lmt mayjune 2010
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Lubrication Management & Technology May/June 2010 magazine...Achieving Efficiencies Through Practices & ProductsTRANSCRIPT
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Fluid Contamination Under Control with…Innovative Filtration Products, Support, and SolutionsMake Hy-Pro a part of your lube team and arm yourself with tools and industry expertise to maximize reliability from your hydraulic & lube assets. Hy-Pro will help you develop and implement strategies to achieve and maintain target fluid cleanliness levels and extend useful fluid life.
www.hyprofiltration.comMade in U.S.A., ISO 9001 Certified
Fishers, Indiana U.S.A. +1.317.849.3535
Lube Oil Contamination Solutions
Maintain Control Over Fluid Contamination
Fluid Contamination Under Control
COT CoalescerRemoves Water
& Particulate
DFE RatedFilter Element Upgrades
With Water Removal Capacity
VUD Vacuum DehydratorRemoves Water
& Particulate
Fluid contamination is the leading cause of component failure and system breakdown. Hy-Pro’s DFE rated filter elements and fluid conditioning equipment extend component and useful fluid life by removing particulate and watercontamination from your fluid.
Keep fluids in bulk storage clean & dry with dedicated off-line skids for particulate and water removal.
New oil is typically too dirty for lube and hydraulic systems. Use Hy-Pro equipment to transfer and condition fluids to critical systems.
Drum Top Filter Tote for Fluid Transfer & Side Loop Filtration
MAY/JUNE 2010 www.LMTinfo.com | 3
ContentsMAY/JUNE 2010 • VOL 11, NO. 3 • www.LMTinfo.com
ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
CONDITION MONITORING
FEATURES
6 The Case Of The Crucial Spare Armed with an arsenal of powerful predictive maintenance tools, the investigators at a nuclear power plant took all the right steps to eliminate a problem with a critical cooling-water pump before it could impede the progress and vastly increase the cost of a planned shutdown. Ray Thibault, CLS, OMA I & II, Contributing Editor
14 Lubricant Storage & Handling Tips For World-Class Contamination Control Contamination never quits, nor should you when it comes to fi ghting this destroyer of lubricants and the equipment and systems to which they’re applied. Revisiting and, perhaps, rethinking how your site stores and handles its new lubricants is a great way to strengthen your punch.
Jarrod Potteiger, Des-Case Corporation
16 Another Success All The Way Around Check out who was there and what you may have missed!
19 ■ Big Money Talks ■ Making Energy Audits Feasible
26 Sustainability And Your Facility: It’s All About Choices You’re not alone in this ongoing journey. Just ask your suppliers. M. Randi Young, LEED AP, Grainger
A CLEAN PUNCH
MARTS 2010 RECAP
DEPARTMENTS 5 From Our Perspective
23 Motor Decisions Matter
24 Green Edge Showcase 28 Solution Spotlight
29 Problem Solvers
32 Supplier Index
© S
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UTILITIES MANAGER
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May/June 2010 • Volume 11, No. 3
ARTHUR L. RICEPresident/CEO
BILL KIESELExecutive Vice President/Publisher
JANE ALEXANDEREditor-In-Chief
RICK CARTERExecutive Editor
KENNETH E. BANNISTERRAY THIBAULT, CLS, OMA I & II
RAYMOND L. ATKINSContributing Editors
RANDY BUTTSTADTDirector of Creative Services [email protected]
GREG PIETRASEditorial/Production Assistant
ELLEN SANDKAMDirect Mail
EDWARD KANEReprint Manager
800-382-0808, ext. [email protected]
Editorial Offi ce1300 South Grove Ave., Suite 105
Barrington, IL 60010847-382-8100 / FAX 847-304-8603 www.LMTinfo.com
Lubrication Management & Technology (ISSN 1941-4447) is published bi-monthly by Applied Technology Publications, Inc., 1300 S. Grove Avenue, Suite 105, Barrington, IL 60010. Periodical postage paid at Barrington, IL and additional o� ces. Arthur L. Rice, III, President/CEO. Circulation records are maintained at Lubrication Management & Technology, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Lubrication Management & Technology copyright 2010. No part of this publication may be reproduced or transmitted without written permission from the publisher. Annual subscription rates for nonquali� ed people: North America, $140; all others, $280 (air). No subscription agency is authorized by us to solicit or take orders for subscriptions. Postmaster: Please send address changes to Lubrication Management & Technology, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Please indicate position, title, company name, company address. For other circulation information call (630) 739-0900. Canadian Publications Agreement No. 40886011. Canada Post returns: IMEX, Station A, P.O. Box 54, Windsor, ON N9A 6J5, or email: [email protected]. Submissions Policy: Lubrication Management & Technology gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned.
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4 | LUBRICATION MANAGEMENT & TECHNOLOGY MAY/JUNE 2010
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Achieving Effi ciencies Through Practices & Products
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ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS
FROM OUR PERSPECTIVE
Ken Bannister, Contributing Editor
I grew up in the shadow of The Beatles, in the industrial port city of Liverpool, England. Dad was a fleet-truck mechanic for a frozen-food company; Mom was a seamstress.
While both were skilled workers, due to our modest post-WWII means, the only family transportation was a motorcycle and sidecar— a British motorcycle that Dad regularly needed my “help” to “fix.” Always up for a challenge, I would dive in, shouting, “I six it! I six it!”
I must have shown real promise. On my third birthday, I received my first toolbox. It was an honest-to-goodness toolkit with a small wood saw—sharp metal teeth included—a hammer, rule, screwdriver and wrenches, all packed neatly in a wooden chest (no plastic for kids back then). Armed with these tools, I embarked on a relent-less campaign to re-engineer everything I could put my hands on. Nothing was spared, including a leg of the family’s heirloom dining room table that I sawed halfway off!
Despite such setbacks, my parents continued to be supportive, supplying items for me to dismantle, then helping me reassemble them, patiently providing answers to my constant “Why?” “Why?” “Why?” At the early age of three, my destiny was sealed: I was, and remain, an incorrigible tinkerer, fascinated by the design and inner workings of all things man-made.
At the recent MARTS 2010 event in Chicago, Keynote speaker John Ratzenberger (famous for his work in the Cheers and John Ratzenberger’s Made in America television series and all Pixar films to date) introduced us to the work of his “Nuts, Bolts & Thingamajigs Foundation” (NBT). Through humor-laden personal testi-mony, this self-confessed, inveterate tinkerer evoked powerful memories in quite a few of us in that room full of skilled maintenance pros. Who among us wasn’t thinking back to a time when someone first encouraged us to find our inner “tinkerer,” something that helped define both our careers and our self-esteem?
Ratzenberger’s NBT organization works to introduce young people to the joys of working with their hands through sponsored summer industrial camps, and provides scholarships for those pursuing technical degrees at trade schools and colleges. A skilled carpenter turned actor, he has long recognized what much of North America seems afraid to accept—that our one-time manu-facturing might, supported by the greatest skilled workforce in the world, is rapidly disappearing. With an average skilled-worker age of 56, and no national backup plan to replace these critical “assets” once they retire, we’re facing one of our greatest challenges ever. An early, widespread addiction to television, along with a pervasive video-gamer numbness and the closing of school “shop” programs, have led to an almost non-existent pool of up-and-coming tinkerers to fill the critical skilled-trade positions of tomorrow.
John Ratzenberger has had enough—he’s out there trying to “six it.” Let’s help. Let’s encourage our own children and grandchildren and those of others to tinker. Help them see that learning a skill is not only for life, it’s an honorable pursuit. One way to do this is by sending a deserving youngster to a Nuts, Bolts & Thingamajigs Camp!
