.com888-246-2665
MARINE ENGINE OILRoyal Purple’s new line of multi-vis 30-weight and 40-weight four-stroke High Performance Marine (HPM) engine oils promise to give boaters better protection for their engines. These new oils feature Royal Purple’s advanced additive lubricant tech-nology, Synerlec, which creates an ionic bond that adheres to metal parts to provide continu-ous protection and strengthens the oil for better performance. It also has high fi lm strength that prevents contact between metal parts and improves sealing inside the engine for more complete combustion and reduced wear.
Royal Purplewww.royal-purple-industrial.com
888-382-6300
20 | September - October 2011 www.MachineryLubrication.com
Q What made Rio Tinto and Kennecott Utah Copper (KUC) decide to put more emphasis on machinery lubrication?
A At the KUC smelter, we implemented changes that led toward improving reliability, including hydrocarbon management in 2001 and 2002. This improvement was aided by Rio Tinto’s corporate drive toward improved reliability and hydrocarbon management during the same timeframe. The rate of improvement increased when Rio Tinto placed additional focus on these areas in 2004.
Q How did you get your start in machinery lubrication?
A I have been working at the KUC smelter since January 2002. Prior to working at the smelter, I worked on heavy equipment for 30 years. I also purchased lubricants and did oil sampling. I came to this job in the lube group in November 2006 under the direction of the reli-ability group and have been with the group since then.
Q What types of training have you taken or been involved with? What about future training?
A Before working for KUC, I had several hydraulic and electrical training classes on cranes and other heavy equipment. Since coming to KUC, I have had oil analysis level I, II and III and machinery lubri-cation level I training from Noria, as well as training from suppliers. I have also been involved in several Rio Tinto internal human capital management (HCM) program assessments.
Q What is the range of equipment that you service through lubrication tasks at the smelter?
A We service pumps, fans, conveyor belts, compressors, feeders, agitators, ball-and-roller mills and other smelter-processing equipment.
Q What is a normal work day like for you?
A We have a six-man lube crew that is dedicated to grease and oil-related issues. On any given day, you could fi nd us doing any of the following: oil changes, grease routes, oil routes, oil sample routes and fi lter cart routes. On these routes, we check automatic
lubricators, replacing faulty or empty units as needed, check and maintain oil levels, and inspect desiccant breathers and replace them as needed.
Q What lubrication-related items are you currently working on?
A I am working on installing a head space-management system for our bulk oil totes in an effort to improve our new/bulk oil cleanli-ness. I am also gathering data to set up electric motor grease routes throughout the plant.
Q How does your company view machinery lubrication in terms of importance, strategy, etc.?
A Our six-man crew works for Fluor Industrial Services, the company KUC contracts to perform maintenance at the smelter. The lube group reports to the reliability group. Both of these groups are highly motivated to make sure the equipment is lubricated prop-erly and with the correct lubricant. Rio Tinto and KUC have high HCM standards, which we are working hard to meet.
Q What have been some of the biggest lubrication project successes in which you have played a part?
A We have installed new poly totes with kidney-loop systems used to store new bulk oils, as well as a lube trailer to be used on some of our remote equipment for oil changes. We have also installed several kidney-loop systems throughout the plant and implemented fi lter cart routes. I have also been involved with peer review/peer assist HCM assessments at the smelter and other plants within KUC.
Q What do you see as some of the more important trends taking place in the lubrication and oil analysis field?
A We are seeing oil companies being pushed to become more accountable for their products, and we have been getting more on-site oil analysis testing equipment.
GET TO KNOWML
Christensen Directs Lube Crew at Kennecott Utah Copper
Jan Christensen began working on heavy equipment as a mechanic in 1973. He started with Fluor Industrial Services working at Kennecott
Utah Copper’s smelter in 2002 as a mechanic. He joined the lube team in November 2006 and has worked in several important roles for the lube team, providing valuable input and overseeing key projects since that time.
Name: Jan ChristensenAge: 60Title: Lubrication Technician 2Company: Kennecott Utah CopperLocation: Magna, UtahYears of Service: 10 years
22 | September - October 2011 www.MachineryLubrication.com
1 2
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ACROSS
1 A process for treating raw extracted base stocks with hydrogen to saturate them for improved stability.
7 The degree of opacity of a fluid.
8 A failure generally associated with a valve whose movements are restricted due to small particles that have wedged in between critical clearances.
10 The sum of atmospheric and gauge pressure.
13 The most common type of grease today.
14 Wear phenomena taking place between two surfaces having oscillatory relative motion of small amplitude.
16 Particles added per unit of circulating fluid volume.
17 A form of wear in which seizing or tearing of the gear or bearing surface occurs.
18 The addition of fatty oils and similar materials to lubricants to impart special properties.
DOWN
2 A measure of the total acidity or basicity of an oil.
3 An engine design in which oil is not retained in a pan beneath the crankshaft.
4 The brown or black viscous residue from the vacuum distillation of crude petroleum.
5 Ability of a lubricant to resist natural degradation upon contact with oxygen.
6 Capable of being mixed in any concentration without separation of phases.
9 A unit of kinematic viscosity.
11 Ability of a fluid to dissolve inorganic materials and polymers, which is a function of aromaticity.
12 The relationship of flow per unit area to differential pressure across a filter medium.
15 A container for storage of liquid in a fluid power system.
CROSSWORD PUZZLERML
Get the solution on Page 29.
Get a Printable Version of This Puzzle Online at:
MachineryLubrication.com/puzzle
24 September - October 2011 www.MachineryLubrication.com
OIL ANALYSIS
Lubricant Analysis in Steam TurbinesTTurbine oils are subjected to a wide range of conditions —
extreme heat, entrained air, moisture, contamination by dirt and debris, inadvertent mixing with different oil, etc. — that degrade the integrity of the hydrocarbon base stock and deplete the addi-tive chemistries, causing irreversible molecular changes. There are two primary degradation mechanisms in turbine applications — oxidation and thermal degradation.
Oxidation is a chemical process where the oxygen reacts with the oil molecules to form a number of different chemical products, such as carboxylic acids. The rate at which this occurs depends on a number of factors. Temperature is perhaps the most critical one, since the rate of oxidation doubles for every rise of 10 degrees C. The temperature above which this occurs is infl uenced by the oxidation stability of the oil and the presence of catalysts and pro-oxidant conditions such as water, air, certain metals, fl uid agitation and pressure.
Thermal degradation is the breakdown of the oil molecules by heat (high temperature), forming insoluble compounds that frequently are referred to as soft contaminants. Typically, thermal degradation occurs as a result of micro-dieseling, electrostatic
spark discharge and hot spots. Micro-dieseling is the combustion of imploding air bubbles creating adiabatic compressive heat (often exceeding temperatures above 1,000 degrees C). Electro-static spark discharge results from the internal molecular friction that generates high-voltage electric charges such as where oil passes through very tight clearances at high fl ow rates, producing temperatures over 10,000 degrees C.
Over time, it has become clear that the oxidation performances of the different base stock classes are quite different. The high natural oxidative resistance of Group II turbine oils combined with specifi c antioxidants employed (usually based in phenol and amine compounds) provide a non-linear behavior in terms of their molecular degradation over time. As a result, the majority of standard oil analysis tests offer little to no warning as the lubri-cant starts to degrade and generate system deposits. Instead of degradation occurring in a linear and predictable fashion, many of the modern turbine oils fail rapidly.
Changes in the oil’s molecular structure due to additive deple-tion and the development of insoluble particulates are among the fi rst oil degradation conditions that affect equipment perfor-mance. The sequential process will be the formation of sludge and varnish, which are common occurrences in turbo-generators. Besides these oxidation and thermal degradation byproducts being the main contributors for the development of varnish and deposit problems in turbines, they interfere with other important properties in steam turbine lubricants, such as demulsibility and the detrainment of air. Therefore, it is vital that appropriate diag-nostic analysis be performed to detect these conditions in critical and sensitive lubrication systems.
Ferrography AnalysisFerrography is a technique that provides valuable information
about wear evolution in machinery through analysis of a repre-sentative lubricant sample. Developed by Vernon Westcott at
BY: BEATRIZ GRAÇA, INEGI; JORGE SEABRA, FEUP; AND PINTO SOUSA, PORTUCELO
il D
eg
rad
atio
n
Time
Group I Oils
Group II & III Oils
The majority of phenolshave depleted
Degradation trend of different base stock oils
OIL ANALYSIS
the U.S. Navy in the 1970s as a condition-monitoring technique, it has been applied by hundreds of worldwide users to all kinds of lubricated systems.
The potential of ferrography is not only limited to predictive maintenance strategies. Its important contribution to tribology studies, by assisting in a better understanding of the wear mechanisms and of the lubricant effects on the contact surfaces, turns this versatile technology into one of the most powerful diagnostic tools to assess machine health, providing valuable information about the past, present and future condition of the machine’s lubricated components.
The test procedure is lengthy and requires the skill of a well-trained analyst. As such, there are signifi cant costs in performing analytical ferrography not present in other oil analysis tests. However, if time is taken to fully understand what analytical ferrography uncovers, most agree that the benefi ts signifi cantly outweigh the costs and elect to automati-cally incorporate it when abnormal wear is encountered.
In analytical ferrography, the solid debris suspended in a lubricant sample is separated and thoroughly deposited onto a glass slide while passing across a bipolar magnetic fi eld. When the sample fl ow is completed, a solvent “wash” cycle removes any lubricant remaining on the substrate, resulting in a “ferrogram,” where the particles are all arranged by size and permanently attached to the slide for optical analysis using a biochro-matic microscope. The particles are then examined and classifi ed by size, shape,
concentration and metallurgy. This infor-mation carried by the wear particles is valuable for the identifi cation of the wear mode and mechanism.
Steam Turbine Monitoring This case study is about the condi-
tion monitoring of the lubricant in a steam turbo-generator at a local cellulose industry plant. The turbine is a 26 MW Siemens G 800-2. It has been in service for 22 years, operating continuously, with a lubricating oil reservoir holding 8,500 liters of ISO VG 46 oil to lubricate and cool bearings, gears and oil shaft seals and to act as a hydraulic medium for operation of the governor and steam control valves.
Since its initial operation in 1988, this turbine worked with solvent-refi ned base stock oil (Group I). However, due to a manufacturer upgrade, this oil was replaced by a hydrocracked base stock (Group II) in 2002. In the meantime, about 6,000 liters of makeup fl uid was added, along with a few periodic oil reser-voir fi ll-ups, making the circulating fl uid a blend of these two base stocks.
The turbo-generator was operating and performing normally, and no occurrences of anomalous functions of the lubricated components had been recorded. Never-theless, a close monitoring of the oil condition was ensured by analyzing the turbine oil periodically.
Turbine Oil AnalysisA lubricant analysis program was
applied quarterly, taking two samples from the oil reservoir and sending it to independent laboratories. The standard methods used at one of the laboratories to assess the condition of the turbine oil were:
• Kinematic viscosity at 40 degrees C (ASTM D445)
• Water by Karl Fisher (ASTM D6304)• Insoluble particulates (ASTM D4898) • Acid number (ASTM D664)• Neutralization number (ASTM D974)• Elemental spectroscopy (ASTM D5185)• Rust (ASTM D665-A)• Demulsibility (IP 19)• Foam (ASTM D892)• Flash point (ASTM D92)• Air release (DIN 51636)• Cleanliness code (ISO 4406)• Linear sweep voltammetry (LSV),
(ASTM D6971)
Simultaneously, at another laboratory, ferrography and Fourier transform infrared (FTIR) analysis were performed along with other techniques. These analyses allowed a complemented diagnosis not only of the condition of the oil but also of the turbine wear rate conditions.
In this case study, among all the standard test results obtained, those that showed some indications of fl uid
Oil Flow
Magnet
Slide
Large particles deposit at entry point where themagnetic pull is the weakest.
Smaller particles depositalong the slide as the
magnetic pull strengthens.
Analytical ferrography deposited patterns
A steam turbo-generator at a cellulose industry plant
26 September - October 2011 www.MachineryLubrication.com
degradation were the demulsibility, air release, particle count and LSV. As can be seen in the table above, the oil viscosity and acid number are within the range over the time period. Water contamination and foam tendency are main-tained low. However, the particle contamination is high for all the evaluated period, the phenolic content falls below critical in some samples and the demulsibility is also affected signifi cantly.
The sequential events in the oil degradation produces an eventual depletion of the antioxi-dant additives. The aminic/phenolic antioxidant mixtures actuate as a complex system. The aminic inhibitor works to neutralize the free radicals that cause oil oxidation, but it is then regenerated by phenolic, which is a good free-radical trap. When phenolic levels fall below a critical level, the oil is in danger of rapid degradation, resulting in the formation of soft contaminants and varnish. Soft contaminants are typically less than 2 microns in size and cannot be removed through standard mechanical fi ltration. They are insoluble and polar in nature, and are unstable in a non-polar oil envi-ronment, such as hydrocracked base oil (Group II).
The high ISO Codes obtained, mainly in terms of small particles (less than 4 microns), can be related with this turbine oil degradation process. Demulsibility is also compromised by the pres-ence of polar contaminants.
For the lubrication of turbo-generator bear-ings, the cleanliness level with respect to particles in the oil is of the utmost importance. Conse-quently, a proactive action is taken through periodical on-line oil purifi cation (fi ltration during 24 hours) to achieve the system cleanliness in accordance with OEM recommendations (ISO
18/16/12). However, a swift increase of the ISO Codes is consistently verifi ed during the operation of this turbine.
The ferrography analysis completed for the same period revealed valuable information on the oil’s solid contamination. In all ferrograms, the presence of soft contaminants that resulted from oil thermal degradation and additive deple-tion was observed. This information is essential to identify the reason for the persistent high ISO Codes obtained in particle counting. Although soft particulates are not harmful in terms of wear, they contribute to the generation of surface deposits, as detected through ferrography.
Figure 1 shows two photomicrographs of these particles deposited on a ferrogram as observed under white/green light and polarized illumination. The polarized light allows the identi-fi cation of non-metallic particles (crystalline and amorphous materials, for instance) by the bright-ness of light refl ected. Note the brown pattern evidenced by some of these particles.
The particles in the ferrogram of Figure 2 are very small in size, and due to polarity, they easily aligned along the magnetic fi eld of the ferro-graph. These particles have the tendency to form agglomerates, which when overstressed with the
Analytical results from standard oil tests show the oil viscosity and acid number are within the range over the time period.
Figure 1. These two photomicrographs show turbine oil crystalline contaminants (1,000x magnification).
www.MachineryLubrication.com September - October 2011 27
ANALYTICAL RESULTS FROM STANDARD TESTS
DATE Jan-10 Oct-09 Jul-09 May-09 Jan-09REFERENCE
PHYSICAL PROPERTIESViscosity@ 40°C [cSt] 41.4-50.6 45.9 45.8 44.3 45.9 46.6Acid Number [mgKOH/g] 0.3 0.14 0.08 0.12 0.1 0.06Demulsibility [s] 300 606 442 368 305 >1200Air Release [min.] 5 3.2 4.4 4.2 8.4 2.4Foam, seq. I [ml/ml] 450/0 400/0 50/0 300/0 190/0 470/0Flash Point [°C] >185 242 238 229 232 210CONTAMINATIONWater Content [ppm] 100 <0.05 147 65 179 <0.05Insolubles [mg/100ml] 10 7 3.7 5.8 9.5 7.5ISO CODE 18/16/12 23/21/17 22/19/16 22/19/16 23/23/22 23/21/18VARNISH POTENTIAL RULER Amine % >25 95 - 62.2 67 70
Phenolic % >25 <10 - 19.7 4 -
28 September - October 2011 www.MachineryLubrication.com
OIL ANALYSIS
oil, form a large coherent structure by a molecular polymerization.
The varnish build-up seems to be a consequence of this physico-
chemical process, as can be realized by the photomicrographs in Figure 3, obtained in different oil samples. All these kinds of particulates have polar affi nities and high molecular weight and tend to be adsorbed onto dipolar metallic surfaces as a sticking matter, which in turn captures hard contaminants as they fl ow within the system. They are capable of shutting down a turbine or causing serious damage, which is frequently related to bearings and servo applications.
Another technique employed to monitor the oil condition was FTIR, which is used to measure organic molecular components, monitor additive deple-tion (antioxidants) and identify organic degradation byproducts (oxidation). The monitoring of specifi c antioxidant
depletion in used lubricants is still considered a rela-tively new research
area. However, some studies show that the rate of antioxidant depletion is related to lubricant degradation or affected by the antioxidant mix or base stock type used to produce the lubricant.
Used oil samples are complex mixtures of different chemicals, including compounds derived from the formula-tion of the base oil and its additives, and from oil degradation products and contaminants. As a result, a used oil spectrum is complex and essentially the net sum of the spectra of all the individual compounds making up the sample. In fact, because of this complexity, the used oil spectrum alone is of limited value and must be compared against the spectrum of the unused oil to be of signifi cant analytical value.
Figure 4 shows transmittance spectral snapshots of the new and used turbine oil. The black spectrum is that of the new oil (new base stock – Group II), while the red spectrum is from the blend oil in service, which still contains a small percentage of Group I base stock oil. Nevertheless, the spectra revealed iden-tical functional groups.
In analyzing the spectrum overlays, you can clearly see relative molecular changes in the oxidation peaks, as well as thermal degradation of the oil through the signs of nitration. Another molecular alteration is observed where the phenolic antioxidants are characterized. The type of decomposition detected in the used oil spectrum is commonly observed in FTIR analysis of fl uids where thermal breakdown took place.
Filter AnalysisStatic-generated sparks are very
common incidents in the fi ltering systems of turbo-generators. This is a phenom-enon of molecular friction occurring as oil fl ows through small clearances, such as the fi lter media. Since oil and fi lter media are both dielectric, this electrical energy builds until a limit is reached, and then sparks are released in the lubrication system in the direction of the ground. These electrical arcs can have an extremely high, localized temperature (about 20,000 degrees C), instantly cracking the hydrocarbon molecule.
Since spark discharges generated on fi lters and other locations are a key root cause of varnish, and some of the previous oil analysis results confi rmed that (through additive depletion and high particle counts), one of the duplex-type fi lters was dismantled and analyzed through an optical microscope.
Evidence of electric discharge can be easily seen through microscopic inspec-tion of the fi lter media, fi lter core, fi lter meshes and from debris carried away from the fi lter.
Figure 5 shows one of the plugged fi lters changed in a periodic maintenance action due to a plugged fi lter alarm, with a microscopic view of the fi lter mesh. As can be seen, black and brown shiny deposits (sludge and varnish) are present in high concentrations, clogging the fi lter mesh.
The solvent used for cleaning the fi lter mesh was collected and used to prepare a ferrogram where signifi cant amounts of ferrous spherical wear particles were identifi ed (Figures 6 and 7). One source of spherical ferrous debris is the erosion wear activated by electrical discharges. The high temperatures attained by the sparks on the steel surface thermally liquefy the steel debris, which acquires a spherical shape due to rapid cooling under the action of surface tension.
The microscopic analysis of the fi lter core surface showed several small, circular burned holes left by the high-temperature spark discharges on the metal surfaces.
In conclusion, turbine oils must be well-maintained to extend their service life
phenolinhibitors
(depletion)
oxidation andthermal
degradation
Used Oil
New Oil
Figure 4. FTIR spectra in transmittance/wavenumber (cm-1) of new and used turbine oils
Figure 2. Particles aligned on the ferrogram to the magnetic field
Figure 3. Ferrogram photomicrographs of the turbine oil particles in different samples (1,000x magnification)
www.MachineryLubrication.com September - October 2011 29
and simultaneously provide the maximum turbine performance. However, the recent upgrade in the turbine oil formulations has caused some controversy. The older analytical techniques are no longer the predictive tools able to monitor the real condition that they once were.
The generation and presence of soft contami-nants are among the main consequences of the actual turbine oil degradation process. There are four likely reasons for this:
• Unlike old-generation base oils (Group I), the type of base oil currently used (Group II) does not hold varnish precursors in suspension. These insoluble particles may form deposits.
• Group I and Group II turbine oils possess signifi cantly different oxidation properties and failure mechanisms.
• The antioxidants precipitate as they are preferential oxides generating insoluble
particulates.
• The new genera-tion of anti-foam additives has less effective air-release
characteristics, and these small air bubbles are adiabatically compressed, causing varnish to appear.
In this case study, it was recognized that only the following techniques used to monitor the condition of the turbine oil were effi cient in predicting eminent problems related to the gener-ation of varnish and sludge:
• Particle counting (ISO Code) was effective in monitoring particle contamination. This was in spite of the fact that most particle counters are not sensitive to the small size of the polar particles (less than 2 microns). The reason for their effi ciency was that the particles have a tendency to form agglomerates, increasing the size of the particulates and thus allowing particle counting to detect them.
• The demulsibility of the oil was a critical char-acteristic to evaluate since it is affected by the presence of polar particles. The alteration of this property could be a signal of extreme particle contamination.
• The LSV technology and FTIR are both already recognized as important techniques to monitor the condition of modern turbine oils. They effi ciently monitor the condition of the antioxidant package and the creation of soft contaminants.
• Analytical ferrography was effective in the detection of soft contaminants and in the identifi cation of their nature. In the hands of a skilled analyst, analytical ferrography is a powerful technique to identify turbine oil-related problems, providing a root cause based on the morphology and characteris-tics of the insoluble particles, as well as monitoring the progressive mechanism of varnish formation.
Figure 5. Plugged filter from the turbo-generator and filter mesh with black and brown shiny residue (200x magnification)
Figure 7. Photomicrographs of small burned holes on the surface filter core (200x and 1,000x magnification)
Figure 6. Photomicrograph showing high concentration of ferrous spheres (1,000x magnification)
H Y D R O F I N I S H I N G D E B R O U I M Y X T U R B I D I T Y T I S I L T I N G R U S U D A C M C M A B S O L U T E P R E S S U R E I P P T O I N N B
E I L Z T L R O V A L I T H I U M G R E A S E M N E T S E S N I T F R E T T I N G A T C O O E B A Y N K S I B I N G R E S S I O N L E V E L
G A L L I N G U R I L M V T I B O Y T E C O M P O U N D I N G
Y R R
From Page 22
30 September - October 2011 www.MachineryLubrication.com
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How to Grease a Motor Bearing Training Video
Format: DVDPublisher: Noria
Corporation Anyone responsible for the maintenance, operation and reli-
ability of electric motors will benefi t from this
training video. It provides plant personnel with an overview of the best practices for lubri-cating electric motor bearings. You can use the video to train operators, lubrication technicians, mechanics, electricians and maintenance personnel for years to come.