Go to www.nutsandboltsfoundation.org ASAP. Consider helping sponsor, or getting your company to help sponsor, a new generation of tinkerers. Working together, we can help “six it!” We can help secure North America’s future, and make our industries great again! LMT
‘I Six It’
MAY/JUNE 2010 www.LMTinfo.com | 5
Consider helping sponsor, or getting
your company to help sponsor,
a new generation of tinkerers.
6 | LUBRICATION MANAGEMENT & TECHNOLOGY MAY/JUNE 2010
CONDITION MONITORING
Ray Thibault, CLS, OMA I & II Contributing Editor
Armed with powerful predictive maintenance tools,
investigators took the right steps to eliminate a problem
with a critical cooling-water pump before it could
impede the progress and up the cost of a planned shutdown.
CSI: Critical Equipment
The Case Of The Crucial Spare
MAY/JUNE 2010 www.LMTinfo.com | 7
CONDITION MONITORING
Data results & evaluation:Both centrifugal pumps were normally sampled every six months for routine in-house oil analysis. Pump #2 (P2) was to serve as the main pump for an upcoming outage; Pump #1 (P1) was to serve as the spare. During routine evaluation, the spare pump (P1) showed a high lubricant viscosity of 58.2 cSt. Table I illustrates the results for a more complete evaluation comparing the results to the previous sampling period and the new oil reference.
Analytical ferrography was run on the oil sample and indicated large amounts of brass sliding wear and small ferrous-particle wear.
Evaluation of the main pump (P2) indicated no major wear metals. With an oil viscosity of 33.2 cSt and an ISO Cleanliness Code of 19/16, this unit was deemed ready for use during the outage.
The problem came about in properly preparing P1 as backup for the outage. The investigation found that the wrong oil had been added to the backup pump and a fl ush and change-out was scheduled. (The results of the oil analysis from the bearing housing are shown in Table II.) At that point, the pump was drained, fl ushed and run for 30 minutes.
Based on the results in Table II, investigators concluded that the oil had been added without a fl ush, resulting in a higher viscosity than the added new oil, and that the wear particles in the bottom had been agitated—which, in turn, led to high wear particles in the sample.
After fl ushing, P1 was fi lled with new oil. It was then run for 12 hours with vibration and infrared thermographic readings taken to identify any bearing defects. The results of a subsequent oil sample evaluation are shown in Table III.
The fl ush and new oil brought the viscosity back in range, but wear metals were still high. The question was where were they coming from, and would they fail the pump if it had to be run for 10 days during the outage? Infrared ther-mography showed no problems in the pump; the vibration readings, though, turned up the following results:
This case study details the use of oil analysis and other powerful condition-monitoring
techniques in the identifi cation and resolution of problems with critical equipment
at a large nuclear power plant. The equipment in question was a centrifugal cooling-
water pump used in the shutdown process before an outage. It goes without saying
that in a nuclear plant, each piece of critical equipment must have a spare that is capable
of functioning at 100%. In this case, two cooling-water pumps were both required to func-
tion at 100% during shutdown. These units were rotated during shutdown events, with one
being the main pump and the other the spare.
This case study details the use of oil analysis and other powerful condition-monitoring
techniques in the identifi cation and resolution of problems with critical equipment
at a large nuclear power plant. The equipment in question was a centrifugal cooling-
water pump used in the shutdown process before an outage. It goes without saying
that in a nuclear plant, each piece of critical equipment must have a spare that is capable
T
Test Results ISO Cleanliness Code 23/20 Viscosity, cSt 34.3 Fe (ppm) 68.2 Cu (ppm) 207 Pb (ppm) 40.4 Zn (ppm) 18.8 Sn (ppm) 9.8
Table III. P1 Bearing Housing Oil Sample After Flushing & Change-Out
Test Results ISO Cleanliness Code 25/22 Viscosity, cSt 40.8 Fe (ppm) 51.5 Cu (ppm) 226 Pb (ppm) 34.6 Zn (ppm) 21.4 Sn (ppm) 9.5
Table II. P1 Original Bearing Housing Oil Sample
New Oil Most Recent Previous Test Reference Sample Sample ISO Cleanliness Code 15/12 22/18 20/16 Viscosity, cST 32.0 58.2 28.7 Fe (ppm) 35.9 3.5 Cu (ppm) 88.9 1.2 Pb (ppm) 32.1 9.2 Sn (ppm) 4.8 0.1 Zn (ppm) 6.6 7.5 1.1
Table I. P1 Bearing Housing Oil Sample
8 | LUBRICATION MANAGEMENT & TECHNOLOGY MAY/JUNE 2010
CONDITION MONITORING
n All readings low
n Bearing defect frequencies very low
n Possible very early inner- and outer-race defects (spike energy)
n Bearing pre-Stage 1 failure
The investigators, therefore, began trying to identify the source of the wear metals and the effect on the pump’s reliability. The fi rst step was to determine the metallurgy of the pump components and to utilize a powerful technique in the determi-nation of the wear particles’ compo-sition by element and amount. These particles were evaluated with use of a scanning electron microscope (SEM), as depicted in Fig. 1.
SEM utilizes electron versus light to form an image of the particle, thus allowing for accurate determination of the element and its percentage in a particle. The samples were prepared with the use of a glass ferrogram slide and a patch. Each of the preparation techniques had its advantages and disadvantages, and the results are a composite of both.
Before the results of SEM could be utilized, a comparison needed to be made to the actual composition of the pump components that could cause the wear. The pump and its components are illustrated in Fig. 2.
Fig. 1. A scanning electron microscope (SEM) used to evaluate composi-tion of wear particles by element and amount (courtesy of Slater)
Identifying the problem
early helped investigators
take all the right steps
in dealing with it.
Continued on Page 12
ElectronBeam
MagneticLens
To TVScanner
BackscatteredElectronDetector
SecondaryElectronDetector
ScanningCoils
StageSpecimen
Electron Gun
Anode
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12 | LUBRICATION MANAGEMENT & TECHNOLOGY MAY/JUNE 2010
CONDITION MONITORING
Individual manufacturers were contacted to obtain the exact metallurgy of the components they supplied for the P1 unit. (Table IV lists the elemental composition of these components.)
After matching the SEM results with the component metallurgy, the investigators concluded that the wear came from the inboard cover (bronze) and the defl ector (grey cast)—components that have only a minor impact on
pump performance. The next question was whether the high levels of abrasive wear generated by these two components would affect bearing life.
The ultimate feasibility of utilizing P1 as a backup without repair had to be established. An outage was scheduled and not enough time was available to repair the pump. Each day of delay would cost $1 million. That’s why it was so crucial to determine if the pump could last a maximum of 10 days (or 240 hours).
The L10 rating of the bearing based on its dynamic load was 5,000,000 hours under ideal conditions. The penalty for a contaminated lubricant reduced the factor by about 500. The L10 life of the bearing was calculated to be 96,700 hours with the contamination penalty.
Stage 1 failure of a bearing means there is probably 10% L10 life remaining—which meant P1’s bearings had about 10,000 hours of life left in them. Since the maximum life required for these bearings to function in the pump for the outage was 240 hours, there was a safety factor of 40 or more.
Based on the bearing calculations, it was determined that no repair was required until after the outage. The following recommendations were made:
n Vibration readings were to be taken at least once per day during the outage to detect early signs or accelera-tion of bearing damage.
Fig. 2. The problematic cooling-water pump (P1) and its components (courtesy of Slater)
Table IV. P1 Component Metallurgy (According To Component Manufacturers)
Element, Slinger Ring Inboard Inboard SKF % Ring Spacer Defl ector Cover Bearings Fe 0.15 99.0 0.3 95.0 98.0 Cu 87.0 85 Pb 0.3 5.0 Zn 1-3 1.0 Ni 1.0 5.0 Sn 10.0 Mn 0.4 0.3 Cr 1.4 Si 0.05 2.0 0.025 P 0.05 0.04 0.025
Bearings & Cage
Ring Spacer
Inboard Defl ector
Inboard Cover
Slinger Ring
MAY/JUNE 2010 www.LMTinfo.com | 13
CONDITION MONITORING
n P1 was to be scheduled for teardown and inspection of its bearing-housing components soon after the outage.
n All parts were to be in stock for repair.
After the outage, the P1 unit was repaired. At that time, the major problem was found to be in the inboard defector disks. Improper installation of these disks was resulting in metal-to-metal contact, which, in turn, was generating high levels of wear metals.
All the right stepsBecause of the enormous consequences of failure, nuclear power plants require an extremely high level of equipment reliability. This case history is a good example of a highly competent reliability group utilizing the proper predictive maintenance tools to identify a problem early—and make the right decisions to deal with it.
As noted in this example, criticality is not based simply on the size of the equipment. The condition of a centrifugal cooling-water pump with a small lubricant reservoir— a pump used only during outages—was the key factor in
whether an outage would be on schedule and not incur a large penalty for any delay.
While oil analysis was the main tool, infrared thermog-raphy and vibration analysis were also utilized in arriving at the correct conclusion. Identifying the individual compo-nents in the bearing housing and contacting the OEMs for complete metallurgical information was a key step. The use of SEM, a very sophisticated tool not normally used in oil analysis, supplied the comprehensive information necessary to determine exactly which components were causing the wear particles in the system. Case closed. LMT
Acknowledgement The author thanks Kevan Slater, one of the most practical and knowledgeable reliability professionals in the industry, for his assistance in the preparation of this article. In addition to Figures 1 and 2, Slater also supplied Tables I, II, III and IV.
Contributing Editor Ray Thibault is based in Cypress (Houston), TX. An STLE-Certified Lubrication Specialist and Oil Monitoring Analyst, he conducts extensive training in a number of industries. Telephone: (281) 257-1526; e-mail: [email protected].
For more info, enter 64 at www.LMTfreeinfo.com
14 | LUBRICATION MANAGEMENT & TECHNOLOGY MAY/JUNE 2010
A CLEAN PUNCH
Developing and implementing a world-class contamination-
control program is a sizable undertaking that usually
requires signifi cant modifi cations to machinery—as well as
changes in procedures and methodologies that can take years.
You don’t need to wait that long, though. To quickly punch up your
facility’s contamination-control efforts, make sure you’re storing
and handling new lubricants correctly.
Is new oil clean? No. Typically, new lubricants are unsuitably dirty for most applications. There are, of course, exceptions: A few manufacturers offer a specifi ed maximum particle count, and some suppliers fi lter bulk oil as it is dispensed. It is imperative that new oil be properly cleaned prior to use. A new drum of lubricating oil will often have a particle count of roughly 19/16/13 or higher. That means every cubic centimeter of oil in the drum contains between 2500 and 5000 particles that are at least 4 microns in diameter—that’s about one billion particles for the whole drum. How do you fi ght this contamination?
#1: Get it clean. The fi rst step is to fi lter “new” oil to an acceptable level—the method for doing so depends on the method of delivery. If the lubricant comes in drums, each drum can be fi ltered using a fi lter cart. Filtering new oil as it is applied to a reservoir or dispensed into a transfer container is an excellent and inexpensive way to ensure the oil’s cleanliness when it arrives at your site.
Another popular approach involves the use of a comprehensive lubricant manage-ment system like the one in the fi gure on the next page. (This addresses a number of storage and handling issues at once). These systems can be confi gured with a wide range of options, including separate pumps and fi lters for different lubricants; high-quality desiccant breathers to prevent subsequent contamination to the fl uid;
Contamination never quits,
nor should you when
it comes to
fi ghting it.
Revisiting and, perhaps,
rethinking how your site
stores and handles new
lubricants is a great way
to strengthen your punch.
Jarrod PotteigerDes-Case Corporation
© F
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POIN
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TOLI
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MAY/JUNE 2010 www.LMTinfo.com | 15
A CLEAN PUNCH
fittings and spigots that minimize contamination; and flow meters to measure and track the amount of oil dispensed. Using such a system, users can easily clean new oil, main-tain its cleanliness, prevent cross-contamination and track consumption by product type without having to engineer the process from scratch.
#2: Keep it clean. Keeping oil clean is not difficult if you use the right tools. While it certainly helps to have an enclosed storage area with climate control, these elements are not essential for main-taining fluid-cleanliness. Common-sense measures, such as good housekeeping, wiping fittings, using dust covers, etc., go a long way in keeping dirt out of stored lubricants. The best way to prevent dirt and moisture from entering a tank or drum, though, is with a high-quality desiccant breather.
Remember this: When you remove five gallons of oil from a drum, you pull in five gallons of air. If that air is not clean and dry, the oil won’t be clean and dry. The desiccant breather prevents most particles and moisture from entering the drum. Quick-connect hydraulic fittings provide an effective means to remove and/or circulate the oil with a filter cart or drum topper without exposing the oil to the ambient atmosphere.
#3: Transfer it clean. Keep in mind that it really doesn’t matter how well you filter your new oil or how clean it’s kept in storage if you dispense that oil into a dirty container. There are several acceptable options for delivering oil to machinery—some much better than others.
For large reservoirs, the best transfer method is to use fixed plumbing to pipe the machine-reservoirs to the storage tanks. This tactic, however, is only feasible for very large systems; it’s too expensive and impractical for small equipment. For other large systems or those with a moderate-size reser-voir, the best method is usually to pump oil directly into the sump from a drum or tote tank using a filter cart.
Portable filter carts are one of the most versatile and effec-tive tools available for lubricant transfers and decontami-nation. One important thing to remember when working with these carts is to use the right fittings on the equipment sumps to make the fluid transfer or decontamination effi-cient and effective. Additionally, it’s important to consider using units that are dedicated to specific oil types—thus preventing cross-contamination of lubricants and avoiding the labor-intensive process of flushing carts to switch products.
Some manufacturers allow you to color-code your filtra-tion unit to help identify which cart should be used with a particular lubricant. As a side benefit, most users find that performing an oil change with a filter cart only takes about half as much time as doing the job with conven-tional methods.
Yet another filter cart option is to combine the storage tank and the filter cart. These types of “top-off” carts offer a convenient solution to performing oil changes and top-ups on small- to medium-size sumps. In addition to performing fluid transfers, they can be used as traditional filter carts for remedia-tion tasks; this eliminates the need for separate units for transfer and filtration.
Finally, for those applications with very small sumps or those that are located in situations that make a filter cart or top-off cart impractical, standard oil cans are acceptable, as long as they meet certain criteria. A good-quality oil-transfer container should be plastic, sealable, color-coded or marked for product type—and it must be cleaned on a regular basis. (It should also have an opening large enough to allow the inside of the container to be cleaned effectively.)