How to Select a Motor Oil and Filter for Your Car or TruckAuthor: Jim FitchPublisher: Noria CorporationBefore spending any more money on oil changes, synthetic oils, premium fi lters, engine fl ushes or oil treatments, learn what leading lubrication expert Jim Fitch recommends. With these sound recommendations, you’ll know exactly what to do next time you change your oil — for about the price of an oil change.
Industry Practices for Electric Motor Bearing LubricationPublisher: Noria CorporationDiscover what works for motor bearing lubrication while bench-marking your lubrication program to 200 plants. Noria Corporation researched electric motor bearing lubrication at 200 North Amer-ican plants and condensed the results into this valuable research analysis report.
Lubrication Fundamentals — Second EditionAuthors: D. M. Pirro and A. A. WessolThis newly revised and expanded reference book emphasizes the need for lubrication and careful lubricant selection. Thoroughly updated and rewritten, the Second Edition of Lubrication Fundamentals discusses product basics, machine elements that require lubrication, methods of application, lubrication, lubricant storage and handling, lubricant conservation and much more.
Machinery Oil Analysis — Methods, Automation & Benefi ts Author: Larry A. TomsThis book uniquely presents the entire practice of oil analysis as a condition-monitoring tool for machines. The in-depth analysis describes the what, when, where and how-to for machinery lubrication, machinery failure and maintenance concepts, oil sampling and testing, statistical analysis and data interpretation.
Welcome to Machinery Lubrication’s Bookstore, designed to spotlight lubrication-related books. For a complete listing of books of interest to lubrication professionals, check out the Bookstore at store.noria.com.
Oil Sampling Procedure PostersPublisher: Noria CorporationThis set of three posters visually displays step-by-step oil sampling procedures for in-service lubricants and hydraulics. Each poster includes a list of required equipment necessary to follow the procedure. The procedures featured in the set are for high-fl uid pressure systems, low-fl uid pressure systems and systems at atmospheric pressure.
How toBearing
Fo
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For descriptions, complete table of contents and excerpts from these and other lubrication-related books, and to order online, visit: store.noria.com or call 1-800-597-5460, ext. 204
Card
32 | September - October 2011 www.MachineryLubrication.com
Every day, thousands of industrial profes-sionals from around the United States
and around the world visit the Noria Corpora-tion Web sites. See what makes these sites so popular and informative. Visit us today and every day at www.machinerylubrication.com.
Automated Lubrication — Benefits and Design Options
While grease guns and manual lubrication seem to get the job done for many maintenance opera-tions, their benefi ts often cannot compare to those provided by an automated lubrication system in terms of productivity, environmental issues and worker safety. An automated lubrication system helps to prevent bearing failure by providing the right amount of the right lubricant at the right time to the right place. Find this article in the Bearing Lubrication section on the ML site.
How Infrared Thermography Predicts Failures
This video offers expert analysis of how infrared technology can predict equipment fail-ures. Access this 9-minute, 11-second video at www.machinerylubrication.com.
Demystifying Sludge and VarnishYou could tar your roof with it. It sticks to
everything. It spreads like cancer. You thought you were getting rid of it with the oil change and f lush, but it is back again, lurking in your oil and gripping the insides of your machine. Maybe you have it now . . . sludge and varnish. Do you know what causes it and how to stop it from spreading? Discover the destructive potential of sludge and varnish as well as how to prevent it from coming back by reading this article on the ML site.
Hydraulic Gear Motors and How They Work
Get a detailed look at the interior of a motor, its gears and body. Watch how oil is pushed into the inlet port and through the outlet, traveling between the gear teeth and the gear housing, generating the rotation of the shaft. Access this 2-minute, 11-second video at www.machinerylubrication.com.
Managing the Risk of Mixing Lubricating Oils
Today’s high-performance lubricants are specif ically formulated with a carefully selected balance of performance additives and base stocks to match the lubrication require-ments of the equipment in which they are used. When lubricants are mixed, this balance is often upset. Mechanical problems leading to shorter equipment life can occur, sometimes catastrophically. Read this article on the ML site to learn why mixing lubricants is fraught with danger to your equipment, your business and your wallet.
ML MachineryLubrication.comNOW ON
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Ten years ago, ICML held its very fi rst examination session in Biloxi, Miss., changing the course of the machinery
lubrication industry. In the small pioneering group of only six practitioners stood Rendela Wenzel, who took it upon herself to be part of the very fi rst group of ICML candidates. By success-fully completing that fi rst ICML exam, she not only became one of the fi rst ICML-certifi ed professionals but also the very fi rst ICML-certifi ed female practitioner.
In celebration of ICML’s 10th anniversary, we wanted to tell Wenzel’s remarkable story.
Wenzel remains one of a still few female reliability engineers and machinery lubrication practitioners. Although part of an ICML-award-winning team, she was one of the people ICML recognized at the 2011 Reliable Plant Conference in Columbus, Ohio, as embodying the spirit of ICML in the area of certifi cation.
Wenzel is currently the corporate lubrication technical team leader for Eli Lilly. She has 14 years of experience in maintenance and operations, troubleshooting maintenance issues, implementing
solutions to these problems and supervising skilled trades. Wenzel has a level II certifi cation in both lubrication and vibration analysis, and a level I certifi cation in both infrared thermography and ultra-sonic analysis. A Six Sigma Green Belt and a certifi ed maintenance and reliability professional (CMRP), she has a bachelor’s degree in mechanical engineering and a master’s degree in business admin-istration. Wenzel is also a member of ICML and the Society of Maintenance and Reliability Professionals (SMRP).
She began her career at the Chrysler Foundry in 1997 as a process engineering intern in the core delivery area. After a few months, Wenzel became the team leader for operations and maintenance for the cleaning area.
“All engineers at Chrysler start out on the fl oor to gain experi-ence working with the people and equipment that they support and redesign,” Wenzel says. “This was an excellent opportunity for me to be able to see the struggles that workers have with equip-ment and learn how to design those issues out with mechanical solutions. I also learned to work with people of various back-grounds in a union environment and still be able to be effective at implementing those solutions.”
Wenzel then moved to International Truck and Engine (Navistar) in 1999 as a maintenance engineer over the crankshaft line for the steel business unit at the Indianapolis engine plant.
“I was tasked with developing a job description for a mainte-nance engineer and a predictive maintenance program for the entire site,” she recalls. “Navistar knew that this was a new role in industry, and they needed individuals to go out and get trained on how to implement it in their facilities. This is where I learned about Noria and the ICML.”
Wenzel’s task was to develop a lubrication program and imple-ment it in a union environment.
“I went to Oil Analysis I and II training from Noria and became MLA I certifi ed through ICML in January 2001,” she says.
Wenzel took the information she learned back to her facility and developed a robust and highly successful lubrication program,
CERTIFICATION NEWSML
BY SUZY JAMIESON, ICML
ELI LILLY’S WENZEL EMBODIES the SPIRIT OF ICML
Rendela Wenzel (center) and her team from Eli Lilly were the recipients of the 2008 John R. Battle Award.
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CERTIFICATION NEWS
which was later replicated at Melrose Park and also the Huntsville, Ala., facility. She was able to transform the culture of reactive main-tenance into a proactive environment that valued reliability activities and wanted them integrated into their PMs and daily operator tasks.
“I took the structure of the existing vibration program as a model and integrated an oil and thermography program into the PM tasks and jobs of the craftsmen,” Wenzel notes. “This was a daunting task in a union environment. Oil analysis was an extra task for the machine repairmen, and thermography was an extra task for the electricians.”
Oil analysis became something that Wenzel and her team did routinely over the next three years to diagnose many potential fail-ures, which resulted in greater uptime.
“I implemented the changes in very small increments, including oil leak-detection devices such as a UV light and dye that could fi nd oil leaks,” she says. “One leak in our facility equated to more than $42,000 per year in savings. I decreased oil consumption by 25 percent and eliminated time-based oil changes. I added proper sampling ports, revamped our lube room and instituted an oper-ator machine-cleaning program. The production on our bottleneck step increased by 10 percent, which eliminated one shift per week of overtime.”
Wenzel then had the opportunity to obtain her master’s degree in 2003 and wanted to broaden her experience base by switching industries. She started with Eli Lilly in 2003 as a reliability engineer in the insulin side of the business. Her role was to be the reliability engineer over the Humalog product line in B130.
“I took the knowledge from my Noria training and replicated my efforts in B130 to establish a robust and successful oil analysis program,” she says. “My building was certifi ed by the corporate lubrication technical team as world class in the fall of 2003 and was the fi rst manufacturing facility to be certifi ed by the corporate team. This was a great achievement only being with the company fi ve months.”
For a minimal investment of $5,000, Wenzel took the shell of a lubrication program and turned it into the pilot plant for the rest of the company to follow. After replicating this program for the remaining manufacturing facilities at Eli Lilly, the corporate team applied for the ICML John R. Battle Award.
“Our team decided to use my area for the application, and we were the 2008 John R. Battle Award recipients,” Wenzel says. “I took over the reins of the corporate lubrication technical team from Wayne Ferguson in 2009. Since then, we have maintained the 12 areas of the company that are world-class certifi ed, established two lubrication courses (basic and advanced lubrication fundamentals) at Lilly for all engineers, supervisors and crafts, and are in the process of replicating all these policies and procedures to all our sites.”
To date, more than 900 Eli Lilly and contract employees who come into direct contact with critical machinery have been trained in lubrication fundamentals.
When asked to think back to Jan. 26, 2001, the day she took that fi rst ICML exam, and about her journey until now, Wenzel offered a gracious response that demonstrates why she is one of the best examples of the spirit of ICML.
“The last 10 years have been a very rewarding journey for me through three different types of industries, learning the cultures, designing and implementing lubrication programs, and developing policies and procedures to ensure the longevity of the programs,” she adds. “I feel very blessed to have been put in the situation to be able to make a difference by helping make equipment safer, more reliable and easier to maintain.”
Along with Kurt Bittner of PSEG Nuclear and Scotty Lippert of Clopay Plastics, Wenzel was honored at the 2011 Reliable Plant Conference in Columbus, Ohio, as representing the spirit of ICML.