When using top-off containers, remember to avoid funnels whenever possible. Many of the new containers utilize hand pumps that eliminate the need for funnels. Don’t forget to wipe the container nozzle and the fill port area on the reser-voir before transferring the oil. Even a minute amount of material around the fill port can add millions or billions of particles to the oil in the reservoir.
It’s a knockout.World-class contamination control can’t happen in the absence of good lubricant-handling practices. Any good storage and handling policy or system has several common elements: good filtration, high-quality breathers, filter carts and a highly conspicuous tagging or color-coding system to avoid cross-contamination of products. When these four items are addressed, the fight is almost over. LMT
Jarrod Potteiger is a product and educational services manager for Des-Case Corporation, headquartered in Goodlettsville (Nashville), TN. E-mail: [email protected]; Internet: www.descase.com.
For more info, enter 01 at www.LMTfreeinfo.com
A comprehensive lubricant management system.
MARTS 2010 RECAP
16 | LUBRICATION MANAGEMENT & TECHNOLOGY MAY/JUNE 2010
MAINTENANCE and RELIABILITY TECHNOLOGY SUMMITMAINTENANCE and RELIABILITY TECHNOLOGY SUMMIT
(1) John Ratzenber-ger during his com- pelling Keynote and (2) later talking with attendees while he autographs copies of his book, We’ve Got it Made in America.
(10, 11 & 12) Attendees visit with MARTS exhibitors.
(3) Ratzenberger greets Ali Sturman, associate manager Certifi cation & Education for the Society for Maintenance & Reliability Professionals
1
2
3
10
The 2010 MARTS (Maintenance & Reliability Technology Summit) wrapped up on April 30 at the Hyatt Regency O’Hare Hotel in Rosemont, IL.
This year’s event, the 7th in an increasingly successful series of these conferences, spanned almost an entire week with 13 full-day Workshops and 32 one-hour Conference sessions devoted to issues of maintenance, reliability and energy effi ciency, among others. The 200+ maintenance professionals in attendance got to learn from and network with a number of inter-nationally known experts in the fi eld and a host of noted practitioners, consultants and manufacturers with deep industrial insight.
One of this year’s very special highlights was Keynote speaker John Ratzenberger, the well-known actor, director, author and champion of the skilled trades. He spoke for nearly 90 minutes on topics ranging from his New England upbringing and hard-work ethic to the life philosophy he’s gained through acting. It was while he was working on his Made in America television series that he became keenly aware of the shortage of trained industrial workers. This realization, in turn, inspired him to establish the Nuts, Bolts & Thingamajigs Foundation (NBT) that encourages youngsters to consider manufacturing as a career choice. Following his talk, Ratzenberger autographed copies of his book We’ve Got It Made in America for long lines of enthusiastic attendees.
Other highlights included Keynoter Bob Chernow, a futurist and fi nancial professional, who provided an analytical look into tomorrow’s business environ-ment, and the “Reliability Gives Voice to Autism” dinner and gala that kicked off MARTS week. The dinner raised funds and awareness for autism with comments from MARTS attendees who have been affected by autism, and top-fl ight entertainment.
Preparations are already underway for next year’s successful MARTS. Look for details in upcoming issues, or on www.MARTSconference.com. LMT
ANOTHER SUCCESSALL THE WAY AROUND
THE CAPACITY ASSURANCE CONFERENCE
MAY/JUNE 2010 www.LMTinfo.com | 17
MARTS 2010 presenters at work: (4) Tara Denton, Life Cycle Engineering; (5) Bill Livoti, Baldor Electric Co.; (6) Hugh Blackwood, U.S. Navy (retired); and (7) Applied Technology Publications contributing editor Bob Williamson
(8) John Ratzenberger with editor-in-chief Jane Alexander and (left to right) contributing editors Bob Williamson and Ken Bannister.
(9) Team MARTS members (left to right) Tom Madding, Bill Kiesel, Jim Hanley and Art Rice with a restored 1946 “Whizzer” motorized bicycle.
4 5
6
8 9
11 12
7
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When you think “Innovation”, you think about a better way to do the job. We think about industry-
specific solutions to your motion and control challenges, like NSK’s Molded-Oil™ bearings. This innovative
product not only delivers high performance in water and dust contaminated applications, but also
extends bearing life and eliminates the need for relubrication. When it comes to innovative
products designed to increase efficiency in food industry applications, Think NSK.
www.nskamericas.com1.800.675.9930
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VOLUME 2 / NO. 2 UTILITIES MANAGER | UM1
XX UM
Understanding Power Factor
William C. Livoti
BIG MONEY TALKS UM
If your organization is focusing to any extent on cutting energy consumption, driving sustainable growth and reducing operating costs, it’s a good idea to review power factor. Here’s a very brief
explanation.The power factor (PF) of an AC electric power
system is defi ned as the ratio of the real power fl owing to the load to the apparent power, and is a number between 0 and 1 (frequently expressed as a percentage, e.g. 0.5 pf = 50% pf). Real power is the capacity of the circuit for performing work in a particular time. Apparent power is the product of the current and voltage of the circuit.
A PF of 1.0—or “unity power factor”—is the goal of every electric utility. If the PF is less than 1.0, the utility has to supply more current to the user for a given amount of power use. In so doing, it (the utility) incurs more line losses.
Industrial facilities tend to have a “lagging power factor,” where the current lags the voltage (like an inductor). This is primarily the result of having lots of electric induction motors; as seen by the power supply, their windings act as inductors. Capacitors have the opposite effect; they can compensate for the inductive motor windings.
The signifi cance of power factor lies in the fact that utility companies supply customers with volt-amperes, but bill them for watts. The relationship can be stated as:
watts = volts x amperes x power factor
Power factors below 1.0 require a utility to generate more than the minimum volt-amperes necessary to supply the power (watts). This increases genera-tion and transmission costs. Utilities may impose penalties on customers that do not have good power factors on their overall buildings.
Watts—or real power—is what a customer pays for. VARS (volt-ampere reactives) are the extra “power” transmitted to compensate for a power factor less than 1.0. The combination of the two is called “apparent” power (VA or volt-amperes).
A low PF is expensive and ineffi cient—some utility companies may charge additional fees when it’s less than 0.95. A low PF reduces the electrical system’s distribution capacity by increasing the current fl ow and causing voltage drops.
Think of it this way: Based on personal experi-ence, many of us would acknowledge that a mug of draft beer typically has a “head” on it. Let’s say your favorite pub institutes a new policy—you pay only for beer, not foam. While foam is simply aerated beer, it’s not really usable. So, if your mug is half full of foam, you’ll pay half the price. This is the same principle as electricity generation: The consumer pays just for the beer (real power), not the foam.
Main benefi ts from power factor correction
■ The utility’s electrical load is reduced, thereby allowing it to supply surplus power to other consumers, without increasing generation capacity.
■ Most utilities impose low PF penalties; by correcting the power factor, penalties can be avoided.
■ High PF reduces load currents, which leads to considerable savings on hardware, such as cables, switchgear, substation transformers, etc. UM
Bill Livoti is a fl uid power and power industry engineer with Baldor Electric Company. He also is vice chair of the Pump Systems Matter (PSM) initiative. Telephone: (864) 281-2118; e-mail: [email protected]
VOLUME 5 / NO. 2 UTILITIES MANAGER | 19
The signifi cance of power factor
lies in the fact that utility companies
supply customers with volt-amperes,
but bill them for watts.
ENERGY
Target in on these tools, techniques and useful resources.
We’ve all heard and/or read the exhortations: “You can fi nd annual savings of $200,000, $500,000 or more, in the unlikeliest of places.” “You can save 18% on energy costs with minimal capital investments.” “You can discover enough immediate savings to pay for an energy audit and the recommended system upgrades.”
Alas, many people have dismissed such claims as fantasy. Some may think that their operations are too lean and don’t have the budget or the staff to fi nd the savings. “We’ve already cut everything we can cut. Management will never approve this use of time and money.” On the fl ip side, contractors may be hearing “not now” from clients that are already stretched too thin.
Here’s the missing ingredient: We know more now than we did, even a few years ago, about where to look for unneces-sary waste. We also know how to quantify the dollar value of that opportunity. That allows you to create a more accurate proposal that’s more likely to be approved and achieved.
Size for who you areThe big dollars are usually associated with audits at large facilities with lots of heavy machinery and little preventive maintenance. The energy audit team collects data ahead of time, spends three to fi ve days inspecting, decides what to change, then imple-ments fi xes, updates and process improvements. Depending on the facility, the inspections may cover everything from motors and drives to electronic equipment usage patterns to waste-management practices. If you can do a comprehensive audit, you should—and not just because the overall dollar amount will be larger and quicker to achieve. By inspecting multiple areas in the same time period, you’ll also notice common waste patterns and fi nd ways to leverage improvements across multiple systems. But some facilities fi nd that three days and a full team of experts and tools is just too much. For them to get started, it might make more sense to tackle one system at a time. This is fi ne, as long as you circle back to see how changes in one system have affected other areas.
Kate Anderson, ActionEco, with support from Colin Plastow, Fluke
ENERGY AUDITSUM
20 | UTILITIES MANAGER VOLUME 5 / NO. 2
Somewhere, there’s a technician climbing up onto a facility roof with a thermal imager.
Inside, the head of operations and the HVAC person are calculating the effect of raising
or lowering indoor temperatures just a bit. Someone else is over in the side offi ce with six
months of electricity bills, analyzing usage patterns and rate fl uctuations. They’re all on
a hunt—but not for critters. The big bucks these hunters are hoping to harvest are associated
with increased operating effi ciencies and reduced energy consumption. They’re tracking every-
thing, looking for savings anywhere they can fi nd them…hidden in a vent that’s stuck open…
in ineffi cient lighting…in a chiller that’s running an hour a day more than necessary…
On the hunt for big bucks...
Making Energy AuditsFeasible
UM ENERGY AUDITS
VOLUME 5 / NO. 2 UTILITIES MANAGER | 21
The leanest companies often fi nd the best value in outsourcing all or part of their energy inspection to a contractor that special-izes in energy audits. Then, as improved practices reduce the immediate troubleshooting load, existing staff can retrain on system upgrades and inspection practices. Contractors can add particular value by knowing all the local, regional and national tax incentives, providing ROI for system upgrades, mastering the more complex power-logging tools and, simply, having enough tools, expertise and people to get the job done.
Build and pitch your planIf you run into opposition in getting a complete audit approved, you may need a more convincing proposal. What you may not realize is that much of the savings can be discovered up front, using a power logger and your computer.
1. Tabulate the kind of equipment in use and log how often it’s deployed.
2. Review utility bills.
3. Plug that data into energy calculators.
4. Quantify and monetize the savings opportunity.
With reasonably solid numbers and a return-on-investment schedule, management is more likely to approve and support an energy audit. For calculators and other tools to estimate ROI and build your proposal, see the reference list on the next page. There’s no need to reinvent the wheel! Learn what others have done and apply their best practices. UM
Almost all audits fi nd equipment turned on but not in use, ineffi cient lighting technologies or usage and
HVAC systems that are not optimized.
Smaller long-term opportunities: Building envelope, waste/recycling, IT/electronics
Medium opportunities: HVAC, motors and drive
Biggest opportunities: Lighting, compressed air, steam systems
Top Places To Look For Energy Waste
$$$
$$
$
$$$
$$$
$$
$
$
$
Applying Energy-Audit Tools Tool ApplicationPower logger Conduct load studies; perform energy consumption testing
Clamp meter Make branch circuit and individualor clamp load evaluations; take quick poweraccessory measurements
Thermal Scan electrical, electro-mechanical,imager process, HVAC and other equipment for hotspots noting ineffi ciencies; scan buildings for leaks
Logging digital Monitor power usage cycles;multimeter measure pressure and temperature
Infrared Scan motors, insulation, steamthermometer pipes, ducts, breakers, connections and wires
Air Evaluate and adjust ventilationmeter levels; verify HVAC controls
Continued on page 22
Dedication
Technical Ability
Why would you need to useany other lab?
Contact Herguth Laboratories, Inc.today to fi nd out what sets us apart.
1-800-OIL-LABS • www.herguth.com
Customer Service
Integrity
Systems
UM ENERGY AUDITS
Kate Anderson is editor of ActionEco.org, an online education and advocacy community that demonstrates the business benefi ts of sustainable business operations and maintenance best practices.
Colin Plastow is industrial product manager for Fluke. To learn more about the products and services referenced in this article, including Fluke’s energy audit training offered through the company’s Energy Answers program, e-mail: colin.plastow@fl uke.com.
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Online Resources
• EPA Energy STAR, www.energystar.gov, has calculators, guidelines, check-lists, schedules, how-tos and many other tools for designing and imple-menting energy plans and audits.
• American Council for an Energy Effi cient Economy, www.aceee.org, convenes conferences and workshops for energy-effi ciency professionals, conducts technical and policy analyses and offers advice for program managers.
• Building Owners and Managers Association, www.boma.org, offers a sustainable operations Webinar series for training on operational cost savings and evaluating green building opportunities.
• Consortium for Energy Effi ciency (CEE), www.cee1.org, has a database of companies that manufacture CEE and Energy STAR equipment. An energy and effi ciency think tank, CEE is a good source for technology reviews.
• Commercial Building Tax Deduction Coalition, www.effi cient buildings.org, explains tax deductions for energy-effi cient building expenditures made by a building owner.
• Database of State Incentives for Renewables and Effi ciency, www.dsireusa.org, is a comprehensive source of information on state, local, utility and federal incentives that promote energy effi ciency.
• U.S. Department of Energy, www.energy.gov, is the gateway to thousands of pages of how-to energy-audit information.
• U.S. Department of Energy’s Energy Effi ciency and Renewable Energy Network, www.eere.energy.gov. Click on “Industry” on the left of the page for industrial and operations information and research.
• Tax Incentives Assistance Program, www.energytaxincentives.org, provides information about federal income tax incentives for energy effi cient prod-ucts and technologies.
• OpenEco, www.openeco.org, has assembled helpful news, resources and calculators.
• FacilitiesNet, www.facilitiesnet.com/energyeffi ciency, is focused squarely on facilities.
While the Internet is full of great information on energy audits, fi nding it can take some time. Here’s a head start. Use these sites to get reports on successful audits, online tools, best practices, technology evaluations, even fi nancial incentives.
22 | UTILITIES MANAGER VOLUME 5 / NO. 2
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Building Blocks Of Motor Management
BOOSTING YOUR BOTTOM LINE
M
The Motor Decisions Matter (MDM) campaign is managed by the Consortium for Energy Effi ciency (CEE), a North American nonprofi t organiza-tion that promotes energy-saving products, equipment and technologies. For further information, contact MDM staff at [email protected] or (617) 589-3949.
otor management—understanding your motors, their operating condi-tions and costs and what you are going to do when they fail—can
reduce downtime, save money and lower carbon emissions at your facility. Some facility managers have already mastered the practice. They know how many motors they have, where they’re located, their size and nameplate effi -ciencies, their load factors and number of run-hours. They keep track of each motor’s age and maintenance history and have plans in place for what is going to happen with every one of those units when they fail. Yes, such facility managers defi nitely are out there…
For the rest of us, the following set of motor-management building blocks from the Motor Decisions MatterSM Campaign can help.