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CERTIFICATION NEWS
RECENT RECIPIENTS OF ICML CERTIFICATION
Azman BinBadron, MLT IEduardo Bruschi, MLT IClaudio Marcos Madureira Martins,
MLT IHumberto Mozer Carvalho, MLT IBrittany J. Russo, MLA I
Acerias Paz del Rio S.A.Jaime Augusto Rodriguez Orozco,
MLT I
Aerospace Testing AllianceJoo D. Reynolds, MLA II
Al Bedaya Consultancy & Marine Survey LLCKhaled Aly Matar, MLA I
AlcoaCheyene Robert Buse, MLT IJennifer Lynn Cheaney, MLA I & MLT IJoseph F. Clayton, MLA I & MLT IJonathan A. Fulton, MLA I & MLT IDavid T. Gainer, MLA I & MLT IAllen Hohl, MLA INathan Jones, MLA I & MLT INeil Kennedy, MLA IRobert Koehler, MLA I & MLT IShawn L. Mayo, MLA I & MLT IDavid Michael Patterson, MLT IBen Robak, MLT IRobert C. Rockhill, MLA I & MLT IDave A. Swindell, MLA I & MLT IYi-Hsien (Tim) Yang, MLA I & MLT I
Allegheny TechnologiesBrandon Gaskey, MLA I & MLA IIDale L. Jones, MLA I, MLA II & MLT II
Allied ReliabilityJohn M. Trulli, MLT I
Apache CorporationKeith Madsen, MLT I
AraucoJaime Bohme Fuentealba, MLT IAlfredo Boettcher Schell, MLT I
ATI Wah ChangBoyd Koehler, MLA IJim Scofi eld, MLT IJon Walberg, MLA I
AV Technology Ltd. Carl Dawson, MLA ITim Wilkinson, MLA I
Birmingham Water Works BoardJonathan Malloy, MLA I
Cargill Inc.Jessie Barlow, MLT ISteve Brantley, MLT ITerry Wayne Brewer Jr., MLT IRodolfo Cabrera, MLT IDaniel M. Dicke, MLT IJimmy Goff, MLT IKevin Gorski, MLT IDave Horn, MLT IThomas Edward Jackson, MLT IHarrison W. Joyce, MLT IJoe Lemer, MLA II & MLT IChris M. Lindgren, MLT IMichael S. Moore, MLT I
David J. Peraza, MLT IMark Resendez, MLT IJohn Reyes, MLT ITroy Rooney, MLA IIJeremie D. Walker, MLA II
Cariboo Pulp & Paper CompanyDon Edwards, MLT I Brent Janischewski, MLT ISteve Logan, MLT IYork Malner, MLT ICameron McPhedran, MLT IJames R. Porter, MLT IScott E. Richardson, MLT IRob Rolfe, MLT IJason Phillips-Watts, MLT I
ChevronHilary A. Fernando, MLT IIAimee Hawkins, MLT IISorasak Saengwanit, MLT IIAlexander William Stephenson, MLT II
Cia. Vale do Rio DoceLuis Orlando Pino Delgado, MLA II
Cliffs Natural ResourcesJohn Freiberg, MLT I
Cloud Peak EnergyJeffrey Biegel, MLA III
Compañia Teck Minera Quebrada Blanca S.A.Rodrigo Gonzalez C., MLT ICristian Jesus Parra Rios, MLT IRoberto Joaquin Ramos Hernandez,
MLT I
ConautoJorge Fernando Calero Mejia, MLT I
Del Monte Phils., Inc.Cirilo Amoy, MLT IEleazar S. Orina Jr., MLT I
Diavik Diamond MinesGeorge M. Fancy, MLA IIDave Frederick Forster, MLA I &
MLA IIJ. David Monchuk, MLA I & MLA IIAlexander Shank, MLA IAnand Sharma, MLA IIJim Simmons, MLA IIJim A. Strickland, MLA I
Dubai Aluminium Co. Ltd.Shajeev Puthalath, MLA I
DuPontErica R. Cross, MLT ILarry E. Kunze, MLA IIRichard Lipscomb, MLT IAaron P. Moore, MLT IJohn Edward Nesselroad, MLT IBrian Thompson, MLT I
Eastman ChemicalEarl F. Edens, MLA III
EMA Lubricants Co.Syed Sadath Hussain, MLT I
Emirantes AluminiumMohammed Yousef Abusheikha,
MLA I
Energy NorthwestJeff Scott, MLA II
Entergy, Inc.James R. Fraser, MLA II
Exelon CorporationSteven Wood, MLA I
FiltramaxFrancois Lepine, MLA I
First Energy Corp.James E. Black Jr., MLA IIScott K. Graton, MLA II
Florida Power & LightDavid LaGuardia, MLA II
Flow Dynamics and AutomationPhillip Scrimpshire, MLT I
GenOn EnergyRyan Bailey, MLT I
Georgia-Pacifi cGreg Van Camp, MLT IShawn M. Day, MLT IDennis R. Leach, MLT IAlex Moses, MLT IWilliam R. Nichols, MLT IWayne Noakes, MLT IWilliam Paul Terrell, MLT IIJason Vance, MLA I & MLT II
Greenlub Lubrifi cantes Ltda.Rogerio Zadra, MLT I
Hedcor Inc. Niel Cabang, MLT IDennis Miranda, MLT I
Holcim Inc.Jason Frankiewicz, MLT ICharles E. Gibbs, MLT IAlvin Chester C. Oreiro, MLT IPete Oviedo Jr., MLT IDavid “Coop” Towle, MLT I
The Hurt Company, Inc.Newton Hopkins, MLT IRoy M. Christoffel, MLT I
Industrial Oils UnlimitedDanny “Mike” Toney, MLT I
Insight ServicesEric Ambrose, MLA IIMonika Malcolm, MLA IDwon Ruffi n, MLA I
IPMDavid Williams, MLT I
ITW PolymexRicardo Joel Duarte Loperena, MLT IAldo Guatemala, MLT IIEdgar Guzman Lopez, MLT I
Japan Atomic Power Co.Atsuya Tsuruzono, MLA III
Jimah O&M Sdn BhdSofi an Bin Sahat, MLT IMohd Fauzi Bin Hamin, MLT I
JM HuberDana Rowan, MLT I
The JM Smucker Co.Patrick Lalor, MLT IJames Robert Pant, MLT I
Kanden Plant Corp.Kazuyoshi Hagane, MLA IIYoshitaka Nakano, MLA IITomohiro Sanda, MLA II
Kennecott CopperKirk Dittmar, MLT I
Lubrication Engineers Inc.Patrick R. Bilberry, LLA ILarry Boyle, MLT IBruce A. Bruner, MLA IIJames Cowles, MLA II & MLT IIJacob Bryant Davisson, LLA I & MLA IIMike Hall, MLT ISarah Hall, MLT IBerle Hartman, MLT ICaleb D. Hayes, MLT IEric Ndegwa, LLA IBrian L. Nelson, MLT IIStan Nelson, MLT ISam R. Quakenbush, MLT IDaniel Roberts, MLT IBirju Shah, MLT IChris Shelly, MLT IBob Sodergren, MLT IGregory Spiers, MLA I & MLT IDerek Taylor, MLT IBernie A. Thomsen, MLT IMatthew Valentine, MLA I & MLT I
Lubrication Systems CompanyOsmari Chacon, MLA III
Luminant PowerJeremy Layne Swanson, MLA III
Machine EvaluationMichael E. Thornton, MLT I
Matzan Reliability EngineeringMatt Arndt, MLA II
Mecoil Diagnosi Meccaniche SrlGiacomo Mariani, MLT I
Michelin Tires CorporationJerry Gibson, MLT I
Micron TechnologiesDavid A. Peck, MLT I
Mighty River Power Ltd.Allan Heath, MLT IPeter Martin, MLT IMike Ranger, MLT IAndre Richards, MLT IPeter Smith, MLT IJeremy Wilson, MLT I
MillerCoors Brewing Company Thomas Lloyd Davis, MLT I
MinePro Chile S.A.Marcos Castro, MLA IICarlos Tomas Mondaca Lopez, MLA II
Mosaic CompanyRodney E. Bernath, MLA IIKelly M. Chalus, MLA IIBrad L. Gabrielli, MLA IIGarrett Matthew Kuntz, MLA II
David William Niebergall, MLA IIDerek Rice, MLA IIKelly Therrien, MLA IIReid Foley Williams, MLA IIShaun K. Wright, MLA IIGreg A. Zimmer, MLA II
MRG LabsRichard N. Wurzbach, LLA I
Newmont Mining Corp.Brett Eugene Morton, MLA I
NextEra EnergyJerry Lee Barske Jr., MLA II
NissanChad Crane, MLT IDavid Gross, MLT I
Noria Latin AmericaFrancisco J. Paez Alfonzo, MLA III
Norske Skog TasmanGrant Carncross, MLT IEric Horwood, MLT IRhys Drayson, MLT I
NRG Energy Inc.Joshua Shewan, MLA I
OCI Wyoming L.P.Dean Kendall, MLT I
Oil-DriDonald K. Everett, MLT IKim Robert Jaynes, MLT IMitchell Jon Schalk, MLT IJim Warden, MLT I
Overlake OilPaul Hawkes, MLT I
Owens CorningAndrisa Jefferson, MLT I
Pemex Gas & Petroquimica BasicaAlejandro Castillo Lazaro, MLT ICarlos Alberto Dominguez Osuna,
MLT IRamiro Fernandez Martinez, MLT IJavier Garcia De Leon, MLT IJuan Enrique Germanos Otero, MLT IFrancisco Javier Gonzalez Juarez,
MLT I & MLT IIOctavio J. Guerrero Hernandez,
MLT IWilberth Guillermo Herrera Osorio,
MLT IJorge Higa Arvizu, MLT I Roberto Martinez Bustos, MLT IIMiguel Martinez Luria, MLT IErick Martinez Ramirez, MLT IMedardo Melo Sanchez, MLT I &
MLT IIGabriel Olan Gonzalez, MLT IJose Manuel Perez Sosa, MLT IRaymundo Rodriguez Romero, MLT IOmar Valdivia Maza, MLT I & MLT IIEdgar Genaro Vega De Leon, MLT IGabriel Zavala Gomez, MLT I
PetrobrasJulio Cesar L. Alves, MLT ISolange Virilo Borbily, MLT I
The International Council for Machinery Lubrication (lCML) would like to congratulate professionals worldwide who have recently achieved certifi ed status through ICML’s certifi cation programs. ICML offers certifi cation in the areas of oil analysis and machinery lubrication. The following is a list of recently certifi ed professionals in the area of machinery lubrication who have attained their status as a certifi ed Machine Lubricant Analyst (MLA), Machine Lubrication Technician (MLT) or Laboratory Lubricant Analyst (LLA).