Motor inventoryA motor inventory is a list of every motor in a facility, its size, nameplate effi ciency, operation, load factor, run-hours and maintenance history. With this resource alone, you can ensure that the most effi cient motors are the most often used; track “problem” motors (those with histories of repeated failure); and identify candidates for cost-effective replacement. Many vendors and service providers can help facilities assemble motor inventories. Ask a vendor or service provider in your area for assistance. Check out http://www.easa.com/fi nd/active_members for motor service providers.
Repair/replace decision guidelinesIt is easier to manage a plan than a crisis. Know in advance what will be done with every motor upon failure, and label the motor accordingly. The information in your motor inventory—nameplate effi ciency, age, run-hours and main-tenance history—will assist you in determining the cost-effective choice. (A free Motor Deci-sions Matter calculation spreadsheet can help you do this in three easy steps.)
Purchasing specifi cationOnce the decision to replace a motor has been made, know what type of unit you’ll be purchasing as the replacement. Because energy costs represent 95% of the lifetime costs for most motors, NEMA Premium® effi ciency motors may save your facility money in many applications. Keep in mind that a motor failure is also a good opportunity to make sure the size and type of motor are appropriate for the application.
Best-practice repair specifi cationEnsure that motors are returned to their name-plate effi ciency by specifying best-practice repair. Without this type of specifi cation, a repair could result in a unit that operates less effi ciently. Take the time to check out the best-practice repair resources that are available through the Motor Decisions Matter initiative, and contact your motor service provider to develop a specifi cation for your facility. Motor Decisions Matter provides motor users with a variety of free tools and information, including the “Simple Savings Calculator,” “Motor Plan-ning Kit” and numerous case studies from facilities throughout the United States and Canada, at www.motorsmatter.org. LMT
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A SPECIAL GREEN EDGE LUBE SHOWCASE
24 | LUBRICATION MANAGEMENT & TECHNOLOGY MAY/JUNE 2010
DOES YOUR COMPANY HAVE A GREEN EDGE?E-mail your product and service news to: [email protected] information on advertising in the Green Edge section,contact JERRY PRESTON at:
Phone: (480) 396-9585 / Fax: (480) 264-4789 / E-mail: [email protected]
High-Viscosity Bio-Based Lubes
Formulated from renewable, biodegradable vegetable oils, the LubriMatic Green™ prod-
ucts from Plews/Edelmann are designed to replace and mix readily in conventional petroleum products for a more environmen-tally friendly lubricant. With its high viscosity index, bio-based oil is less likely to “thin down” at high temperatures, which leads to lower operating temperatures and a higher degree of lube safety, espe-cially in high-speed applications.
Plews/EdelmannDixon, IL
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Ceramics-Industry Lubricant
Hutch 101 Green is a non-soap, water-based lubricant with all the benefi ts of oil-based formulations, but none of the downsides. The company says this envi-
ronmentally safe product designed to meet the needs of the ceramics industry also costs less than oil-based lubes.
Hutch 101 Fort Worth, TX
Soy-Based Alternatives ToConventional Hydraulic Fluids
ELM notes that its Biotechbased SoyFluid™ Hydraulic Industrial (ISO 46 & 68) oils are formulated with opti-mized USA-grown natural seed oils that surpass the
lubricity of most conventional oils. They’re particularly suited for use near water, as well as in forests and other environmentally sensitive areas.
Environmental Lubrication Mfg., Inc.Grundy Center, IA
Replacements For Your Petroleum-Based Gear Oils
United Bio Lube’s Bio Gear Oils are non-hazardous, high-performance gear lubricants engineered as drop-in replacements for petroleum-based formulas.
Meeting the newest OEM industrial requirements for premium, heavy-duty energy-conserving gear oils, they’re compounded with an environmentally friendly zinc-free additive that meets API Service Classifi cations for Ashless GL-3, GL-4 & GL-5 type gear lubricants.
United Bio LubePalo Alto, CA
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A SPECIAL GREEN EDGE LUBE SHOWCASE
MAY/JUNE 2010
A SPECIAL GREEN EDGE LUBE SHOWCASEA SPECIAL GREEN EDGE LUBE SHOWCASE
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High-Pressure Hydraulic Oils ForMarine Service
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Low-Temperature Food Grade Grease
Marine-Safe Hydraulic Oils from Lubriplate are a line of high-performance, antiwear
products for use in high-pressure equipment that operates in envi-ronmentally sensitive areas. The biodegradable oils are formulated with premium-quality USP white mineral oils and an ashless “zinc-free” antiwear additive system. Non-toxic to aquatic life, they exceed U.S. EPA LC50 test require-ments adopted by the U.S. Fish and Wildlife Service and the EPA.
LubriplateNewark, NJ
INOX-mx6, distributed by Green-Tech Lubricants, is a food grade, fully synthetic, extreme pressure grease
suitable for use in below-zero temper-atures, especially in the refrigerated, frozen food and beverage industries. This non-toxic grease can operate
from -30 C up to short bursts of 300 C without breaking down, and meets US FDA and USDA requirements.
Green-Tech Lubricants, Inc.Greenfi eld, IN
Biodegradable High-Temp GreaseFormulation
Bio-High Temp 180 E.P. Grease from Renewable Lubricants is a high-temperature, bio-
based grease characterized by a super-high-viscosity-index base. Containing no heavy metals or other environmentally undesir-able additives, such as chlorine, barium or lead, its performance is supported by an environmentally friendly extreme pressure addi-tive. This multipurpose, lithium complex grease also provides good cold-temperature mobility.
Renewable LubricantsPalo Alto, CA
26 | LUBRICATION MANAGEMENT & TECHNOLOGY MAY/JUNE 2010
SUPPLY CHAIN LINKS
One of the critical emerging issues on
customers’ minds (and some of the most
common questions they’re asking us)
involve how to operate and maintain
sustainable facilities. Organizations everywhere
are constantly looking for ways to operate in
a more environmentally responsible manner
than before—and also cut operating expenses.
Maintaining and operating a sustainable facility is achieved by looking at the essential areas of the opera-tion. Sustainability industry experts, such as the United States Green Building Council (USGBC), look at the environmental-savings categories of a building’s exterior, water effi ciency, energy and atmosphere, materials and resources and indoor environmental quality. Each of these components represents a critical element when it comes to reducing carbon footprint and the use of natural resources. But there’s an additional element to remember when attempting to operate a sustainable facility: behavior. One could argue that buildings don’t use power or water or generate waste—people do.
By better understanding the decision process that employees go through as they discard items or use water and energy, you can help identify what steps need to be taken in order to drive toward more sustainable choices. Utilizing effi cient lighting within your facility, for example, will provide value in reduced energy costs and better light quality. Couple that with good choices for how the lighting
You’re not alone in this ongoing journey.You’re not alone in this ongoing journey.