www.MachineryLubrication.com September - October 2011 | 39
Mario Roberto Leao Burle, MLT ICesar Figueiredo, MLT ISergio Peixoto Augusto Junior, MLT IMarcos Thadeu Giacomin Lobo,
MLA IVinicius Moia Monte Alegre, MLT IRosana Villela Santos, MLT I
Petronas Gas BerhadGladwyn Bacena, MLT IMuhammad Effi rdaus Bin Abdul Hakim, MLA II
Pilipinas Shell Petroleum Corp.Kerchieval G. Balingit, MLT IDonna Christine Enriquez, MLT I
PQ CorporationStuart Hensley, MLT IWilliam M. Ledbetter, MLT I
Praxair, Inc.Matthew Thomas, MLA I
Progress EnergyLarry E. Barnett, MLA II
PT Newmont Nusa TengarraNeka Damartha, MLA I
Queensland Nickel Pty. Ltd.Andrew Camp, MLT IJames Leslie Filmer, MLT IAnthony Philip Greinke, MLT ITak Sam Lee, MLT IRussell Vernon McIntosh, MLT IAngelo Nobile, MLT IMatthew Joseph Paulger, MLT ICraig Pegg, MLT IRisto Reissenberger, MLT ICameron Smith, MLT IDane Tappenden, MLT IJason Bradley Townsend, MLT IDaniel Vogler, MLT IBill Weston, MLT I
R.J. Reynolds Tobacco Co.Michael D. Cornett, MLT IJoseph Scott Poindexter, MLT I
Right Flow Reliable Solutions Inc.Dawn April Lumbas, MLT I
Rio TintoMorgan Hall, MLA IBrendan Moffat, MLA IBrian Wagstaff, MLA I
Robinson Nevada Mining Michael Sean Farrell, MLT IJustin Shalako Pope, MLT I
Roquette America, Inc.David Chandler, MLT IMarceyMarcey Lonning, MLT I
Sabic Innovative PlasticsAdam E. Ball, MLA INorman Bulloch, MLA IChristopher M. Corbitt, MLA IJoseph Lee Dean, MLT IDennis R. Dick, MLT ILance Foreman, MLA IGerald Goebel, MLA IJeff C. Hutcheson, MLT I
Charles Arthur Lewis, MLA IHeidi A. Marshall, MLA ICharles James Pence, MLT IMatthew T. Platek, MLA ICraig Alan Schrowang, MLA IRichard D. Segovich, MLA IGordon L. Seymour, MLA ICarol Jean Straub, MLT IDavid S. Thompson, MLT IJimmy L. Uhde, MLA ICraig William Walker, MLT IReggie R. Wulff, MLT I
Samsung EverlandDae Keun Kang, MLA IISungil Park, MLA IIHyun Gyu Yang, MLA II
San Roque Power Corp.Leo V. Tibayan, MLT I
Sarawak Shell BerhadChow Kim Vui, MLA II
SaskPowerMark Crooks, MLA I
Saudi AramcoRabi M. Hakeem, MLA I
SeaTec UK LimitedAjay Arora, MLA IIStanly George, MLA II
Shell Markets Middle EastSandeep Banerji, MLA I
Shikoku Electric Power Co.Yuji Yano, MLA III
Siemens Power Operation Inc.Edmund M. Castro, MLT IElena Kristine A. Javal, MLT ISandy L. Uson, MLT I
SKF del PeruRoy Felix Cabezas Jara, MLA IRonald Vidal Ravelo, MLA II
SKF Maintenance ProductsGustavo Yesid Sabogal Rozo, MLT I
Solvay Advanced PolymersMichael D. Dye, MLA II & MLT II
Southcoast Petroleum Ltd.Oleksandr Bodnya, MLT I
Southern CompanyNeal Mac Namara, MLA II
Sterling Steel LLCMichael Kyarsgaard, MLA II & MLT IJeff Trancoso, MLA II & MLT I
Taylor EnterprisesThomas J. Loar, MLA II
Teck Highland Valley CopperMark Baker, MLA IIShane Kozoriz, MLA IIMark Mulroy, MLA II
Temple-Inland Forest ProductsWilliam Scott Davis, MLA II
Tenaga Nasional BerhadVenoth Kumar Govindasamy, MLA II
Thomas PetroleumRicky Edward Cantrell, MLT IJames Grant Clark, MLT IDee Harold Draper, MLT IBrandon S. Ford, MLT IRodolfo J. Gonzalez Jr., MLT IKimbery A. Gregory, MLT IChris Dewain Harris, MLT IMark Wesley Hudson, MLT IJames C. LaBeff, MLT IDennis G. Maietta, MLT INicole Martin, MLT IRonnie Wayne Pewitt, MLT IRicky Roden, MLT IDavid L. Sanchez, MLT IFrank Eidin Slaugh, MLT IGarrick Ashley Thomas, MLT I
Thunder Bay Coal Co.Michael Siegert, MLA II
Tohoku Electric Power Co.Takuya Saito, MLA IIMasayuki Shimada, MLA IINobuhiko Umeki, MLA II
TSNZ Pulp & Paper Maintenance Ltd.Selwyn Pryor, MLT I
UniccoAaron Chad Abbott, MLT IJames R. Anderson, MLT ICharles Mettler, MLT IBrian Keith Miles, MLT I
Valero Energy CorporationAllan R. Thibodeaux, MLA IIJimmy Thomson, MLA II & MLT I
Verso PaperEdwin W. Ames, MLT ICaleb Bell, MLA IStephen P. Blair, MLT IReginald A. Cloutier, MLT IRobert Allden Downes, MLT IScott Dyar, MLT IThomas Henry Heywood, MLT IJames H. McClure, MLT IMichael D. Michaud, MLA ITerry Arlene Ring, MLT ITravis C. Veilleux, MLT I
We EnergiesMark J. Smith, MLA II
WesTrac Pty. Ltd.Philip De Wet, MLA II
XstrataLuis Angel Romero Carlos, MLA II & MLT I
Yonden Engineering Co.Keiichi Shimomoto, MLT I
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
ICML CertificationsLLA I = Laboratory Lubricant Analyst Level IMLA I = Machine Lubricant Analyst Level IMLA II = Machine Lubricant Analyst Level IIMLA III = Machine Lubricant Analyst Level IIIMLT I = Machine Lubrication Technician Level IMLT II = Machine Lubrication Technician Level II
40 September - October 2011 www.MachineryLubrication.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 Companywww.cannoninstrument.com
Know when to lubricate with UE Systems Ultraprobe® 201 Grease Caddy. Sensing ultrasound, Grease Caddy isolates bearing sounds mak-ing it easier to listen in noisy plant environments. Wear on a holster or attach to grease gun.
UE Systems, Inc.www.uesystems.com
Isn’t it time you streamlined your fl uid handling?
The IFH Group, Inc. www.ifhgroup.com
Maximize productivity and reduce costs with the power of Castrol High Performance Lubricants. • Gear Oils • Greases • Hydraulic Oils • Way Lubricants • Compressor Oils • Chain Oils. Only Castrol Industrial has the technology inside. Contact us [email protected]
Castrol IndustrialNorth America Inc.
877-641-1600
Summit Varnasolv will alleviate prob-lems from varnish and carbon in your rotary screw or rotary vane compres-sor. Clean your compressor while it is running, no need to disassemble. Use Varnasolv to clean heat transfer systems, high temperature chains and gearboxes.
Summit Industrial Products www.klsummit.com/varnasolv.pdf 800-749-5823 [email protected]
Ensure protection from live parts and arc fl ash - Safety Plugs allow techni-cians to quickly connect/disconnect electrical equipment. Exclusive fea-tures protect from electrical hazards and simplify NFPA 70E compliance. FREE samples available.
Meltric Corporationwww.meltric.com 800-433-7642
The SureSample utilizes a patented vacuum technology that eliminates the need for sample pumps. Sim-ply affi x the length of tubing to the SureSample bottle, insert into a reservoir or sample port, and let the bottle do the rest.
Analysts, Inc.www.analystsinc.com 800-655-4473
Escalator Chain Lube is a synthetic lubricant; it excels in lubricating the chains of escalators, moving sidewalks & elevator doors. Its high-fi lm strength improves equipment reliability while reducing lubricant consumption.
Royal Purple, Inc.www.royal-purple-industrial.com
888-382-6300 [email protected]
Krytox® Fluorinated Greases and Oils are chemically inert, insoluble in com-mon solvents. Temperatures range from -103° to 800°F. Compatible with plastics, rubber, ceramics and metals. Nonfl ammable, oxygen compatible, no silicones or hydrocarbons. H-1/H-2 Food Grades available.
Miller-Stephenson Chemical Company, Inc.
www.miller-stephenson.com 203-743-4447
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Valve reduces sampling time by 80% Plus - Unique 360° rotating spout allows easy one hand sampling. Stain-less steel chain and clip. NEW higher fl ow for low pressure applications. NEW rugged spout design with easy to grip knurled cap.
Checkfluid, Inc.www.checkfl uid.com 866-652-8728
info@checkfl uid.com
Inolex Chemical Company synthesizes premium ester base oils for high-per-formance lubricant applications such as chain formulations for oven temper-atures up to 550°C. HX-1 food grade oils for baking chains are available.
Inolex Chemical Companywww.inolex.com
The Easylube RFID Patrol Manage-ment Automatic Lubrication System provides precision bearing lubrica-tion and condition monitoring in one system. Easily calculate and manage greasing quantities and intervals using our software.
Hornche Corporationwww.easylube.com
MEMOLUB® Lubrication Systems – Precise, Reliable. Lube up to 12 points with the reusable MEMOLUB®. Avail-able in 3 sizes and 4 power options, MEMOLUB® uses low-cost replace-able lube cartridges with customer-specifi ed grease or oil.
PLI LLC www.memolub.com
Harvard’s fi lter systems are designed and built with quality materials and crafts-manship to provide years of trouble-free service. Filter elements for viscosity ranges from fuels to gear oils (ISO 1000). Cus-tomers report clean fl uids 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 Corporationwww.harvardcorp.com 800-523-1327
BELL ULTRA’s formulation substan-tially reduces friction in hydraulic systems by resurfacing metal surfaces, resulting in LOWER OPERATING TEMPERATURES AND POWER INPUT and LONGER COMPONENT LIFE.
Cornerstone Controlswww.ccisupply.com/BellUltra
352-291-2300fl pwr@cfl .rr.com
Maintain your fl uid cleanliness from storage to point of use with the PROFILL portable fl uid transport container. PROFILL pro-vides sealed, reliable, and effi cient, transport and accurate dispensing of your critical fl uids.
FLUIDALL Solutionswww.FLUIDALL.com
One Eye Industries for all your mag-netic and industrial fi ltration needs. Our fi ltration solutions have applica-tions in all industries. We manufacture an extensive product line utilizing new magnet technology.
One Eye Industries, Inc.www.oneeyeindustries.com
Fundamentals of Machinery Lubrica-tion provides more than 24 hours of foundational training on best prac-tices for machinery lubrication and oil sampling. It lays the groundwork for establishing a world-class lubrication program and is a Level I certifi cation prep course.This online training format allows 24/7, anywhere accessibility.
Noria Corporationstore.noria.com 800-597-5460
PAID ADVERTISING SECTION
42 September - October 2011 www.MachineryLubrication.com
GARZO Model 108B controllers main-tain oil levels in engines and compressor crankcases to prevent equipment dam-age and save oil. The standard valve assembly works with atmospheric tanks or up to 15 psig oil supply pressures.
GARZO, Inc.www.garzoproducts.com/108.html
Equip your Lube Room of the future with FLUIDALL Lubrication Storage Solu-tions. Reliable, Clean, Cost Effective, and Space Effi cient fl uid storage systems available in bulk and portable gravity fed and pump/fi ltered confi gurations.
FLUIDALL Solutionswww.FLUIDALL.com 800-849-0591
This DVD includes instructive videos and animations to give viewers a better understanding of electric motor bearings and how to lubricate them properly.
Noria Corporationstore.noria.com 800-597-5460
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This month, Machinery Lubrication continues its “Test Your Knowledge” section in which we focus on a group of questions from Noria’s Practice Exam for Level I Machine Lubrication Tech-nician and Machine Lubricant Analyst. The answers are located at the bottom of this page.