It’s All About Choices
Sustainability And Your Facility:
M. Randi Young, LEED APGrainger
MAY/JUNE 2010 www.LMTinfo.com | 27
SUPPLY CHAIN LINKS
Sustainability And Your Facility:
is used and you’re on track for even more savings and less harmful environmental impact. Simply shutting the lights off when the last person leaves a room or leveraging sensors to judge when lighting is required would make an even bigger impact on bottom-line costs. The same is true when looking at the other key areas of a building that use natural resources and energy, or contribute to waste. When responsible actions are coupled with the right equipment, sustainability and cost savings are likely to follow—as will the culture change necessary for lasting impact.
Another piece to consider is the relationship between the personal comfort of employees while inside the building and worker produc-tivity. This is an important consideration as you make changes in your facility. Alterations in filtering or outside air intake can affect the indoor air quality. Updated lighting or indi-vidual lighting controls can add to comfort.
And the use of natural cleaning materials can reduce the toxins that enter the air, as well as reduce harmful chemicals going into water-treatment systems. All of these factors impact productivity of the employees occupying the affected space in a gainful fashion. Generally, that impact is positive, but it’s important to continuously engage employees for input and feedback with regard to improvements.
The path to sustainability does not have a “fi nal destination,” rather it’s an ongoing journey. With a commitment to continued learning, as well as partnership with experts who can help you achieve your sustainability goals, the journey is sure to be an enjoyable and benefi cial one. LMT
M. Randi Young is a solutions development manager with Grainger and a LEED AP.
Listening To Customers For 83 years, Grainger has been serving businesses and institutions across a variety of indus-
tries by helping them save time and money related to their maintenance, repair and operating supplies needs. Today, the company remains committed to listening to its customers and helping to collaboratively fi nd the most cost-effective solutions for their evolving business needs.
With more than 8000 green products across a broad array of categories, Grainger defi nitely provides the product solutions that organizations need to “go green,” including those that help save energy, reduce water usage, improve indoor air quality and reduce waste. In addition to products, Grainger is educating business professionals on how to embrace energy-effi cient solu-tions in their operations. Through supplier partnerships and its recent acquisition of Alliance Energy Solutions, the company offers training, needs assessments and audits in areas such as energy, water, green cleaning and waste reduction.
Grainger also diligently looks for ways to reduce its own environmental impact. From adopting Leadership in Energy and Environmental Design (LEED) standards for all new construction, to completing certifi cation as an EPA SmartWay shipper partnering with carriers to reduce transportation emissions, the company is helping to preserve the natural resources within the communities where it does business. Currently, Grainger operates 12 LEED-certifi ed facilities, 10 being LEED Gold. For more information about Grainger’s green products and solutions, visit www.grainger.com/greeninfo.
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SOLUTION SPOTLIGHT
28 | LUBRICATION MANAGEMENT & TECHNOLOGY MAY/JUNE 2010
SOLUTION SPOTLIGHT
Cooling towers dissipate both ambient and process heat in most large manufacturing facilities. These structures facili-tate the transfer of unwanted energy (heat) from a transport
liquid (usually water) to the atmosphere. Problems with effi cient heat transfer, equipment protection and pathological risks to employees can most often be traced to an issue with suspended solids. These solids can originate in the process, in the piping, from the atmosphere or from internal biological growth.
Common methods of maintaining minimal suspended solids in a cooling system are side-stream fi ltration, a process that cleans only a portion of system fl ow; cyclonic devices, which typically treat all water in a system, but are best at removing high-specifi c-gravity solids; and granular media fi ltration, which is also used to treat all water, but is best at removing low-specifi c-gravity organic solids.
Orival offers yet another method—automatic self-cleaning screen-fi lter technology—that can be used for all system water. Trapping both organic and inorganic solids, regardless of specifi c gravity, this process also requires minimal energy and little or no coolant liquid for the self-cleaning process. Fully automatic self-cleaning screen fi lters use weave-wire screens as the fi ltering media. These provide a positive removal system and eliminate all particles larger than the fi ltration degree of the screen from the cooling system, and many smaller particles as well. This is due to the fi ltration effect of the fi lter cake that builds on the screen element surface between cleaning cycles.
The fi ltration improvement can be loosely quantifi ed as removing particles down to about 1/10 the size of the screen-fi ltration degree when the fi lter cake is at its thickest. This 1:10relationship, as employed in screen-fi ltration systems, is called the capture ratio. An effi cient suction-cleaning principle allows the fi lter cake to be removed completely from the screen surface within seconds, without touching the cake or screen.
During the suction-cleaning cycle, the fi ltration process is uninterrupted, thereby providing fi ltered water downstream at all times and eliminating redundant equipment. Water and chemical losses are minimized, and organic and inorganic solids are removed with equal effi ciency. Since only a small pressure differential occurs across the screen element, extru-sion of soft organic material through the screen is prevented. If a problem should occur with the fi lter, a controller will open a built-in bypass valve to provide continuous water fl ow. The controller will then send a signal to notify personnel.
Routine maintenance of automatic self-cleaning screen fi lters is minimal, consisting of a monthly inspection of the rinse valves (to see that they are seating properly) and an annual inspection of the screen and hydraulic piston. An occasional manually induced cleaning cycle is recommended to assure proper operation.
Orival, Inc. Englewood, NJ
Cool Solution For Hot
ProblemsAutomatic self-cleaning screen-fi lters
provide cooling-system protection and more.
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Orival’s technology at work in a cigarette-manufacturing operation
MAY/JUNE 2010 www.LMTinfo.com | 29
PROBLEM SOLVERS
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KrytoxFluorinated Lubricants
miller-stephenson chemical company, inc.California - Illinois - Connecticut - Canada
e-mail: [email protected] www.miller-stephenson.com
Krytox® Fluorinated Greases and Oilsare: Chemically Inert. Insoluble in commonsolvents. Thermally stable. Temperaturerange (-103˚F to 800˚F). Nonflammable.Nontoxic. Oxygen Compatible - safe foroxygen service. Low Vapor Pressure. LowOutgassing. No Migration - no silicones orhydrocarbons. Krytox offers ExtremePressure, Anticorrosion and Antiwearproperties. Mil-spec, Aerospace and FoodGrades (H1 and H2) available! Useful inVacuum Systems. For technical informa-tion, call 203.743.4447 / 800.992.2424(8AM - 4 PM ET)
®
ms
Krytox Medical Ad 2008:Krytox Medical ad 2007E 7/28/08 6:27 PM Page 1
Control Troublesome Oil Mist And Fumes
JLM Systems’ Oilmiser™ Vapor Guard (OVG) is designed for machinery like gearboxes and bearing housings that are
vented to atmosphere. Under continuous operation and high working loads, oil mist and fumes build up in the air space above the oil. Temperature changes and thermal expansion cause these fumes to exhaust into the workplace and also bring in outside air through the same vent. The OVG helps prevent the serious housekeeping and mechanical problems associated with this situation by way of a central diffuser post inside a sealed aluminum containment chamber. Migrating vapors are dispersed inside the chamber and condensed back into liquid oil that collects at the bottom of the unit. From here, recovered and uncontaminated lube oil is channeled through bleed-back holes into the gearbox, where it continues to lubricate.
JLM Systems Ltd.Richmond, BC
Lab-And-Field Wear-Metal Analysis
Spectro’s new Spectroil Q100 Oil Analysis Spectrometer detects and quantifi es metals in used (in-service) oils and hydraulic fl uids. Capable of helping predict mechanical failures in their early stages, the device is designed to work well in
both lab and fi eld. The standard confi guration can analyze 22 wear metals, contami-nants and additives in 30 seconds. Additional elements can be added at any time.