1. Benefits generally associated with the use of synthetics include: A) Better oxidation resistance B) Better compatibility with elastomers (seals) C) Less toxicity D) Higher cost E) Better paint compatibility
2. The concentration of wear debris: A) Always increases throughout the oil circulating system B) Varies throughout the oil circulating system C) Always decreases throughout the oil circulating system D) Is constant throughout the oil system E) Varies with the pressure in the oil system
3. Which maintenance strategy is based strictly on tasks performed at specific time intervals? A) Proactive B) Predictive C) Preventive D) Percussive E) Reactive
4. A critical issue when greasing a rolling bearing is to:A) Use only the exact calculated regreasing frequencyB) Use only a pump-action grease gunC) Allow the grease to ooze out past the sealsD) Wipe the excess grease from the zerk fi tting when fi nishedE) Allow excess grease to get out of the roller path and exit the housing through the drain port
5. Which component generally requires the cleanest oil? A) High-pressure hydraulics B) Gears C) Engines D) Turbines E) Journal bearings
Answers: 1-A; 2-B; 3-C; 4-E; 5-A
44 | September - October 2011 www.MachineryLubrication.com
In today’s culture of looking for high returns on investments, there are not many that can compare to a comprehensive
lubrication program. Tremendous fi nancial savings can be enjoyed by eliminating poor lubrication practices from an organization. Numerous fi nancial losses are attributable to poor and inadequate lubrication programs and techniques, and most of the losses are not going to jump out at you. This is wh y it is important to think of every aspect of lubrication. Just working on one area will not yield the fi nancial results you desire. It is all or nothing. This article will offer valuable guidance as to why and how to look at the big picture when updating your lubrication program.
BenchmarkingTo understand where your lubrication program needs
to be, you must fi rst fi nd out where it currently stands. In order to accomplish this, an in-depth benchmarking process must be performed to compare your current
program to industry best practices in key areas of lubrication. Without having a metric to compare your program to, it becomes the blind leading the blind. All successful programs start with a clear picture of how much work they need to do to become world class and what they need to do to get there. Transitioning a lubrication program is not like turning on a light. It takes understanding, clear vision, dedi-cation, champions, time and fi nancial resources to make it happen.
Design and EngineeringDuring the design and engineering phase, look at
every lubrication point and determine what actions need to be put into place. These actions can range from equipment modifi cations and routine inspections
to one-off inspections, etc. They are usually dependent upon the equipment type, criticality, reliability needs, fi nancial benefi t, safety consequences and other factors that affect the bottom line. Based on these factors, you should create clear, concise and specialized procedures for each lubrication point. These procedures will be used to modify equipment for contamination control, provide standards for oil analysis and coach the lubrication technician on proper lubri-cation techniques (i.e., top-ups, drains, fi ltration and oil sampling).
During this phase, you also should make sure the correct lubri-cant is being used in each lubrication point. This process involves checking the OEM recommendations for a baseline and then performing certain calculations for proper viscosity selection,
lubricant type, performance properties, re-lubrication volumes, re-lubrication frequencies, etc. Re-lubrication volumes and frequen-cies often are left out of procedures, and a “shoot-from-the-hip” method is used. Not understanding how much and how frequently the lubricant should be supplied to an application, especially grease-lubricated bearings, can cause frequent lubrication-related failures.
Lubricant ConsolidationMany times, as a byproduct of the design and engi-
neering phase, lubricant consolidation occurs. This is important on many levels, as it allows for a clearer picture of what products need to be purchased, which reduces
purchasing costs, eliminates unnecessary or unused products from inventory, decreases the likelihood of lubricant cross-contamination and helps the lubrication team understand which products they need and why. As the specialized procedures are created during the design and engineering phase, each lubrication activity should have the correct lubricant specifi ed. This will help ensure that the techni-cian is using the right product in the right place.
Storage and HandlingOnce all of the necessary lubricants are identifi ed, it is
time to think about your storage and handling practices. Proper storage and handling techniques are essential in developing a successful lubrication program. You
can perform all of the equipment modifi cations for contamination control, but if you can’t get the lubricant from the storage room to the application without introducing contamination, all of those modifi -cation efforts were in vain. This is why it is so critical to have a proper lube room with dedicated receiving fi ltration, storage systems, fi lter carts, stored fi ltration, dispensing equipment and a safe and clean environment for the lubricants to be stored.
Lubricant labeling is another frequently missed opportunity. Labeling should be a high priority when thinking of execution. Lubricant-specifi c labels should be created and placed on stored lubricants, top-up containers, grease guns, fi lter carts and the equip-ment. This makes lubrication tasks much more effi cient and reduces the likelihood of the wrong lubricant being used in the wrong applica-tion. If technicians can clearly see the label on the equipment, go back to the lube room and fi nd the matching label on the fi lter cart, top-up container or grease gun, their jobs become much easier and safer.
6 STEPS to UPDATE your LUBRICATION program
FROM THEFIELD
STEPHEN SUMERLIN
L u b r i c a t i o n P r o g r a m s
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ImplementationAfter designing and engineering
a lubrication program, the next step is to implement what you have developed. Many times this is where
organizations fail to execute and never see the value of all their previous efforts. Implementa-tion is not a one- or two-day exercise but a multi-month commitment based on available resources. Complex types of equipment such as hydraulic systems will necessitate multiple modi-fi cations in order to be considered best practice, requiring a substantial fi nancial commitment. The modifi cations can include breathers, sight glasses, dedicated sampling ports, quick-connects for periodic decontamination, fi lters, etc. This is where all the time spent developing the specialized procedures from the design and engineering phase pays off.
Every modifi cation activity for each piece of equipment should have its own dedicated specialized procedure to instruct the labor force on how to perform the modifi cation correctly. Other less complex types of equipment such as grease-lubricated bearings may not have any modifi cation procedures but only routine lubri-cation procedures. These applications do not require as much of a fi nancial or labor commit-ment to implement, and once the specialized procedure is written, the technician can start with the needed tasks immediately.
Re-benchmarking and Continuous Improvement
After your newly revamped lubri-cation program has been up and
running for a while, it is time to re-benchmark your program with industry best practices to see where your program is now compared to where it was during the initial benchmarking. This is where all of the hard work in the previous steps will show the fi nancial rewards and re-enforce that the decision to develop a real lubrication program was worth the fi nancial commitment.
As with any change of culture, management and workforce, a lubrication program needs constant refi nement and continuous improve-ment. It is easy to slide back to the old ways of doing things if not careful, especially if the orga-nization has a high turnover rate in the labor force. This is why it is so important to have developed the specialized procedures during the design and engineering phase, as they make it easier to train new members of the lubrication team and defi ne how to do things correctly and accurately the fi rst time, which promotes a sustainable culture change.
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The “Lube Tips” section of Machinery Lubrication magazine features innovative ideas submitted by our readers. Addi-
tional tips can be found in our Lube-Tips e-mail newsletter. If you have a tip to share, e-mail it to us at [email protected]. To sign up for the Lube-Tips newsletter, visit www.machinerylubrication.com and click on the “Newsletters” link at the top.
Use Crackle Test to Detect Water Contamination
If an oil is looking cloudy, the problem could be water contamination. The crackle test can generally be relied upon to confi rm the presence of water.
Check Your Records to Control Oil Losses If you decide to implement a program to control oil losses, one
of the fi rst steps you can take is to check historical records of the amount purchased compared with the amount sent for disposal. Try to account for the difference by looking for leaks, products consumed in the process, evaporative losses and products wasted due to contamination or misapplication.
Know the Pour PointThe pour point is the lowest tempera-
ture at which an oil will fl ow. This property is crucial for oils that must fl ow at low temperatures. A commonly used rule of thumb when selecting oils is to ensure that the pour point is at least 10 degrees C (20 degrees F) below the lowest anticipated ambient temperature.
What You Should Know When Using Additives
Regarding the use of aftermarket additives and supplemental oil conditioners, keep in mind that some base oils respond well to additives while others may not. Also, increasing the percentage of a certain additive may improve one property of an oil while at the
same time degrade another. When specifi ed concentrations of addi-tives become unbalanced, overall oil quality can be affected.
Oil Reclaiming vs. Oil Re-refining Although defi nitions vary, the general difference between oil
reclaiming and oil re-refi ning is:• Reclaiming removes solids, water, gas and other impurities
extractable by vacuum dehydration and fi ltration.
• Re-refi ning removes both soluble and insoluble impurities and most additives, effectively bringing the used oil back to a pure base stock. It would then need to be readditized.
Avoid Additive Leaching Particle contamination in a lubricating or hydraulic system is
widely known as one of the most devastating contaminants. One effect of particle contamination that is rarely discussed is additive leaching. Many additives attach to particles and are removed along with the particle by fi ltration.
Oil Sampling Strategies When sampling new oil deliveries for testing, one strategy is to
pull the sample from just above the drum or tanker compartment bottom — where contamination is most concentrated. Dispensing lines from bulk transports may also be a good choice (the fi rst and last fl uid out).
LUBE TIPS
Readers Supply Super Solutions and Sound Suggestions
48 | September - October 2011 www.MachineryLubrication.com
I’ve been instructing the Fundamentals of Machinery Lubri-cation course for a few years now, and many times the
course has been the birthplace of the articles I’ve written. The ques-tions and discussions in the course are very representative of what the average maintenance professional is curious about. Most tend to like the discussions about passenger car and truck oils because they not only affect them at work but also at home. In fact, I use this curiosity to my advantage. If I ever notice a subject is starting to bore an audience, I’ll fi nd a way to incorporate an automotive twist to it. Soon all the ears seem to perk up. This article is no different. I plan to explore the similarities and differences between gasoline and diesel engine oils to appease your curiosity.
In the broadest sense, gas and diesel engine oils have the same anatomy or makeup. They are formulated from the blending of base oils and additives to achieve a set of desired performance characteristics. From this simple defi nition, we start to diverge when examining the lubricant’s required performance for each engine type.
Emissions and the Catalytic Converter A catalytic converter is a housing that contains porous metal
fi ller located between the engine and muffl er in the exhaust system. Its role is to convert toxic emissions coming from the engine to stable byproducts before they enter the atmosphere. Some of the byprod-ucts of combustion (lead, zinc and phosphorus) can severely cripple the converter’s ability to perform this job. Therein lies the fi rst major difference between the oils. Diesel engine oils have a higher anti-wear (AW) load in the form of zinc dialkyldithiophosphate (ZDDP). The catalytic converters in diesel systems are designed to be able to deal with this problem, while the gasoline systems are not. This is one of the main reasons you don’t want to use a diesel engine oil in your gasoline engine. If your automobile was built prior to 1975, there is a good chance it does not have a catalytic converter, and thus the above statements do not apply.
Viscosity Viscosity is the single most important property of a lubricant. When
I am working as a consultant and designing a lubrication program, one of the fi rst steps I take is to calculate required viscosities. Getting the right viscosity is of the utmost importance. The selected viscosity needs to be pumpable at the lowest start-up temperature while still protecting the components at in-service temperatures.
Typically, diesel engine oil will have a higher viscosity. If we were to put this higher viscosity in a gasoline engine, several problems might arise. The fi rst is heat generation from internal fl uid friction. I’ve covered before how this heat affects the life of an oil. A good rule of thumb is that for every 10 degrees C you increase the temperature, you cut the life in half. The second problem is the low-temperature pumpability of this higher viscosity. During cold starts, the oil may be very thick and diffi cult for the oil pump to deliver to the vital engine components in the lifter valley. This most certainly will lead to premature wear, as the components will be interacting without the benefi t of lubrication.
Additive Levels Diesel engine oil has more additives per volume. The most preva-
lent are overbase detergent additives. This additive has several jobs, but the main ones are to neutralize acids and clean. Diesel engines create a great deal more soot and combustion byproducts. Through blow-by, these fi nd their way into the crankcase, forcing the oil to deal with them. When you put this extra additive load in a gasoline engine, the effects can be devastating to performance. The detergent will work as it is designed and try to clean the cylinder walls. This can have an adverse effect on the seal between the rings and liner, resulting in lost compression and effi ciency.
So how do you know if an oil has been designed for gasoline or diesel engines? When reading a label, look for the API (American
Petroleum Institute) doughnut. In the top section of this doughnut will be a service
designation. This designation will either start with an “S” (service or spark igni-tion) for gasoline engines or a “C” (commercial or compression ignition)
for diesel engines.
Comparing GASOLINE and DIESEL ENGINE Oils
BACK PAGEBASICS
JEREMY WRIGHT | NORIA CORPORATION
A u t o m o t i v e L u b r i c a t i o n
Getting the right viscosity is of the utmost importance.
Level 1 Certification Preparation
How to build a safe and effective lubricant storage and handling program
How to rate filters and select the right filtration for the job
Lubricant labeling and coding systems -- what works and what doesn’t
Industry’s best procedures for greasing electric motor bearings
How to get the right lubricant in the right place at the right time and in the right amount
Noria Skills Training
MACHINERYLUBRICATION
Fundamentals of
Here’s a Sample of What You’ll Learn:
Learn Precision Lubrication Skills For Maximizing Machine Reliability
Presented by
Noria CorporationEnroll Today! Visit Noria.com or call 800-597-5460
Learn Precision Lubrication Skills For Maximizing Machine Reliability
“The information from this coursecould save my company as muchas $20,000 in monthly oil costs.”
Jeff Smith, Maintenance Planner, Mueller Copper Tubes
2
Who Should Attend?• All Maintenance Professionals• Lubrication Technicians• Craftsmen or Millwrights• Equipment Operators• Laboratory Analysts• Lubrication Engineers• Maintenance Managers• Maintenance Supervisors• Manufacturing and Industrial Engineers• Operations Managers• Predictive Maintenance Technicians• Reliability Engineers
What Industries Will Benefit?• Aerospace• Automotive Manufacturing• Earthmoving• Food and Beverage • General Manufacturing• Lumber and Wood• Municipal Utilities• Petrochemical• Pharmaceuticals• Power Generation• Primary Metals• Process Manufacturing• Pulp and Paper• Rubber and Plastic• Textile• Transportation
If You Use Any Of These Machines, This Training Is A Must:• Electric Motors• Compressors• Diesel Engines• Final Drives• Gas Turbines• Gearboxes• Hydraulic Systems• Hydrostatic Transmissions• Paper Machines• Process Pumps• Rolling Mills• Steam Turbines• Blowers/Fans
Enroll Today! Visit Noria.com or call 800-597-5460
Improve Equipment Meantime Between Failures
An Organized And SafeLubricant Storage Room
Extend Machine Life
By Up To
Solve Water-In-Oil Problems Squeeze Maximum Life
From LubricantsLubricants and hydraulic fluids can have infinite life when specific operating conditionsare stabilized. The rising costs of new lubricants and the disposal costs of usedfluids are directives for change. Learn aproven action plan for extending fluid life.
Reduce Electric MotorFailures and ReplacementCosts
Improve HealthAnd WorkplaceSafety
Stop Pesky Oil And Hydraulic Fluid LeaksLeakage is a festering sore to a machinemaintenance program. It is often the symptom of a host of other problems. If leftunchecked, reduced machine performanceis imminent. Eliminating leakage involvesthe lubrication and oil analysis programsand should be a principal goal.
A More Effective Oil Analysis Program
When the goals of a lubrication program are in sync with the oil analysis programobjectives, oil analysis becomes far moreeffective. Learn how to align the programsfor maximum results.
Effectively Troubleshoot Lubricant-related MachineFailures
Stop CostlyBearing Failures
Compare And Select TheBest Lubricants For The JobWith hundreds of lubricant types, basestocks, additive packages and viscositygrades to choose from, how can a persondecide which lubricant is right for a machine?The options are endless… synthetic or hydrocracked?… EP or AW?… naphthenicor paraffinic?… ISO VG 32 or 68?
Reduce Energy And Fuel Costs
Create More Effective Lubrication PMs
Solve Annoying Hydraulic System Problems
Spend Less On LubricantsAnd Filters – Not More
10XApply What You Learn And Reap The Benefits
This course will empower you with the knowledge to understand important lubricant properties and strategies to select the correct lubricant for each machine application.
Satisfied Customers Say It Best…
“Packed with powerful information that can beapplied with measureable results, this courseprovides the right training to influence a cultural change in maintenance and operationorganizations.” Brian Baldwin, Reliability Engineering Manager, Dynergy
“ABSOLUTELY AWESOME! Should reducedowntime 25 to 50 percent.” Scott Gilreath, Lube Tech, UNICCO
“Until I attended this training, I had no idea howpoor our best practices were. Improvementswill be easy. Justifications will be easy. Recouping the cost of this class will take about a week!”Tim Pendley, Mechanical Engineer, Westlake Chemical
“Implementing the basic principles taught during this training would prevent prematurefailure of most all of our rotating machinery!”Brittany Russo, Reliability Engineer, Braskem
“I think the information I learned can improveour hydraulic systems by 40 percent.” Vernon Player, PDM Tech, International Paper
“This training set a good foundation of knowledge to make a measurable difference in our lubrication program.”David Hull, Reliability Supervisor, Holcim, Inc.
“This course has provided me with an in-depthview on how to create a world-class lubricationprogram.” Dennis Hill, Facility Engineer, Alcoa
“Vendor-neutral Makes A Difference!”
Alfredo Romaro,Maintenance Technician,
Kawneer Company
You’ll Gain Practical New Skills That YouCan Use Right Away:
3
The Secrets Of Lubricant Selection.
Right lubricant, right time, right quantity and right place. If these fourbasic elements aren’t properly addressed, you could be doing yourequipment more harm than good. Learn the newest methods for implementing the best lubrication practices.
The Four Rs Of Lubrication.
In the hands of an untrained operator, a grease gun can deliver pressureup to 15,000 psi. That’s 30 times what a typical bearing seal can handle. Once the bearing seal is broken, the bearing is on its way toearly failure. This course will teach you proper grease gun practices.
Grease Gun Or Lethal Weapon?
Learn how to get data-rich oil samples, exactly where to install oilsampling ports, and what sampling equipment should and shouldn’t be used.
Effective Oil Analysis With Precision Oil Sampling.
Learn how award-winning maintenance programs design lube storageareas, dispensing stations and transfer carts.
The Best Practices For Lubricant Storage, Handling And Dispensing.
When you leave this course, you’ll consideryour course manual an indispensable on-the-job reference for years to come.
Enroll Today! Visit Noria.com or call 800-597-5460
What You Get When You Attend• Case Studies• How To’s• Worksheets
• Checklists• Look-up Charts
If you aren’t using the correct lubricant at the right time in the right quantity and in theright place, you could be doing your equipment more harm than good. Modern lubrication programs have changed considerably from “old school” methods that have been passed down through generations.
This course contains a strategic collection of the very best practices for applying and managing lubrication that you can take home and begin using right away.
Take The Guesswork Out OfMachinery Lubrication
How Lubrication Affects Machine Reliability• Financial benefits from achieving lubrication
excellence • Four equipment maintenance strategies and
when each applies • Important implementation steps to lubrication
excellence
Lubrication Fundamentals• Six important functions of lubricating oils • How oils and greases are formulated and why it
is important • How friction is generated in lubricated machinery• The importance of oil film thickness and critical
clearances
Understanding Additives, Base Oils And Grease Thickeners
• How lubricant properties irreparably change • Seven important physical properties of a base oil • The importance of API’s five base oil categories• What causes grease to dry out and 18 ways to
prevent it• How to detect the root causes of lubricant oxidation• When to select one of the six most commonly
used synthetic base oils • How to use temperature to determine the right
base oil for your machine • How to select grease thickeners for your application
Lubricant Performance Properties
• Key additives that enhance lubricant performance• Viscosity grades, measurement and reporting • Why Viscosity Index is important• What causes oil viscosity to change and how to
set monitoring limits• Lubricant performance tests and reporting
– what you need to know • How water contamination generates other
contaminants • How to control and eliminate aeration problems
Food-grade And Environment-friendlyLubricants• Important USDA requirements and government
regulations for food-grade lubricants• What you need to know about food-grade
additives, base oils and grease thickeners • Guidelines for food-grade lubricants
Lubricating Grease Application Methods
• How to protect against incompatible grease mixtures
• Advantages and disadvantages of centralized lubrication systems
• Best practices for greasing motor bearings
• How to control pressure when greasing bearings
• The unique problems caused by over-greasing – specific steps to eliminate
• 3 critical instructions to give your electric motorrebuild shop
• Comparing single- and multi-point lubrication options
• How to calculate greasing intervals and quantity
• Best practices for ultrasonic/sonic-based greasing
Lubricating Oil Application Methods
• Overview of oil lubrication methods and devices
• How to use oil mist and other automatic lubrication methods
• Using pressure spray methods for gearboxes
• Best practices for the maintenance of greaseguns and fittings
• How to protect against problems caused byconstant-level oilers
• Overview of single-point direct lubrication systems
Journal Bearing Lubricants
• The 8 most common journal bearing lubricationproblems
• How to select journal bearing viscosity based onspeed
Rolling-element Bearing Lubricants
• The nine critical factors affecting rolling-elementbearing lubricant selection
• How to convert required operating temperatureviscosity to ISO viscosity grades
Gear Lubricants
• 5 key requirements for gear oil
• How to select the best viscosity for a gear lubricant
• Best practice guidelines for storing spare gear-boxes – lubrication matters!