Spectro Inc.A business unit of QinetiQ North AmericaMcLean, VA
Eco-Friendly Absorbent Pads, Rolls & Socks
According to Kafko International, its new eco-friendly Oil Eater Naturals offerings absorb up to 20% more than melt-blown polpropylene products, yet cost less. The line’s Oil Only Pads and Rolls soak up oil and repel water; Universal Pads and
Rolls soak up oil, water and other liquids; the Absorbent Socks control larger spills and protect drains. All are available in a variety of weights, fi nishes and sizes.
Kafko International Ltd.Skokie, IL
High-Performing Metal-Cutting Oil
LENOX’s Cycle HD Water Soluble Oil is suitable for a variety
of metal-cutting appli-cations. The company says that the product’s advanced extreme pres-sure (EP), non-harmful additive package leads to outstanding perfor-mance in moderate to heavy-duty machining of ferrous and non-ferrous metals. Superior resistance to bacteria leads to both extended sump life and odor control. The fl uid is also prepared with smaller oil droplets that prevent separation of the oil from water, leading to a more stable emulsion.
LENOXEast Longmeadow, MA
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30 | LUBRICATION MANAGEMENT & TECHNOLOGY MAY/JUNE 2010
PROBLEM SOLVERS
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An Alternative To Standard Oil Sight Windows
According to Esco Prod-ucts, the standard sight windows on oil reservoirs
make it diffi cult to view the oil level, stain easily and must be replaced often. To take care of those problems, the company now offers a replacement sight window plug called the 3-D BullsEye. It’s a clear cylinder made from one solid piece of acrylic, with threading on one end and a rounded polished end for easier viewing of the oil on the other. NPT sizes of ½”, ¾”, 1”, 1 ¼”, 1 ½” and 2” are available.
Esco Products, Inc.Houston, TX
end and a rounded polished end for easier viewing of the oil on the other.
Eliminate Lubrication Mistakes
Lubrication Engineers now offers battery-powered Clear Grease Guns™ that allow 100% visual identifi cation of the lubricant, thus helping prevent cross-contamination. The
high-impact, fracture-resistant polycarbonate tubes fi t many standard grease guns, making upgrades of existing tools easy and cost-effective. Durable aircraft aluminum collars are avail-able in a variety of colors for secondary identifi cation.
Lubrication Engineers, Inc.Fort Worth, TX
Electric Grease Lubricator
The new KPL-24 Grease Lubri-cator from Ya-
mada America is a 24-volt electric unit that allows for effi cient greasing of heavy-duty equip-ment without tap-ping into hydraulic or pneumatic lines. It fi ts directly onto a 5-gal. grease pail (a 16-gal. unit also is available); works with a hose reel and hand grease gun; and can be used alone or as part of a centralized system.
Yamada AmericaArlington Heights, IL
with a hose reel and hand grease gun; and can
Gel For Tube-Bending Applications
Accu-Lube JL-12 from ITW Rocol North America
is an opaque, ready-to-use gel formulated specifi cally for tube-bending applications. Pumped or applied by hand directly to the tube or bending mandrels, it leaves a clean coating that won’t build up over time. Formulated to stay where it’s applied, it eliminates the mess of conventional lubri-cants. No cleaning is required before welding, and the gel is easily cleaned before painting or plating.
ITW ROCOL North AmericaGlenview, IL
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PROBLEM SOLVERS
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Comfortable, U.S.-Made Unvalved Respirator
3M is now offering a new 8510, N95 model Particulate
Respirator that’s been designed for comfort and increased wear-ability. It features a soft inner material and cup-shape design that make it both spacious and durable, along with braided straps and an adjustable M-noseclip. U.S. customers can now pick from 25 models of 3M’s domestically made fi ltering products.
3M St. Paul, MN
Oil-Mist System For Multiple Converting Lines
Converting-equipment supplier Precision AirConvey (PAC) offers a central oil-mist system
for label manufacturers, converters and others relying on oil mist to run pressure-sensitive adhesives or other high-tack materials smoothly through automated trim-removal systems. The PAC central oil-mist system replaces multiple lubricant containers at individual presses with a single reservoir set away from the production area. The labor required to constantly monitor and maintain the proper lubricant levels and fl ow rate at each press is eliminated, along with the risk of clogged ductwork and associated downtime.
Precision AirConveyNewark, DE
with a single reservoir set away from the production area. The
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ENGTECHIndustr ies Inc.
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MAY/JUNE 2010 • Volume 11, No. 3
32 | LUBRICATION MANAGEMENT & TECHNOLOGY MAY/JUNE 2010
Submissions Policy: Lubrication Management &Technology
gladly welcomes submissions. By sending us your submission, unless
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SALES STAFF
ATP Lists ............................................ www.atplists.com .................................... 71 ................... 31
Cannon Instruments ........................ www.cannoninstrument.com ................ 64 ................... 13
Des-Case Corporation ..................... www.descase.com/extreme .................... 62 ..................... 4
Engtech Industries Inc. ..................... www.engtechindustries.com .................. 70 ................... 31
Herguth Laboratories, Inc. ............... www.herguth.com ................................... 66 ................... 22
Hy-Pro Filtration .............................. www.hyprofi ltration.com ....................... 61 ..................... 2
Inolex Chemical Company .............. www.inolex.com ...................................... 68 ................... 25
Inpro/Seal Co. .................................... www.inpro-seal.com/CDR ..................... 73 ................... 34
Miller-Stephenson Chemical Co. .... www.miller-stephenson.com ................. 69 ................... 29
NSK Corporation ............................. www.nskamericas.com ........................... 65 ................... 18
OIL Miser ........................................... www.oilmiser.com ................................... 67 ................... 24
Royal Purple ...................................... www.royal-purple-industrial.com ......... 72 ................... 33
WD-40 ............................................... www.blueworksbrand.com/sample....... 63 ........ Insert,11
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For more information on Royal Purple, visit royal-purple-industrial.com today.
“...we extended drain intervalsfrom every 15 days to everythree months AND reduced
engine repairs and replacements.”
Luis GarzaKingfisher Marine
Most efforts to improve operating efficiency and lowermaintenance costs are labor intensive and involve painfulcultural changes. Numerous progressive companies haveexperienced significant cost savings simply by upgradinglubricants. You can learn how by reading the special report‘Lowest Total Cost of Ownership’. This special reportincludes extensive case studies that document real-worldsavings through lubricant upgrades.
Get your FREE copy of the ‘Lowest Total Cost ofOwnership’ today by calling 866-447-5173 . . .
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Inpro/Seal Company has been in the business of bearing protection for rotating equipment for 32 years and counting. We have been supplying bearing protection for the IEEE-841 motors since they were first introduced. It is only logical that we would expand into the field of motor shaft current mitigation to protect motor bearings. The CDR is:
Machined entirely out of solid corrosion resistant and highly conductive bronze, the CDR/MGS is capable of carrying 12+ continuous amps. They are made exclusively by the Inpro/Seal Company in Rock Island, IL, to ensure consistent quality and same-day shipments when required.
The CDR and MGS (Motor Grounding Seal) products were developed in our own Research and Experimentation Laboratory and then extensively tested and evaluated by professional motor manufacturing personnel. Our standard guarantee of unconditional customer satisfaction of product performance applies. We stand behind our products.
When you order a CDR or MGS from Inpro/Seal, you are assured of the complete responsibility for technology and performance from a single source. We want to earn the right to be your first choice for complete bearing protection.
ROBUST
RELIABLE
REALISTIC
For more information visit www.inpro-seal.com/CDR or contact800-447-0524 for your Inpro/Seal Representative.
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