• 10 conditions that may require synthetic gear lubricants
• Lubrication best practices for enclosed gears – a 12-point checklist
• Mastering the challenges of open gear lubrication
3MAlabama PowerAlcoaAlumaxAmerenAmerican Electric PowerArcelorMittalArcher Daniels MidlandBarrick GoldstrikeBHPBoeingBoise CascadeBPCargillCastrolCaterpillarCentralia MiningChevronCitgoClopayConAgra FoodsConocoPhillipsConstellation EnergyDow ChemicalDow CorningDTE EnergyDuPontDynegyEli LillyEntergyExxonMobilFirst EnergyFlorida PowerFord Motor Co.Formosa PlasticsGeneral ElectricGeneral MotorsGeneva SteelGeorgia PacificGeorgia PowerGoodyearGreat Lakes ChemicalHarley-DavidsonHolcimHoneywellIntel
HeinzHouston Metro TransitInternational PaperInvistaJohn DeereKinder MorganKoch IndustriesLockheed MartinLukens SteelM&M MarsMillerCoorsMichelinMosaicNoranda AluminumNova ChemicalsOwens CorningOxyChemPacific Gas & ElectricPeabody EnergyPfizerPowder River CoalPPG IndustriesProcter & GambleProgress EnergyReliant EnergyRio TintoSeattle TimesSeminole ElectricShell OilSouthern CompanyTemple-InlandTexacoTexas InstrumentsToyotaTXU EnergyUnileverU.S. ArmyU.S. NavyU.S. Postal ServiceUSG CorporationVerso PaperVia Rail CanadaWestinghouseWeyerhaeuserWhirlpoolWillamette Industries
Join This List Of World-classCompanies That Have Benefited From Noria Training
Fundamentals Of Machinery Lubrication
Course Outline
4 Enroll Today! Visit Noria.com or call 800-597-5460
Automotive And Mobile Equipment Drive-line Lubricants• How to read a motor oil label – what really matters• The six critical objectives a motor oil must accomplish• Understanding API service classifications for
engine and gear oils• The No.1 reason automatic transmission fluids fail
and how to protect against it• Service classifications for automotive greases – how
to select• Extending engine life – surprising engine oil filter
study results
Compressor Lubricants• Steps you can take right now to combat compressor
lubricant failure• The most common compressor lubricant stressors• When to use synthetic compressor lubricants
and why
Steam And Gas Turbine Lubricants• Why turbine/generator lubricants are the No.1
contributor to forced outages• Comparing steam and gas turbine oils – how
they differ• Checklist for best practice steam turbine lubrication
Hydraulic Fluids• How to select the ideal hydraulic fluid viscosity for
gear, vane and piston pumps• Nine key hydraulic fluid requirements and why
they matter• Specific conditions that may require a synthetic
hydraulic fluid• Fire-resistant hydraulic fluids – what you need
to know• Hydraulic system maintenance best practices
– 21-point checklist
Contamination Control• Strategies for building reliability through
contamination control • The seven most destructive contaminants and how
to control them • Specific steps for managing a proactive lubricant
management program • The ISO Solid Contaminant Code – understand it,
track it • 10 ways to get more mileage out of portable
filter carts • How dirt, metal particles and soot mechanically
destroy machine surfaces
• Guidelines for controlling machine surface fatigueand extending machine life
• The No.1 cause of machine wear and how to manage it• How to set realistic cleanliness levels for lubricants• Effective lubricant contamination control strategies
for extending machine life• 4 ways water contamination attacks lubricant
additives• How to set limits for water-in-oil contamination• Managing the root causes of foam and aeration• Best practices for excluding and removing
contaminants• The right way to control contamination in tanks and
sumps• How oil filters are rated • Calculating the clean-up rate for portable filters• Best practices for removing water contamination
from oil• The unique problems created by varnish – how to
remove and stop it
Oil Drains, Flushing And Reservoir Management
• How to optimize and extend oil change intervals
• Interval vs. condition-based oil changes – pros and cons
• Metrics for monitoring lubricant consumption
• Best practices for oil changes
• Know how and when to perform a flush
• The best procedures for oil draining and refilling
• How and when to use the bleed-and-feed strategyfor extending oil drains
• Selecting the right cleaning and flushing procedures
Storing, Handling And Managing Lubricants
• How to set up a world-class lube room
• How to know when to reject a new oil delivery
• How to optimize your lubricant selection and procurement process
• How to implement a lubricant consolidation program and select suppliers
• Used lubricant storage, handling and disposal bestpractices
• Bulk lubricant storage do’s and don’ts
• Guidelines for storing and handling drums
• Lubricant dispensing options and what you mustavoid
• Lubricant coding and identification systems – what works and what doesn’t
• Portable oil transfer and filter cart selection advice• How and where to store oil transfer and filter carts• Understanding and managing lubricant storage life• Keeping grease fresh – best practices for storage
Design And Inspect for Lube Excellence
• World-class strategies for accessorizing equipmentfor lubrication excellence
• Seven critical accessories for lubricant inspectionand sampling
• The right machine accessories for effective contamination control
Used Oil Sampling And Analysis Fundamentals
• What oil analysis can tell you • Types and categories of oil analysis • Applications for oil analysis • Overview of oil analysis tests • Elements of a successful oil analysis program • How clean should oil sample bottles be? • How to find the best sampling locations • Oil sampling valve and hardware recommendations • A quick method for optimizing sampling intervals • An oil sampling technique that ruins trending • The importance of primary and secondary
sampling points• Advice for sampling hard-to-reach machines • How to properly sample circulating systems • Safe, effective high-pressure sampling from
hydraulic systems
Essential Field Inspections
• 12 questions your oil filter will answer about yourmachine
• Visual inspections you can get big results fromright now
• Quick tips for using scent, sound and touch to inspect lubricants
Fundamentals Of Machinery Lubrication
Take This Course Online!
Get Started Now Visit LubeIQ.com
5Enroll Today! Visit Noria.com or call 800-597-5460
6 Enroll Today! Visit Noria.com or call 800-597-5460
Get Certified!
Level I certification testing will be held on the Friday following the training by the International Council for Machinery Lubrication.
How To CertifyThere are two ways to register for a certification exam.
Online:www.LubeCouncil.orgPhone: 918-259-2950
Which Certifications?This course is designed to help you prepare for the following ICML certificationexams:
• Level I Machine Lubricant Analyst (MLA)
• Level I Machine Lubrication Technician (MLT)
Find out more about these ICML certification exams at the ICML web site:www.LubeCouncil.org
What Is ICML?The International Council for MachineryLubrication (ICML) is a vendor-neutral,not-for-profit organization founded to facilitate growth and development of machine lubrication as a technical field ofendeavor. Among its various activities, ICMLoffers skill certification testing for individ-uals in the fields of machine conditionmonitoring, lubrication and oil analysis.
On-Site Training
We can customize Fundamentals of Machinery
Lubrication – or any of our other courses– to meet your unique needs. We’ll provide expert instruction at a time andplace most convenient for your group.Want to know more? Call 800-597-5460.Whether you have 5 or 500 people totrain, Noria is the answer.
From Our Resource Center...The Level 1 Study PacketThe Level 1 MLT / Level 1 MLA Study Packet Includes:
Flash Card Pack 385 flash cards to help you prepare for bothICML Level I MLT and Level I MLA certification.
125-Question Practice Exam This multiple-choice practice test is a great self-assessment tool and helps you prepare for both ICML Level I MLT and MLA certification. Licensed for use by one person.
How To Take A Multiple-Choice Exam Includes advice from professionals who have passed ICML certification exams as well as helpful hints for the night prior to the exam, steps to takebefore entering the exam room, techniques to manage your time during the exam and advice for handling different types of questions.
Lubrication Fundamentals Discusses lubricant basics, machine elements that require lubrication,methods of application, lubrication, lubricant storage and handling, and lubricant conservation.
Oil Analysis Basics Presents the fundamentals of oil analysis for machinery condition monitoringin an easy-to-understand format. You’ll learn everything from how to take a proper oil sample to how to select a test slate for your applications.
The Practical Handbook Of Machinery Lubrication Once you start reading this book, you probably won’t stop until you finish it. It is that easy to read. You’ll find understandable explanations of how lubricants work, what they’re made of and how they break down. Topics ranging from engine lubricants to industrial oils and hydraulic fluids are covered.
Retail Price: $410.95 Your Price: $355Plus $14 for shipping in the U.S.
TrainersJim Fitch Jim Fitch, a founder and president of Noria Corporation, is a highlysought-after consultant and trainer described by his clients as “insightful,dynamic and thorough.” He has advised hundreds of companies on developing their lubrication and oil analysis programs and has taughtmore than 400 training courses in more than 20 countries.
Jeremy WrightJeremy Wright, a Noria senior instructor, provides a lively interactiveforum for learning at his courses. As a consultant, Jeremy has helpednumerous Fortune 500 companies develop lubrication procedures,benchmark to best practices and implement world-class lubrication programs.
Bob ScottBob Scott brings to his courses a wealth of “in the trenches” experience.His practical “how to” advice and engaging teaching style consistentlyreceive top scores from audiences. You’ll reap the benefits from his25+ years of experience with lubricants, lubrication and oil analysisand come away from the training with solid, practical skills.
Preparation Tools ForICML Level 1 MLT And Level 1 MLA
Registration InformationCheck-in: Tuesday, 7:30 a.m. – 8:00 a.m.Program: Tuesday – Thursday, 8:00 a.m. – 4:00 p.m.
The fee for Fundamentals of Machinery Lubrication is $1,195 perperson. For fast registration, call 800-597-5460 ext. 143 toll-freebetween 8 a.m. and 5 p.m. central time Monday through Friday. Or, fax your registration form to 918-746-0925 at any time. The faxline is open 24 hours a day, seven days a week. We will send aconfirmation of your registration via e-mail. If your confirmationdoes not arrive within 48 hours, please contact us to process yourregistration immediately. In lieu of cash, check and credit cards arepreferred when paying at the training site.
What’s IncludedYour fee provides you the best training around, a comprehensivemanual, a free package of training materials, continental breakfast,lunch each day and refreshments. Certification exam fees are notincluded.
Cancellations And SubstitutionsYou may cancel your registration prior to the course date or send asubstitute. If you cancel prior to the course date, we will refundyour entire payment, cancel your invoice or, if you prefer, applyyour payment to another Noria program of your choice scheduledwithin 12 months of your original event. Please note that if you donot cancel and do not attend, you are still responsible for payment.
Certification ExamsCertification testing is offered by the ICML the morning followingthis training course at the same hotel. Please contact the ICML toregister for the certification exam or register online at their web site:
International Council for Machinery LubricationPhone: 918-259-2950 • Fax: 918-259-0177E-mail: [email protected] • Online: lubecouncil.org
4 Ways To Register
Payment is due before the course
❑ Check enclosed payable to: Noria Corporation
Mail to: Noria CorporationATTN: Training1328 East 43rd CourtTulsa, OK 74105
Call toll-free!800-597-5460 Or 918-749-1400
Fax your registration!918-746-0925
Mail the registration form!
Onlinewww.noria.com
2011 Locations And DatesThe phone numbers below are for booking hotel reservations only. To register for the course call 800-597-5460 ext. 143.
Seattle, WAJuly 26-28, 2011Red Lion Hotel18220 International BlvdSeattle, WA 98188800-733-5466
Nashville, TNAugust 16-18, 2011Sheraton Nashville Downtown623 Union StreetNashville, TN 37219800-325-3535
Las Vegas, NVSeptember 20-22, 2011Rio All-Suites Hotel & Casino3700 West Flamingo RoadLas Vegas, NV 89103888-746-6955
Branson, MOOctober 4-6, 2011Hilton Promenade at Branson Landing
3 Branson LandingBranson, MO 65616417-336-5500
New Orleans, LANovember 8-10, 2011Chateau Bourbon800 Iberville StreetNew Orleans, LA 70112888-404-6875
San Diego, CADecember 6-8, 2011Courtyard by Marriott595 Hotel Circle SouthSan Diego, CA 92018619-481-5720
Check Noria.com for more dates and locations
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